120A

BD120149 Mechanical Systems Manual Preface
Copyright 2006 Harnischfeger Corporation P&H Mining Equipment - Knowledge and Development
Preface.fm -i- Preface, Version 00 - 03/06
Preface
This manual is provided as a guide to personnel involved with the operation, maintenance and repair of this rotary
blasthole drill. We recommend that such personnel review and become familiar with the general procedures and
information contained within this manual. In addition, we recommend that this manual be kept readily available for
reference when repairs or maintenance are necessary.
Due to the complexities of mining equipment and the environment in which it operates, situations may arise which
are not directly discussed in detail in this manual. When such a situation arises, past experience, availability of
equipment, and common sense play a large part in what steps are to be taken. In addition, a P&H MinePro Ser-
vices Representative is available to answer your questions and assist you upon request.
Copyright
Copyright 2006 Harnischfeger Corporation. All rights reserved. All materials contained herein are protected
by United States copyright law and international treaties, and may not be reproduced, distributed, transmitted,
displayed, published or broadcast without the prior written permission of Harnischfeger Corporation. You may
not alter or remove any trademark, copyright or other notice from copies of the content. All rights in transla-
tions of these materials shall remain exclusively with Harnischfeger Corporation.
Preface BD120149 Mechanical Systems Manual
P&H Mining Equipment - Knowledge and Development Copyright 2006 Harnischfeger Corporation
Preface, Version 00 - 03/06 -ii- Preface.fm
BD120149 Mechanical Systems Manual Change Record
Change Record.fm iii- Change Record, Version 00 - 03/06
Changes to this manual are made by direction of the P&H Mining Equipment Knowledge and Development Department
Manager through recommendations of Instructors, Technical Writers, Engineers, Service Personnel, and results of the
manual review process. All changes shall ensure effective user comprehension and fulfillment of the topic being
described. Use the form below to enter all change information contained on the PDF enclosed on your manual CD.
Number and Description of Change Entered By Date
Change Record
Change Record BD120149 Mechanical Systems Manual
Change Record, Version 00 - 03/06 iv- Change Record.fm
BD120149 Mechanical Systems Manual Table of Contents
Copyright 2006 Harnischfeger Corporation P&H Mining Equipment - Knowledge and
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Change Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xv
List of Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxv
SECTION 1, Blasthole Drill Safety
1.1 General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
1.1.1 Safety Websites. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
1.2 Safe Operating Practices for Users of P&H Mining Equipment - Large Rotary Blasthole Drills .
1.2
1.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.2.2 Qualifications for and Conduct of Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.2.3 Responsibilities of All Crew Members . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
1.2.4 Planning the Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
1.3 Operation Near Electrical Lines Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
1.4 Safety Decals and Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
1.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
1.4.2 Hazard Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
1.4.3 Safety Hazard Decals and Signs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
SECTION 2, Introduction
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.1.1 Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.1.2 Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
2.2 Questions concerning the drill or this manual should be referred to your P&H MinePro Services
representative.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
2.3 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
2.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
2.3.2 Drill Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
2.3.3 Power Unit R10433F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
2.3.4 Main Air Compressor 51U165D4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
2.3.5 Undercarriage and Propel 100J6626F4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
2.3.6 Rotary Carriage R54410F4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
2.3.7 Pulldown Mechanism 916J204F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
2.3.8 Drill Pipe Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.3.9 Mast and Back Braces R14102F6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.3.10 Winch 23U52D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.3.11 Deck Wrenches GH5007463 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.3.12 Operators Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.3.13 Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.3.14 Automatic Lubrication System 944J461F5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
2.3.15 Bailing Air System R45797. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
Table of Contents
Table of Contents BD120149 Mechanical Systems Manual
P&H Mining Equipment - Knowledge and DevelopmentCopyright 2006 Harnischfeger Cor-
Table of Contents (Continued)
2.3.16 Towing System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
2.3.17 Hydraulically Operated Dust Curtains R6349F1-F2 . . . . . . . . . . . . . . . . . . . . . . . . 2.10
2.3.18 Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
2.4 Sign Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
2.5 Reader Comment Form. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
2.6 Material Safety Data Sheets (MSDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
2.7 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
2.8 Drill Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
SECTION 3, Auxiliary Hydraulic System
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
3.2 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
3.2.1 Hydraulic Tank R6908D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
3.2.2 Auxiliary Hydraulic Pump 37U153D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
3.2.3 Valve Bank 1 36R198D3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
3.2.4 Valve Bank 2 36R199D7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27
3.2.5 Valve Bank 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.40
3.2.6 Bill of Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.54
3.2.7 System Data Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.55
3.3 Auxiliary Hydraulic System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.57
3.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.57
3.3.2 Hydraulic Tank R6908D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.59
3.3.3 Suction Filters R16280D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.60
3.3.4 Temperature Probe 89Z724D2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.62
3.3.5 Low Level Switch R16982D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.63
3.3.6 Hydraulic Tank Breather 1046Z994. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.64
3.3.7 Magnetic Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.65
3.3.8 Return Filters 46Z529 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.66
3.3.9 Auxiliary Hydraulic Pump 37U153D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.70
3.3.10 Valve Banks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.72
3.3.11 Dual Counterbalance Valves R6268D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.82
3.3.12 Main Hydraulic Pressure Transducer 36Q549. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.86
3.3.13 Hydraulic Pressure Switch R24844D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.88
3.3.14 Leveling System Pressure Switches 79Z2750D2 . . . . . . . . . . . . . . . . . . . . . . . . . . 3.91
3.3.15 Regeneration Valve 36U437D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.96
3.3.16 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.98
SECTION 4, Main Hydraulic System
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
4.2.2 Main Hydraulic Pumps R51924D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.2.3 Propel Motors 41U100D2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
4.2.4 Pilot Control Valve Bank 36U435D4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
4.3 Main Hydraulic System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
4.3.2 Main Hydraulic Pumps R51924D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
4.3.3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
4.3.4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
4.3.5 Pilot Control Valve Bank (Valve Bank 4) 36U445D4 . . . . . . . . . . . . . . . . . . . . . . . . 4.18
4.3.6 Charge Filter 46Z547. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.19
4.4 . Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21
SECTION 5, Power Unit
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
5.1.1 Power Unit Assembly Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
5.2.1 Main Drive Motor 5100A1368F12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.2.2 Air Compressor 51U165D4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.2.3 Hydraulic Pump Drive Transmission (PDT) GH5829479. . . . . . . . . . . . . . . . . . . . . . . 5.4
5.3 Main Hydraulic System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
5.3.1 Main Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
5.3.2 Hydraulic Pump Drive Transmission GH5429879 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
SECTION 6, Main Air System
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
6.2.1 Main Air Compressor 51U165D4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
6.2.2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
6.2.3 Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
6.2.4 Oil Circulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15
6.2.5 Bailing Air Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.25
6.3 Main Air System Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.32
6.3.1 Main Compressor Air Cleaner 46Z534 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.32
6.3.2 Main Air Compressor 51U165D4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.34
6.3.3 Compressor Inlet Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.41
6.3.4 T-Tank R55420F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.45
6.3.5 Circulation Pump R56963D1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.50
6.3.6 Compressor Oil Cooler R56568D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.52
6.3.7 Thermostatic Mixing Valve R38039D2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.55
6.3.8 Compressor Oil Filter, R51071F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.59
6.3.9 Subtractive Pilot Valve, 36Q577D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.62
6.3.10 Main Air Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.65
6.3.11 Bit Air Pressure Transducer (BAPT), 44Q1536. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.66
6.3.12 Compressor Oil Pressure Switch (COPS), 79Z5680. . . . . . . . . . . . . . . . . . . . . . . . 6.67
6.3.13 Main Air Pressure Transducer (MAPT) 44Q1536 . . . . . . . . . . . . . . . . . . . . . . . . . . 6.68
6.3.14 Scavenger Oil Return Filter GH5000348. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.69
6.3.15 Air Pilot Valve R56220D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.69
6.3.16 Pressure Relief Valve R12262D4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.70
6.3.17 Butterfly Valve R51305D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.72
6.3.18 Muffler 27Q762D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.75
6.3.19 Dump Valve GH5000369. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.75
6.4 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.75
SECTION 7, Low Pressure Hydraulic System
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
7.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
7.2.2 Intake and Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.2.3 Cab Roof Hatch Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
7.2.4 Boarding Ladder Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
7.2.5 Grease Pump Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
7.3 Low Pressure Hydraulic System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
7.3.1 Hydraulic Pump-Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
7.3.2 Check Valve Cartridge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
7.3.3 Low Pressure Hydraulic System Valve Bank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
7.4 Hoist Brake Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17
SECTION 8, Automatic Lubrication System
8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
8.1.1 Automatic Lubrication System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
8.1.2 Control Panel Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
8.2.1 Pump Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
8.2.2 Lube Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
8.2.3 Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
8.3 Automatic Lubrication System Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10
8.3.1 Hydraulic Pump-Motor, 37Q117D2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10
8.3.2 Grease Pump 37U154D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12
8.3.3 Lubrication Control Panel R7686F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.14
8.3.4 Vent Valve 36Q525 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19
8.3.5 Lubrication Injectors 44Z1169D__. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.21
8.4 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.32
SECTION 9, Propel System
9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
9.2.1 Propel Motor 41U100D2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
9.2.2 Propel Transmission 53R176D2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
9.2.3 Crawler Assembly R6575F3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
9.3 Propel System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
9.3.1 Propel Motor 41U100D2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
9.3.2 Propel Transmission 53R176D2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
9.3.3 Idler Roller 13N385D1F1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24
9.3.4 Upper and Lower Rollers 13P627F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
9.3.5 Crawler Track Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28
SECTION 10, Levelling System
10.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
10.2 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
10.2.1 Rear Jacks 100J6691F5 and 100J6691F6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
10.2.2 Front Jacks 100J6692F3 and 100J6693F3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
10.2.3 Leveling Jack Shoes R56352D1, R56353D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
10.3 System Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
10.3.1 Leveling Jack Shoes R56352D1, R56353D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
10.3.2 Jack Hydraulic Cylinders R4102D2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
10.4 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
10.4.1 Basic Operational Test for Auto Level System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
10.4.2 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
SECTION 11, Mast
11.1.1 Mast Weldment R53818D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2
11.1.2 Ladder 29J333F3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2
11.1.3 Back Braces 100J6487F3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3
11.1.4 Mast Lock Pins GH1302T14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3
11.1.5 Mast Hoist Cylinders R6268D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4
11.2 Mast Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4
11.2.1 Mast Weldment R53818D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4
11.2.2 Auxiliary Winch 23U52D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4
11.2.3 Winch Motor Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.6
11.2.4 Winch Brake Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.9
11.2.5 Winch Planetary Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.12
11.2.6 Winch Drum Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.14
11.2.7 Assembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.16
11.2.8 Auxiliary Winch Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.17
11.2.9 Back Brace Locking Collar Cylinder R7187D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.25
11.2.10 Mast Lock Pin 19T6502D3 And Cylinder R51992D2 . . . . . . . . . . . . . . . . . . . . . 11.27
11.2.11 Mast Raise/Lower Cylinder R6268D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.31
11.2.12 Mast Bottom Plate R11834D2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.37
11.3 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.41
SECTION 12, Rotary Machinery
12.1.1 Rotary Motor 83013-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2
12.1.2 Rotary Gear Case R10678F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2
12.1.3 Rotary Drill Pipe Coupling R12253F9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2
12.2 Rotary Machinery Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3
12.2.1 Rotary Motor 83013-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3
12.2.2 Rotary Gear Case R10678F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.9
12.2.3 Bit Air Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.11
12.2.4 Oil Pump and Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.13
12.2.5 Removal And Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.13
12.2.6 Intermediate Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.16
12.2.7 Main Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.19
12.2.8 Rotary Drill Pipe Coupling R12253F9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.24
12.2.9 Gearcase Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.26
SECTION 14, Hoist/Pulldown Machinery
14.1.1 Pulldown Motor 83013-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.2
14.1.2 Pulldown Motor Blower R37819D2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.2
14.1.3 Pulldown Transmission 914J434F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.3
14.1.4 Pulldown Drive Pinions R5544D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.3
14.1.5 Pulldown Idler Pinions R7560D3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.4
14.1.6 Upper Guide Rollers R54361F3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.5
14.1.7 Lower Guide Rollers R54362F3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.5
14.1.8 Pulldown Brake 15R55D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.6
14.1.9 Pulldown Resolver Assembly 975N20F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.6
14.2 Pulldown System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.7
14.2.1 Pulldown Motor 83013-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.7
14.2.2 Pulldown Motor Blower R37819D2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.10
14.2.3 Pulldown Transmission 914J434F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.12
14.2.4 Pulldown Pinions R5544D1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.17
14.2.5 Idler Pinions R7560D3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.18
14.2.6 Guide Rollers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.18
14.2.7 Pulldown Brake 15R55D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.27
14.2.8 Pulldown Resolver 75Z1252D6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.34
14.2.9 Cleaning, Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.35
14.2.10 Assembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.35
SECTION 14, Pipe Handling Equipment
14.1.1 Pipe Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.2
14.1.2 Deck Wrench GH5007463 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.2
14.1.3 Breakout Wrench R46448F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.3
14.2 Pipe Handling Equipment Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.3
14.2.1 Pipe Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.5
14.2.2 Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.15
14.2.3 Deck Wrench GH5007463. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.17
14.2.4 Deck Wrench Cylinders GH5010453 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.20
14.2.5 Breakout Wrench R46448F1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.22
14.2.6 Hydraulic Circuit Inspection and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.24
SECTION 15, Water Injection System
15.2 Water Injection System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.4
15.2.1 1000 Gallon Water Tank R33238F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.5
15.2.2 Submersible Water Pump 37U152D3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.5
15.2.3 Pressure Relief Valve R12410D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.7
15.3 Sensing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.10
SECTION 16, Lubrication
16.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1
16.1.1 P&H Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1
16.1.2 Operating in Cold Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1
16.1.3 Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.2
16.1.4 ISO Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.3
16.2 Automatic Lubrication System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.4
16.3 Oil Bath Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.4
16.3.1 Pulldown Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.5
16.3.2 Hydraulic Pump Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.6
16.3.3 Auxiliary Winch Gear Reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.7
16.3.4 Cable Reel Gear Reducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.8
16.3.5 Propel Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.9
16.4 Oil Pressure Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.10
16.4.1 Rotary Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.10
16.4.2 Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.11
16.5 Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.17
16.6 Manual Lubrication Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.19
16.6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.19
16.6.2 Pipe Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.20
16.6.3 Mast Back Braces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.21
16.6.4 Rotary Carriage Roller Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.22
16.7 Lubrication Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.23
16.7.1 Reference Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.23
16.7.2 Lubrication Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.25
16.8 Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.26
16.8.1 Material Specification P&H 464. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.26
SECTION 17, Preventive Maintenance
17.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1
17.2 Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1
17.3 Bolt Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1
17.4 Bolts And Bolt Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1
17.4.1 Bolt Torques -- American Standard Coarse Thread . . . . . . . . . . . . . . . . . . . . . . . . 17.2
17.4.2 Bolt Torques -- American Standard Fine Thread . . . . . . . . . . . . . . . . . . . . . . . . . . 17.3
17.4.3 Metric Conversion Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.5
17.4.4 Temperature Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.6
17.4.5 Special Bolt Tightening Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.7
17.5 Maintenance Schedule Check Sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.7
17.6 Using The Maintenance Schedule Check Sheets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.7
P&H Model 120A Rotary Blasthole Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
A Maintenance Checks (Daily / 8-12 hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
P&H Model 120A Rotary Blasthole Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
B Maintenance Checks (Weekly / 40-100 hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
P&H Model 120A Rotary Blasthole Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
C Maintenance Checks (Monthly / 160-250 hours). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
17.7 A Maintenance Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.14
17.7.1 Note and Record Any Faults on GUI Fault Log. . . . . . . . . . . . . . . . . . . . . . . . . . . 17.14
17.7.2 Fill Water Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.16
17.7.3 Inspect Machine For Damage And Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.16
17.7.4 Check Hydraulic Tank Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.16
17.7.5 Check Main Air Compressor Oil Reservoir Level . . . . . . . . . . . . . . . . . . . . . . . . . 17.19
17.7.6 lnspect Operator Cab Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.20
17.7.7 lnspect Drill Pipe Sling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.20
17.7.8 lnspect Auxiliary Winch Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.20
17.7.9 lnspect Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.21
17.7.10 Check Rotary Gearcase Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.21
17.7.11 Check Pulldown Gearcase Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.24
17.7.12 Check Grease Pump Hydraulic Supply Pressure . . . . . . . . . . . . . . . . . . . . . . . . 17.24
17.7.13 lnspect Deck Wrenches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.24
17.7.14 Inspect Pipe Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.25
17.7.15 Inspect Crawler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.25
17.7.16 lnspect Jack Shoes And Retaining Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.25
17.8 B Maintenance Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.25
17.8.1 lnspect Hydraulic System Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.25
17.8.2 Check Cable Reel Drive Reducer Oil Levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.26
17.8.3 lnspect Breakout Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.28
17.8.4 lnspect Mast Racks and Pinions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.28
17.8.5 lnspect Rotary Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.28
17.8.6 Inspect Bailing Air System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.29
17.8.7 Check Crawler Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.31
17.8.8 Check Hydraulic Charge Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.32
17.8.9 Check Hydraulic Return Line Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.34
17.8.10 Check Main Compressor Oil Filter Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.35
17.8.11 Check Main Compressor Oil Separator Element. . . . . . . . . . . . . . . . . . . . . . . . . 17.39
17.8.12 Check Main Compressor Air Intake Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.41
17.8.13 Check Auto Lube Grease Reservoir Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.43
17.8.14 lnspect Trail Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.43
17.9 C Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.43
17.9.1 lnspect Mast Back Braces And Slides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.43
17.9.2 lnspect Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.44
17.9.3 lnspect Auxiliary Winch Sheaves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.45
17.9.4 Clean Main Compressor and Hydraulic Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . 17.45
17.9.5 Inspect Main Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.46
17.9.6 Inspect Crawler Frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.46
17.9.7 Check Auxiliary Winch Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.47
17.9.8 Inspect Cable Reel Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.48
17.9.9 Clean/Flush Water Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.48
17.9.10 Check Pump Drive Transmission Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.48
17.9.11 Change Main Compressor Bearing Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.49
17.9.12 Check Propel Transmission Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.50
17.9.13 Clean/inspect Machinery House Blowers And Filters . . . . . . . . . . . . . . . . . . . . . 17.51
17.9.14 Inspect Rotary Carriage Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.54
17.9.15 Check And Adjust Water Pump Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.55
17.10 D Maintenance Checks - 500 Hours (Quarterly). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.55
17.10.1 Replace Oil Line Scavenger Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.55
17.10.2 Check Bolts, Mounting And Attachment Torques . . . . . . . . . . . . . . . . . . . . . . . . 17.56
17.11 E Maintenance Checks - Semi-annual/1000 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.56
17.11.1 Change Rotary Gearcase Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.56
17.11.2 Change Pump Drive Transmission Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.57
17.11.3 Change Hoist/Pulldown Gear Reducer Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.59
17.11.4 Change Propel Transmission Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.59
17.11.5 Change Hoist/Pulldown Gear Reducer Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.59
17.11.6 Change Propel Transmission Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.60
17.12 F Maintenance Checks - Annual/2000Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.60
17.12.1 Change Hydraulic System Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.61
17.12.2 Change Auxiliary Winch Gearcase Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.61
17.12.3 Change Cable Reel Gear Reducer Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.61
SECTION A, General Maintenance
A.1 Removal General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1
A.2 Disassembly General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1
A.3 Inspection, Cleaning And Repair General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1
A.4 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2
A.5 Maintenance Of Specific Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.3
A.5.1 Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.3
A.5.2 Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.3
A.5.3 Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.5
A.5.4 Coupling Alignment - Straightedge-Feeler Gauge Method . . . . . . . . . . . . . . . . . . . . . A.6
A.5.5 Coupling Alignment - Dial Indicator Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.6
A.5.6 Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.7
A.5.7 Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.7
A.6 Gear Tooth Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.8
A.6.1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.8
A.6.2 Gear Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.8
A.6.3 Surface Fatigue. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.9
A.6.4 Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.10
SECTION B, General Hydraulic
System Maintenance
B.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.1
B.2 General Maintenance Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.1
B.2.1 Correct Tightening of Hydraulic Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3
B.2.2 Pipe Thread Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4
B.2.3 SAE Flare Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4
B.2.4 SAE Straight Thread Connection (O-ring Seal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4
B.2.5 Split Flange Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.6
B.2.6 Flat Face O-ring Seal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.8
B.2.7 Troubleshooting Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.9
B.2.8 Developing Systematic Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.10
B.2.9 Recognizing Trouble Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.10
Reader Comment Form
BD120149 Mechanical Systems Manual List of Figures
BD120149-00-MSLOF.fm -xv- List of Figures, Version 00 - 03/06
Figure 1-1: Look closely to see whats in the water... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
Figure 1-2: Mast and Drilling Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.24
Figure 1-3: Mast Hoist Cylinder Boots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.25
Figure 1-4: Machinery House Exterior Panels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.25
Figure 1-5: Machinery Deck Layout (Overview) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.26
Figure 1-6: Operators Cab Door (Drill Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.27
Figure 1-7: Oil Separator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.27
Figure 1-8: Main Transformer (right side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.28
Figure 1-9: Main Transformer (front view). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.28
Figure 1-10: Fan Room Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.29
Figure 1-11: Machinery House Door (front) (outside) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.30
Figure 1-12: Lube Room Door (outside) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.30
Figure 1-13: Power Skid (typical both sides). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.31
Figure 1-14: PLC Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.31
Figure 1-15: Solenoid Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.32
Figure 1-16: Machinery House Door (rear) (outside) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.32
Figure 1-17: Operators Cab Door (front) (outside) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.32
Figure 1-18: Machinery Deck Layout (electrical cabinets) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.33
Figure 1-19: Auxiliary Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.34
Figure 1-20: Hoist/Rotary Junction Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.34
Figure 1-21: DC Hoist Drive Cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.35
Figure 1-22: DC Rotary Drive Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.35
Figure 1-23: High Voltage Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.36
Figure 1-24: 460V Load Center. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.37
Figure 1-25: 120V Load Center. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.38
Figure 1-26: High Voltage Cabinet (side view) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.38
Figure 1-27: High Voltage Cabinet (front view) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.39
Figure 1-28: Operators Cab (Inside). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.39
Figure 2-1: P&H Model 120A Rotary Blasthole Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
Figure 2-2: Model 120A Rotary Blast Hole Drill. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
Figure 2-3: Model 120A Deck Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
Figure 2-4: Main Drive Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
Figure 2-5: Main Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
Figure 2-6: Undercarriage and Propel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
Figure 2-7: Rotary Carriage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
Figure 2-8: Rotary and Pulldown Mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
Figure 3-1: .Auxiliary Hydraulic Schematic, R57351. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
List of Figures
List of Figures BD120149 Mechanical Systems Manual
List of Figures, Version 00 - 03/06 -xvi- BD120149-00-MSLOF.fm
List of Figures (Continued)
Figure 3-2: Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
Figure 3-3: Handwell Valves and Suction Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
Figure 3-4: Hydraulic Tank Temperature Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
Figure 3-5: Hydraulic Tank Oil Level Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
Figure 3-6: Hydraulic Tank Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
Figure 3-7: Magnetic Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
Figure 3-8: Hydraulic Return Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
Figure 3-9: Level and Temperature Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
Figure 3-10: Filter Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
Figure 3-11: Auxiliary Pump Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
Figure 3-12: Auxiliary Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
Figure 3-13: Pump Cartridge Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
Figure 3-14: Pressure Feed to the Vanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
Figure 3-15: Pressure Plate Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
Figure 3-16: Valve Bank 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
Figure 3-17: Valve Bank 1(spares removed for clarity) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
Figure 3-18: Relief/Unload/Oil Diverter Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
Figure 3-19: Pressure Transducer and Pressure Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
Figure 3-20: Mast Hoist Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
Figure 3-21: Mast Anchor Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
Figure 3-22: Deck Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22
Figure 3-23: Dust Curtain Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
Figure 3-24: Back Brace Lock Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
Figure 3-26: Valve Bank 2 (spares removed for clarity) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28
Figure 3-27: Pipe Rack Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29
Figure 3-28: Pipe Rack Gate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31
Figure 3-29: Pipe Rack Gate Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32
Figure 3-30: Pipe Rack Holdback Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33
Figure 3-31: Deck Hatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
Figure 3-32: Breakout Wrench Engage / Disengage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36
Figure 3-33: Breakout Wrench In / Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.38
Figure 3-35: Valve Bank 3 (spare removed for clarity) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41
Figure 3-36: Relief Unloading Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42
Figure 3-37: Auxiliary Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44
Figure 3-20: Front Jack Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.46
Figure 3-21: Left or Right Rear Jack Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.47
Figure 3-22: Regeneration and Dual Counterbalance Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . 3.48
Figure 3-23: Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.50
Figure 3-22: Jack Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.51
Figure 3-23: Hydraulic Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.52
Figure 3-24: Hydraulic Return Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.53
Figure 3-25: Return Filter Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.53
BD120149-00-MSLOF.fm -xvii- List of Figures, Version 00 - 03/06
Figure 3-26: Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.59
Figure 3-27: Handwell Valves and Suction Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.60
Figure 3-28: Suction Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.61
Figure 3-29: Hydraulic Tank Temperature Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.62
Figure 3-30: Hydraulic Tank Oil Level Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.63
Figure 3-31: Hydraulic Tank Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.64
Figure 3-32: Magnetic Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.65
Figure 3-33: Hydraulic Return Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.66
Figure 3-34: Return Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.67
Figure 3-35: Auxiliary Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.70
Figure 3-42: Solenoid Operated Directional Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.78
Figure 3-43: Valve Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.81
Figure 3-44: Dual Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.82
Figure 3-45: Cartridge Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.85
Figure 3-46: Auxiliary Hydraulic System Pressure Components. . . . . . . . . . . . . . . . . . . . . . . . . 3.86
Figure 3-47: Hydraulic Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.88
Figure 3-48: Hydraulic Pressure Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.89
Figure 3-49: Hydraulic Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.91
Figure 3-50: Bench Test Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.94
Figure 3-51: Regeneration Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.96
Figure 4-1: Main Hydraulic System Block Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
Figure 4-2: Main Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
Figure 4-3: Main Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
Figure 4-4: Propel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
Figure 4-5: Propel Motor Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
Figure 4-6: Pilot Control Valve Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
Figure 4-7: Pilot Control Valve Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
Figure 4-8: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
Figure 4-9: Main Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
Figure 4-10: Pump Start-up and Functional Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
Figure 4-11: Pilot Control Valve Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
Figure 4-12: Pilot Control Valve Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.18
Figure 4-13: Charge Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.19
Figure 4-14: Charge Filter Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.20
List of Figures, Version 00 - 03/06 -xviii- BD120149-00-MSLOF.fm
Figure 5-1: Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
Figure 5-2: Power Unit, Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
Figure 5-3: Legend for Figure 5-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
Figure 5-4: Pump Drive Flexible Coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
Figure 5-5: Coupling Hub Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
Figure 5-6: Bolt Tightening Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
Figure 6-1: Main Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
Figure 6-2: Main Air Compressor and Main Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
Figure 6-3: Compression Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
Figure 6-4: Turn Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
Figure 6-5: Main Air System Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
Figure 6-6: Air Intake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
Figure 6-7: Main Compressor Air Cleaner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
Figure 6-8: Vacuum Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
Figure 6-9: Compressor Inlet Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
Figure 6-10: Inlet Valve Modulation Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
Figure 6-11: Compressor Inlet Pressure Switch CIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
Figure 6-12: Pilot Air Pressure Gauge and Subtractive Pilot Valve . . . . . . . . . . . . . . . . . . . . . . 6.12
Figure 6-13: Inlet Valve Bypass Line Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13
Figure 6-14: Inlet Valve Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14
Figure 6-15: Oil Circulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15
Figure 6-16: Compressor Air Temperature Probe and Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16
Figure 6-17: T-Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17
Figure 6-18: Main Air Pressure Differential Switch and Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . 6.18
Figure 6-19: T-Tank Shutoff Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18
Figure 6-20: Oil Circulation Pump and Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19
Figure 6-21: Thermostatic Mixing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.20
Figure 6-22: Compressor Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.21
Figure 6-23: Compressor Oil Flow Switch COFS (typical; for reference only) . . . . . . . . . . . . . . 6.22
Figure 6-24: Compressor Oil Pressure Switch COPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.22
Figure 6-25: Compressor Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.23
Figure 6-26: Scavenger Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.23
Figure 6-27: Compressor Oil Pressure Differential Switch and Gauge. . . . . . . . . . . . . . . . . . . . 6.24
Figure 6-28: Bailing Air Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.25
Figure 6-29: Subtractive Pilot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.26
Figure 6-30: Main Air Pressure Transducer MAPT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.27
Figure 6-31: Bailing Air Pressure Transducer BAPT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.27
Figure 6-32: Main Air Pressure Switch MAPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.28
Figure 6-33: Air Pilot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.28
Figure 6-34: Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.29
Figure 6-35: Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.29
Figure 6-36: Butterfly Valve with Electric Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.30
BD120149-00-MSLOF.fm -xix- List of Figures, Version 00 - 03/06
Figure 6-37: Dump Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.31
Figure 6-38: Main Compressor Air Cleaner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.32
Figure 6-39: Main Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.34
Figure 6-40: Power Unit (exploded view) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.35
Figure 6-41: Legend for Figure 6-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.36
Figure 6-42: Flexible Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.38
Figure 6-43: Compressor Inlet Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.41
Figure 6-44: T-Tank (on Left Hand Platform) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.45
Figure 6-45: Air/Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.46
Figure 6-46: T-Tank Shut-Off (Drain) Valve Positions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.49
Figure 6-47: Compressor Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.52
Figure 6-48: Themostatic Mixing Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.55
Figure 6-49: Thermostatic Mixing Valve Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.56
Figure 6-50: Thermostatic Mixing Valve Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.57
Figure 6-51: Main Air Compressor Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.59
Figure 6-52: Main Compressor Oil Filter Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.59
Figure 6-53: Changing Main Compressor Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.60
Figure 6-54: Subtractive Pilot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.62
Figure 6-55: Main Air Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.65
Figure 6-56: Butterfly Valve Electric Actuator and Valve Assembly . . . . . . . . . . . . . . . . . . . . . . 6.72
Figure 6-57: Butterfly Valve Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.74
Figure 7-1: Low Pressure Motor/Pump Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
Figure 7-2: Low Pressure Hydraulic Valve Bank (Valve Bank 4) . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
Figure 7-3: Low Pressure Hydraulic Valve Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
Figure 7-4: Low Pressure Hydraulic Circuit Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
Figure 7-5: Intake and Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
Figure 7-6: DC Systems Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
Figure 7-7: Cab Roof Hatch Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
Figure 7-8: Boarding Ladder Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
Figure 7-9: Grease Pump Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
Figure 7-10: Hydraulic Pump-Motor Package. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
Figure 7-11: Low Pressure Hydraulic Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
Figure 7-12: Hoist Brake Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17
Figure 8-1: Automatic Lubrication System Componentsl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
Figure 8-2: Lubrication Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
Figure 8-3: Automatic Lubrication System Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
Figure 8-4: Pump Operation Circuit Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
Figure 8-5: Lube Control Circuit Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
Figure 8-6: Lubrication Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
List of Figures, Version 00 - 03/06 -xx- BD120149-00-MSLOF.fm
Figure 8-7: Hydraulic Pump-Motor Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10
Figure 8-8: Grease Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12
Figure 8-9: Lubrication Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.14
Figure 8-10: Pressure Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.17
Figure 8-11: Vent Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19
Figure 8-12: Vent Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.20
Figure 8-13: Injector Operation, Position 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.22
Figure 8-14: Injector Operation - Position 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.23
Figure 8-17: Injector Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.25
Figure 8-18: SL-1 Injector Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.26
Figure 8-19: Injector Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.27
Figure 8-20: Bleeding Air at Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.29
Figure 8-21: Bleeding Air at Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.30
Figure 8-22: Bleeding Air from Feeder Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.31
Figure 9-1: Propel Drive Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
Figure 9-2: Propel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
Figure 9-3: Propel Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
Figure 9-4: Crawler Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
Figure 9-5: Crawler Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
Figure 9-6: Upper Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
Figure 9-7: Idler Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
Figure 9-8: Propel Motor and Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
Figure 9-9: Propel Motor Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10
Figure 9-10: Motor Displacement Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11
Figure 9-11: Propel Transmission Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
Figure 9-13: Spring Cage Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
Figure 9-14: Brake Disk Arrangement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
Figure 9-15: Crawler Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23
Figure 9-16: Upper and Lower Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
Figure 9-17: Crawler Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28
Figure 9-18: Slide Hammer Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.29
Figure 9-19: Drive Rod Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.30
Figure 9-20: Track Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.32
Figure 9-21: Track Tension Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.33
Figure 10-1: Rear Jack (left shown, right similar) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
Figure 10-2: Front Jack (left shown, right similar) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
BD120149-00-MSLOF.fm -xxi- List of Figures, Version 00 - 03/06
Figure 10-3: Jack shoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
Figure 10-4: Hydraulic Cylinder Components (typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
Figure 10-5: Verify Jack System Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10
Figure 10-6: Auto Level Pressure Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12
Figure 10-7: Auto Level Tilt Sensors (LS1, 2, & 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13
Figure 10-8: Check Machine Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
SECTION 11, Mast
Figure 11-1: 120A Mast (Typ.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1
Figure 11-2: Saf-T-Climb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2
Figure 11-3: Back Braces (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3
Figure 11-4: Mast Lock Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3
Figure 11-5: Auxiliary Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.7
Figure 11-6: Auxiliary Winch Brake Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.9
Figure 11-7: Auxiliary Winch Planetary Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.12
Figure 11-8: Auxiliary Winch Drum Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.15
Figure 11-9: Auxiliary Winch Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.17
Figure 11-10: Back Brace (exploded view) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.19
Figure 11-11: Back Brace Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.20
Figure 11-12: Back Brace Locking Collar Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.25
Figure 11-13: Mast Lock Pin Cylinder Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.27
Figure 11-14: Mast Lock Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.30
Figure 11-15: Mast Raise/Lower Cylinder Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.32
Figure 11-16: Mast Raise/Lower Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.34
Figure 11-17: Mast Bottom Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.37
Figure 11-18: Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.40
Figure 12-1: Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1
Figure 12-2: Rotary Drill Pipe Coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2
Figure 12-3: Rotary Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3
Figure 12-4: Installing Motor Pinion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.5
Figure 12-5: Pinion Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.6
Figure 12-6: Rotary Gearcase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.9
Figure 12-7: Legend for Figure 12-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.10
Figure 12-8: Bit Air Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.11
Figure 12-9: Swivel Housing and Air Pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.12
Figure 12-10: Oil Pump Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.13
Figure 12-11: Intermediate Drive Shaft Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.17
Figure 12-12: Checking Main Drive Bearing Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.22
Figure 12-13: Rotary Drill Pipe Coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.24
List of Figures, Version 00 - 03/06 -xxii- BD120149-00-MSLOF.fm
Figure 14-1: Rotary Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1
Figure 14-2: Pulldown Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.2
Figure 14-3: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.2
Figure 14-4: Pulldown Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.3
Figure 14-5: Pulldown Drive Pinion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.3
Figure 14-6: Pulldown Idler Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.4
Figure 14-7: Mast Racking (typical). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.4
Figure 14-8: Upper Guide Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.5
Figure 14-9: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.5
Figure 14-10: Pulldown Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.6
Figure 14-11: Pulldown Resolver (typical). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.6
Figure 14-12: Pulldown Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.7
Figure 14-13: Pulldown Motor Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.9
Figure 14-14: Pulldown Motor Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.10
Figure 14-15: Pulldown Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.12
Figure 14-16: Legend for Figure 14-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.13
Figure 14-17: Rotary Carriage Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.14
Figure 14-18: Legend for Figure 14-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.15
Figure 14-19: Roller Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.19
Figure 14-20: Roller Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.20
Figure 14-21: Guide Rollers (Upper shown; Lower similar) . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.22
Figure 14-22: Upper Carriage Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.25
Figure 14-23: Pulldown Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.27
Figure 14-24: Pulldown Brake Wear Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.29
Figure 14-25: Pulldown Brake Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.31
Figure 14-26: Pulldown Resolver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.34
Figure 14-1: Pipe Handling Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1
Figure 14-2: Deck Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.2
Figure 14-3: Breakout Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.3
Figure 14-4: Pipe Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.5
Figure 14-6: Pipe Wrenches and Liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.7
Figure 14-7: Pipe Rack Gate Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.8
Figure 14-8: Pipe Rack Swing Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.12
Figure 14-9: Pipe Holder Limit Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.15
Figure 14-10: Deck Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.17
Figure 14-11: Deck Wrench Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.20
Figure 14-12: Breakout Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.22
Figure 14-13: Sure Wrench Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.25
Figure 14-14: Jaw Cylinder Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.27
BD120149-00-MSLOF.fm -xxiii- List of Figures, Version 00 - 03/06
Figure 15-1: Water Injection System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1
Figure 15-2: Multipoint Level Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2
Figure 15-3: Water Level Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.3
Figure 15-4: Water Injection Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.3
Figure 15-5: Water Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.4
Figure 15-7: Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.7
Figure 15-8: Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.9
Figure 16-1: Lubrication, Pulldown Gearcase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.5
Figure 16-2: Lubrication, Hydraulic Pump Drive Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . 16.6
Figure 16-3: Lubrication, Auxiliary Winch Gear Reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.7
Figure 16-4: Lubrication, Cable Reel Gear Reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.8
Figure 16-5: Lubrication, Propel Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.9
Figure 16-6: Lubrication, Rotary Gearcase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.10
Figure 16-7: Lubrication, Air Compressor T-Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.11
Figure 16-8: Main Air System Oil Filter Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.12
Figure 16-9: Compressor Oil Filter Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.12
Figure 16-10: Checking Filter Pressure Differentials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.13
Figure 16-11: Main Compressor Oil Filter Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.14
Figure 16-12: Changing Main Compressor Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.15
Figure 16-13: Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.17
Figure 16-14: Hydraulic Tank Level Sight Gauge and Temperature Gauge. . . . . . . . . . . . . . . 16.18
Figure 16-15: Lubrication, Pipe Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.20
Figure 16-16: Lubrication, Mast Back Braces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.21
Figure 16-17: Lubrication, Backup Roller Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.22
Figure 16-18: Manual Lubricant Point Reference Diagram #1 . . . . . . . . . . . . . . . . . . . . . . . . . 16.23
Figure 16-19: Manual Lubrication Point Reference Diagram #2 . . . . . . . . . . . . . . . . . . . . . . . . 16.24
Figure 17-1: Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.5
Figure 17-2: Temperature Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.6
Figure 17-3: GUI Main Page, Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.14
Figure 17-4: First Sub-Page, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.15
Figure 17-5: Typical Fault List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.15
Figure 17-6: Hydraulic Tank Sight Glass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.18
Figure 17-7: T-Tank Sight Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.19
Figure 17-8: Rotary Carriage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.23
Figure 17-9: Right Angle Gear Reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.27
Figure 17-10: Check Crawler Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.31
Figure 17-11: Charge Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.32
Figure 17-12: Charge Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.33
List of Figures, Version 00 - 03/06 -xxiv- BD120149-00-MSLOF.fm
Figure 17-13: Return Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.34
Figure 17-14: Main Compressor Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.35
Figure 17-15: Main Air Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.37
Figure 17-16: T-Tank (on Left Hand Platform) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.39
Figure 17-17: Main Compressor Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.42
Figure 17-18: Propel Transmission Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.50
Figure 17-19: Filter Packs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.53
Figure 17-20: Blade Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.53
Figure 17-21: Roller Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.54
Figure 17-22: Pump Drive Transmission (typ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.58
System Maintenance
Figure B-1: Tightening SAE Flare Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3
Figure B-2: Incorrect O Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.5
Figure B-3: Correct O Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.6
Figure B-4: Split Flange Tightening Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.6
Figure B-5: Flat-face O Ring Seal Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.9
BD120149 Mechanical Systems Manual List of Tables
BD120149-00-MSLOT.fm -xxv- List of Tables, Version 00 - 03/06
Table 1-1: Safety Hazard Decals and Signs (Ref. Drawing R7243) . . . . . . . . . . . . . . . . . . . . . . . 1.9
Table 3-1: System Data Sheet, Auxiliary Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.55
Table 3-2: Counterbalance Valve Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.83
Table 3-3: Valve Bank Pressure Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.92
Table 3-4: Auxiliary Hydraulic System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.98
Table 4-1: Pump Adjustment Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
Table 4-2: Main Hydraulic System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21
Table 6-1: Inlet Valve States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
Table 6-2: Inlet Pressure Gauge Readings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12
Table 6-3: Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.76
Table 8-1: Automatic Lubrication System Lube Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
Table 8-2: Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.32
Table 10-1: Auxiliary Hydraulic System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
SECTION 11, Mast
Table 11-1: Mast Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.41
Table 12-1: Pinion Mounting Data (refer also to Figure 12-5) . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.6
Table 12-2: Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.29
List of Tables
List of Tables BD120149 Mechanical Systems Manual
List of Tables, Version 00 - 03/06 -xxvi- BD120149-00-MSLOT.fm
List of Tables (Continued)
Table 14-1: Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.37
Table 14-1: Jaw and Die Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.23
Table 14-2: Tools, Supplies and Parts Required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.24
Table 16-1: Gear Oil Operating Limits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.2
Table 16-2: Lubrication, Pulldown Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.5
Table 16-3: Lubrication, Hydraulic Pump Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . 16.6
Table 16-4: Lubrication, Auxiliary Winch Gear Reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.7
Table 16-5: Lubrication, Cable Reel Gear Reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.8
Table 16-6: Lubrication, Cable Reel Gear Reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.9
Table 16-7: Lubrication, Rotary Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.10
Table 16-8: Lubrication, Miscellaneous Pins, Levers and Linkages . . . . . . . . . . . . . . . . . . . . . 16.19
Table 16-9: Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.25
Table 16-10: Performance Requirements, Material Specification P&H 464 . . . . . . . . . . . . . . . 16.27
Table 16-11: Physical Requirements, Material Specification P&H 469. . . . . . . . . . . . . . . . . . . 16.30
Table 16-14: Additional Performance Requirements, Material Specification P&H 474. . . . . . . 16.38
Table 17-1: Recommended Torque Values for American Standard Threads (Coarse Threads) 17.2
Table 17-2: Recommended Torque Values for American Standard Threads (Fine Threads). . . 17.3
Table 17-3: Recommended Torque Values for Metric Threads . . . . . . . . . . . . . . . . . . . . . . . . . 17.4
Table 17-4: A Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.8
Table 17-5: B Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.10
Table 17-6: C Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.12
System Maintenance
Table B-1: Pipe Thread Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4
Table B-2: Flare Connection Leakage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.5
Table B-3: Split Flange Leakage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.7
BD120149 Mechanical Systems Manual List of Tables
BD120149-00-MSLOT.fm -xxvii- List of Tables, Version 00 - 03/06
Table B-4: Split Flange Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.8
Table B-5: Flat-face Seal Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B.10
List of Tables BD120149 Mechanical Systems Manual
List of Tables, Version 00 - 03/06 -xxviii- BD120149-00-MSLOT.fm
BD120149 Mechanical Systems Manual Blasthole Drill Safety
Sec01Safety.fm -1.1- Section 1, Version 00 - 03/06
Section 1
Blasthole Drill Safety
1.1 General Information
Since the earliest days of mining, the job of digging iron and other useful materials out of the earth has been con-
sidered one of the world's most dangerous occupations. Public concern about the toll of deaths, injuries and
destruction in mine accidents has prompted passage of much-needed safety legislation and intensified the search
for safer methods and improved training practices and technology. Growing cooperation among industry, labor and
government also has contributed to making mining safer and more healthful, especially in recent years.
Safety and health in the mining industry has improved greatly since the early 20th Century. Total mining fatalities
reached the lowest level in history in 2004. Listed below are safety information websites that can assist in prevent-
ing mining accidents and injuries:
1.1.1 Safety Websites
www.msha.gov. The U.S. Department of Labors Mine Safety and Health Administration (MSHA) helps to reduce
deaths, injuries, and illnesses in the nation's mines with a variety of activities and programs. The agency develops
and enforces safety and health rules applying to all U.S. mines, helps mine operators who have special compliance
problems, and makes available technical, educational and other types of assistance. MSHA works cooperatively
with industry, labor, and other federal and state agencies toward improving safety and health conditions for all min-
ers. MSHA's responsibilities are spelled out in the Federal Mine Safety and Health Act of 1977.
www.osha.gov. The U.S. Department of Labors Occupational Safety and Health Administrations (OSHA) mission
is to assure, so far as possible, every working man and woman in the nation safe and healthful working condi-
tions. By authorizing enforcement of the standards developed under the Occupational Safety and Health Act of
1970; by assisting and encouraging the States in their efforts to assure safe and healthful working conditions; by
providing for research, information, education, and training in the field of occupational safety and health; and for
other purposes.
www.cdc.gov/niosh. The National Institute for Occupational Safety and Health (NIOSH) is the Federal agency
responsible for conducting research and making recommendations for the prevention of work-related disease and
injury. The Institute is part of the Centers for Disease Control and Prevention (CDC).
NIOSH is responsible for conducting research on the full scope of occupational disease and injury ranging from
lung disease in miners to carpal tunnel syndrome in computer users.
Blasthole Drill Safety BD120149 Mechanical Systems Manual
Section 1, Version 00 - 03/06 -1.2- Sec01Safety.fm
1.2 Safe Operating Practices for Users of P&H Mining Equipment - Large
Rotary Blasthole Drills
NOTICE
A review of many safety sources including MSHA, NIOSH, OSHA, ANSI, and various individual
mine safety policies was conducted to develop these safe operating practices recommenda-
tions. The purpose of these recommendations is to assist and support our customer in their
safety efforts in preventing accidents.
1.2.1 Introduction
P&H drills are carefully designed, manufactured, and tested. When used properly by qualified operators, they will
give safe, reliable service. There are P&H offices worldwide to answer any questions about P&H products or their
safe use. The World Sales and Service Headquarters for P&H Mining Equipment is:
P&H Mining Equipment
4400 West National Avenue
P.O. Box 310
Milwaukee, WI 53201 USA
Telephone: (414) 671-4400
Because drills are complex and contain massive pieces of equipment, they also have the potential for accidents if
safe operating practices are not followed. This section is intended to help prevent accidents which could result in
injury, death, or property damage.
General safe practices for working machinery must be followed as well as safe operating practices. The following
P&H Mining Equipment recommendations are provided to supplement customer/owner, local or national safety
codes, rules or procedures.
1.2.2 Qualifications for and Conduct of Operators
The following P&H Mining Equipment recommendations are presented for the purpose of reducing the possibility of
personal injury, either to the operator, or to those who work on or in the area adjacent to the drill. This documenta-
tion is general in nature, and your drill may not be equipped with all devices mentioned.
The operator of this drill is urged to read this section carefully, and to avoid the hazardous operating conditions
described. All situations described in the following have, at one time or another, contributed to serious accidents.
However, it is impossible to foresee all such conditions, and it must remain the responsibility of the mining com-
pany and the operator to anticipate and avoid any unsafe conditions not described in detail in this manual. It is
understood that safety rules within individual mining companies vary, and that, if a conflict exists, the rules of the
company take precedence over the suggestions contained herein.
1.2.2.1 Operators of P&H Rotary Blasthole Drills
P&H Mining Equipment strongly recommends that only the following qualified personnel be permitted to operate a
drill:
1. Designated qualified operators who have met the requirements of the operation tests and physical and mental
conditions.
2. Trainees under the direct supervision of a qualified operator.
3. Qualified maintenance and test personnel when required to do so in the performance of their duties.
4. Inspectors qualified to operate the drill.
1.2.2.2 Operator Qualifications
P&H Mining Equipment strongly recommends that operators and operator trainees meet the following qualifica-
tions:
1. Operators of P&H rotary blasthole drills must be required by the employer to pass a written examination which
accurately measures practical knowledge of the drill, and an evaluated demonstration of the proper methods
and techniques to be used in operating the drill, facilitated by a P&H Factory Authorized Trainer.
2. An operator must have vision of at least 20/30 Snellen in one eye and 20/50 Snellen in the other, with or with-
out corrective lenses. Good depth perception is required.
Figure 1-1: Look closely to see whats in the water...
3. An operator must be able to distinguish colors, regardless of the position of the color, if color differentiation is
required for operation of the drill.
4. An operator must have adequate hearing for the specific operation, with or without hearing aid.
5. An operator must have sufficient strength, endurance, agility, coordination, and speed of reaction to meet the
demands of drill operation.
6. Evidence of physical defects or emotional instability that could render a hazard to the operator or others, or
which in the opinion of a qualified person could interfere with the operators performance, may be cause for
disqualification. In such cases, specialized clinical or medical judgements and tests may be required.
7. Evidence that an operator is subject to seizures or loss of physical control is reason for disqualification. Spe-
cialized medical tests may be required to determine these conditions.
8. Evidence that an operator is under the influence of alcohol or drugs is cause for disqualification.
9. An operator who is taking medication prescribed by a medical doctor must provide written assurance from that
doctor that the medication will not affect the operator's ability to operate the drill in a safe manner.
10. The operator must have a good attitude towards safety at all times.
1.2.2.3 Operators Conduct
SAFETY FIRST
Safety must always be the operator's primary concern. An operator must refuse to operate the
drill when a known unsafe condition exists. Consult your supervisor when safety is in doubt.
1. The operator must read and understand the Operator's Manual and be familiar with all instructions and signs
on the drill.
2. The operator must see that the drill is in proper order before operating.
3. When physically or otherwise unfit, an operator must not engage in the operation of the drill.
4. The operator must not engage in any practice that will divert attention while actually engaged in operating the
drill.
5. The operator will ensure that people, other mining equipment, and material are kept out of the work area. Do
not operate the drill when people are on the drilling platform.
6. The operator must give a warning signal prior to starting, operating, or traveling the drill.
7. All controls must be tested by the operator before beginning a new shift. If any control does not operate prop-
erly, the operator must contact the appropriate maintenance department and have the controls repaired before
operating the drill.
8. If adjustments or repairs are necessary, or any defects are known, the operator must promptly report the
defects to the appropriate maintenance department who will be responsible for the repair of the drill. The oper-
ator must also notify the next operator of any remaining uncorrected defects upon changing shifts.
1.2.2.4 Operators Functional Checks
The operator must make a safety check before starting to work each shift to see that the drill is in proper order.
Some things to check are:
Check for warning tags or lockout tags on the starting controls; do not operate the controls until the tag has
been removed by the person who placed it there, or by a qualified person. Consult your minesites specific
lockout-tagout procedures.
Check with mine maintenance and operations management to see that periodic maintenance and inspec-
tions have been performed and all necessary repairs made.
Consult with mine management that scheduled inspection of load carrying members such as wire rope (dip-
per trip lines, hoist rope, suspension lines), boom, dipper handle and dipper has been conducted.
Check that all equipment guards are in place and all inspection and cover plates are closed and locked.
Look inside, outside and underneath the drill to make sure everything is clear before starting or energizing
the drill.
After starting the drill, check all gauges and indicators for proper readings and operation.
Test all controls for proper operation and controllability before drill operation or travel, including a thorough
check of the brakes.
Check audible warning devices and alarms used for backup warning for proper operation.
During operation, be alert for unusual noises or vibrations; look and smell for unusual smoke or fumes.
1.2.3 Responsibilities of All Crew Members
Any unsafe condition or practice must be reported to the job supervisor and drill operator. Everyone who works
around drills, including support people and maintenance personnel, must obey all safety hazard signs and watch
out for their own safety and the safety of others in the area. Crew members setting up machines or handling main-
tenance and repairs are expected to know proper procedures including lockout and tagout procedures.
Watch for hazards during operations and alert the operator of potential safety hazards such as the unexpected
presence of people, other equipment in the area, unstable ground, bank conditions, or approaching storms.
1.2.4 Planning the Job
Most accidents can be avoided by careful job planning. The person in charge must have a clear understanding of
the work to be done, consider dangers or hazards, develop a plan to do the job safely, and then explain the plan to
all concerned. Factors such as the following should be considered:
How can the drill trail cable be safely moved at the work site?
Is there other equipment, power lines, or structures which must be moved or avoided during movement of
the drill?
Is the surface strong enough to support the drill and load?
Can the drill be moved with the mast up, or must the mast be lowered?
What steps will be taken to keep unnecessary people and equipment at a safe distance from the work area?
These factors are not meant to be all encompassing, but only a starting point. Each job must be individually consid-
ered.
1.3 Operation Near Electrical Lines Precautions
DANGER
!
Keep clear of power lines when machine is in operation. Death or injury could result
should any part of the machine comes within minimum distance of an energized power
line specified by local, state and federal regulations.
Working in the vicinity of electrical power lines presents a very serious hazard and special precautions must be
taken. Safe operating practices require that you maintain the maximum possible distance from the lines and never
violate the minimum clearances.
Before working in the vicinity of power lines, the following precautions should be observed:
Contact the owners of the power lines or the nearest electric utility before beginning work.
Machine operator and electrical utility representative must jointly determine what specific precautions are
taken.
Machine operator and electrical utility representative must confirm that all precautions are taken and fol-
lowed.
Even when power lines are known to be locked out and tagged out, consider them to be energized.
Inform all ground personnel to stand clear of the machine at all times.
Use a signal person to guide the machine into close quarters. The sole responsibility of the signal person is to
observe the approach of the machine to the power line. The signal person must be in direct communication with
the operator and the operator must pay close attention to the signals
1.4 Safety Decals and Signs
1.4.1 General
Hazard Indicators and Safety Hazard Decals and Signs identify potential safety hazards and prevent accidents by
displaying standard symbols, headers and pictographs or custom graphics. Headers, graphics, and layouts of indi-
cators, decals, and signs conform to current ANSI guidelines, and are consistent with the industry standards for
such devices commonly used for high voltage, personal protection, confined space, and bilingual applications.
1.4.2 Hazard Indicators
DANGERS, WARNINGS, CAUTIONS, NOTICES, and SAFETY FIRSTS are used on signs and decals, and
throughout our manuals to emphasize important and critical instructions. In written documentation, DANGERS,
WARNINGS, CAUTIONS, and SAFETY FIRSTS will precede the paragraph or item to which they apply. NOTICES
will follow the paragraph or item to which they apply. DANGERS, WARNINGS, CAUTIONS, NOTICES and
SAFETY FIRSTS are identified and defined as follows:
DANGER
!
Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury. This signal word is limited to the most extreme situations.
WARNING
!
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION
!
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
major injury.
CAUTION
A Caution without a Safety Alert Symbol (Triangle and Exclamation Point) is used to
warn of hazards that result only in property damage.
NOTICE
Used to indicate a statement of company policy directly or indirectly related to the safety of per-
sonnel or protection of property. This signal word is not associated directly with a hazard or haz-
ardous situation and is not used in place of DANGER, WARNING, or CAUTION.
SAFETY FIRST
Used to indicate general instructions relative to safe working practices, remind of proper safety
procedures, and indicate the location of safety equipment.
1.4.3 Safety Hazard Decals and Signs
Safety Hazard Decals and Signs use hazard indicators discussed in the preceding paragraphs, and also display
pictographs to show, both graphically and verbally, where potential safety hazards exist around the rotary blasthole
drill. These decals and signs do not represent every possible hazard. They are not intended to be a substitute for
safe working practices and good judgement.
The following Safety Hazard Decals and Signs are examples of those found on a typical rotary blasthole drill. Be
certain everyone working on, or near, the drill understands, and knows how to avoid, the hazards they represent.
Do not remove, cover, paint over, or deface these Safety Decals or Signs. If they become damaged or obscured,
request replacement decals and signs from your local MinePro Services office.
1.4.3.1 Description
Safety Hazard Decals and Signs are located throughout the drill in various locations. Table 1-1 describes all Safety
Hazard Decals and Signs used on the P&H Model 120A Rotary Blasthole Drill. The Item Number is the item num-
ber indicated on engineering drawing R7243, SIGN INSTL; the number in parentheses is the P&H part number.
Item Number Safety Hazard Decal/Sign Description
5
(32Z2536D2)
Yellow and black caution
tape.
In compliance with official
regulations that state
Yellow shall be the basic
color for designating cau-
tion and for marking
physical hazards such as:
Striking against, stum-
bling, falling, tripping,
and caught in between.
20
(32Q1770D1)
This CAUTION decal
alerts personnel that
abnormal performance
can cause personnel
injury or property dam-
age.
Do not open switch dur-
ing normal operation.
21
(32Q1752)
This WARNING decal
alerts personnel that haz-
ardous voltage inside can
cause severe injury or
death.
Keep all doors and covers
closed.
Do not open unless quali-
fied and authorized.
Disconnect power to all
circuits.
Use lockout and tagout
procedures before servic-
ing.
Table 1-1: Safety Hazard Decals and Signs (Ref. Drawing R7243)
ES02973a01
ABNORMAL PERFORMANCE
CAN CAUSE
PERSONAL INJURY
OR PROPERTY DAMAGE.
DO NOT OPEN SWITCH
DURING NORMAL
OPERATION.
32Q1770D1
ES03009a01
HAZARDOUS
VOLTAGE INSIDE.
CAN CAUSE SEVERE
INJURY OR DEATH.
Keep all doors
and covers
closed.
Do not open
unless qualified
and authorized.
Use lockout and
tagout procedures
before servicing.
32Q1752
22
(32Q1764D1)
This WARNING decal
rotating parts can cause
injury if contacted.
Do not remove guard if
machine is operating.
Replace guard before
operating machine.
ing.
23
(32Q1780D3)
This NOTICE Decal is
used with 32Q1805D_ to
alert the user of level of
voltage which may be
present.
24
(32Q1801)
This WARNING decal
ardous voltages may be
present.
Can cause severe injury
or death.
circuits.
ing.
ES02919a01
Do not remove
guard if
machine is
operating.
Replace guard
before
operating
machine.
Use lockout
and tagout
procedures
before
servicing.
ROTATING PARTS.
CAN CAUSE
INJURY IF
CONTACTED.
ES02915a01
MAXIMUM LEVEL MAY BE PRESENT.
ES02956a01
HAZARDOUS
VOLTAGE
MAY BE
PRESENT.
CAN CAUSE
SEVERE
INJURY
OR DEATH.
Disconnect
Power
to all
Circuits.
Use lockout
and tagout
procedures
before
servicing.
32Q1801D1
30
(32Q1806)
This DANGER Decal alerts
personnel of hazardous
voltage.
Do not service unless
qualified and authorized.
Check for voltages
present.
circuits. Use lockout and
tagout procedures before
servicing.
Will cause severe injury
or death.
31
(32Q1808)
This CAUTION decal
opening the door stops
the machine.
Unexpected stopping or
abnormal performance
can cause personal injury
and property damage.
Do not open doors while
machine is running.
32
(32Q1809)
This WARNING decal
death.
Keep all doors and covers
closed.
Do not open unless quali-
fied and authorized.
circuits.
ing.
ES03011a01
HAZARDOUS
VOLTAGE.
DO NOT SERVICE
UNLESS QUALIFIED
AND AUTHORIZED.
Check for
voltages present.
Disconnect power
to all circuits.
Use lockout and
tagout procedures
before servicing.
Will cause severe
injury or death.
ES02942a01
OPENING DOOR STOPS MACHINE.
UNEXPECTED STOPPING OR ABNORMAL
PERFORMANCE CAN CAUSE PERSONAL
INJURY AND PROPERTY DAMAGE.
Do not open doors while machine
is running.
32Q1808D1
ES02944a01
HAZARDOUS VOLTAGE INSIDE.
CAN CAUSE SEVERE INJURY OR DEATH.
Keep all doors and covers closed.
Do not open unless qualified and authorized.
Disconnect power to all circuits.
Use lockout and tagout procedures
before servicing.
32Q1809D1
33
(32Q1816)
This WARNING decal
alerts personnel of haz-
ard voltage inside.
circuits.
ing.
or death.
34
(32Q1819)
This CAUTION sign alerts
personnel of rotating
parts.
Keep fingers clear of
rotating machinery.
Use lockout/tagout pro-
cedures to service or
maintenance.
Can cause injury if con-
tacted.
BD0321a01
WARNING
!
HAZARDOUS
VOLTAGE INSIDE.
DO NOT SERVICE
UNLESS QUALIFIED
AND AUTHORIZED.
Disconnect power
to all circuits.
Use lockout and
tagout procedures
before servicing.
Can cause severe
injury or death.
32Q1816D1
ES03014a01
ROTATING PARTS.
KEEP FINGERS
CLEAR OF
ROTATING
MACHINERY.
Use lockout/
tagout
procedures for
service or
maintenance.
Can cause injury
if contacted.
32Q1819
35
(32Q1820)
This WARNING decal
alerts personnel of a haz-
ardous area.
Do not enter when
machine is in operation.
Can cause severe injury.
36
(32Q1912)
This DANGER sign alerts
personnel that no smok-
ing or open flames are
permitted.
37
(32Q1913)
This CAUTION decal
alerts personnel of non-
potable water.
Do not drink.
Do not use for cooking or
washing.
Can cause illness.
WARNING !
BD0323a01
HAZARDOUS AREA.
32Q1820
Can cause severe injury.
DO NOT ENTER WHEN MACHINE
IS IN OPERATION.
ES02971a01
CAUTION
BD0322a01
NON-POTABLE WATER.
DO NOT DRINK.
32Q1913
Do not use for cooking or
washing.
Can cause illness.
38
(32Q1914)
This WARNING decal
flammable materials can
burn or ignite.
No smoking or open
flames inside this room.
Fire or explosion can
cause severe injury,
death or property dam-
age.
39
(32Q1915)
This DANGER decal alerts
personnel that hazard-
ous voltage may be
present.
Energized overhead
power lines can be con-
tacted by raising the drill
mast.
Do not raise mast near
power lines.
or death to ground per-
sonnel near to or touch-
ing the machine.
ES02970a01
FLAMMABLE MATERIALS.
CAN BURN OR IGNITE.
NO SMOKING OR OPEN FLAMES INSIDE THIS ROOM.
FIRE OR EXPLOSION CAN CAUSE SEVERE INJURY,
DEATH OR PROPERTY DAMAGE.
32Q1914
BD180a01
HAZARDOUS VOLTAGE
MAY BE PRESENT.
Do not raise mast near
power lines.
ENERGIZED OVERHEAD POWERLINES
CAN BE CONTACTED BY RAISING
THE DRILL MAST.
or death to ground personnel
near to or touching the
machine.
40
(32Q1916)
This CAUTION decal
alerts personnel of com-
pressed air.
Can spray with force and
noise.
Wear eye and ear protec-
tion while venting the air.
Do not service until pres-
sure is relieved.
Can cause injury or hear-
ing loss.
41
(32Q1917)
This WARNING decal
unexpected machine
movement can cause
severe injury or death.
Always notify machine
operator of your pres-
ence.
Keep hands, body and
clothing away from
machinery.
ES03018a01
COMPRESSED AIR.
CAN SPRAY WITH FORCE AND NOISE.
WEAR EYE AND EAR PROTECTION
WHILE VENTING THE AIR.
Do not service until pressure
is relieved.
Can cause injury or hearing loss.
32Q1916
ES03019a01
UNEXPECTED MACHINE MOVEMENT CAN
CAUSE SEVERE INJURY OR DEATH.
Always notify machine operator
of your presence.
32Q1814
Keep hands, body and clothing
away from machinery.
42
(32Q1948D1)
This WARNING decal
alerts personnel to high
pressure hydraulic hoses
and valves.
Do not service until pres-
sure is relieved.
or death.
43
(32Q1921)
This WARNING decal
alerts personnel to a tip-
ping hazard.
Do not exceed 8 tilt in
any direction without
consulting the stability
diagram delivered with
this machine.
Note: 8 slope = 14%
grade
Can cause severe injury,
death or property dam-
age.
44
(32Q1931)
This NOTICE decal alerts
personnel to read opera-
tors manual before
attempting to operate
machine.
ES03020a01
HIGH PRESSURE HYDRAULIC
HOSES AND VALVES.
Do not service until
pressure is relieved.
or death.
32Q1916
BD181a01
TIPPING HAZARD.
DO NOT EXCEED 8 TILT
IN ANY DIRECTION
WITHOUT CONSULTING
THE STABILITY DIAGRAM
DELIVERED WITH THIS
MACHINE.
CAN CAUSE SEVERE
INJURY, DEATH OR
PROPERTY DAMAGE.
NOTE:
8 SLOPE = 14% GRADE
32Q1921
ES02939a01
READ OPERATORS
MANUAL BEFORE
ATTEMPTING TO
OPERATE MACHINE.
32Q1931D1
45
(32Q1932)
This CAUTION decal
alerts personnel to drill-
ing dust and projectiles.
Keep away from drill and
machine during drill oper-
ation.
Wear face and breathing
protection when working
near operating drill.
ence.
Can injure eyes and
lungs.
46
(32Q1933)
This WARNING decal
alerts personnel to haz-
ardous area. Falling or
flying objects.
Noise, tripping or slip-
ping, moving machinery.
Can cause injury.
Wear head, hearing and
eye protection. Keep
hands, body and clothing
away from machinery.
Watch your step.
BD182a01
DRILLING DUST AND
PROJECTILES.
KEEP AWAY FROM DRILL AND
MACHINE DURING DRILL
OPERATION.
WEAR FACE AND BREATHING
PROTECTION WHEN WORKING
NEAR OPERATING DRILL.
operator of your
presence.
Can injure eyes and
lungs.
32Q1932
ES02938a01
HAZARDOUS AREA.
FALLING OR FLYING OBJECTS.
NOISE, TRIPPING OR SLIPPING, MOVING
MACHINERY.
CAN CAUSE INJURY.
Wear head, hearing and eye protection.
Keep hands, body and clothing away
from machinery.
Watch your step.
32Q1933
47
(32Q1934)
This WARNING decal
alerts personnel to an
open serviceway.
Falling objects and unex-
pected machine move-
ment can cause severe
injury or death.
Do not enter when
Always notify operator of
your presence.
clothing away from
machine.
Use pathways, hold hand-
rails and watch your step.
48
(R57305D1)
This WARNING decal
alerts personnel to poten-
tial arc-flash hazards.
Wear proper personal
protective equipment
while working inside
energized cabinet.
See NFPA 70E.*
*NFPA 70E is a booklet published by
the National Fire Protection Associa-
tion. NFPA 70E: Electrical Safety in
the Workplace is available for sale at
www.nfpa.org/catalog
50
(32Q1937)
personnel to hazardous
voltage.
or death.
Insure that all high volt-
age is removed from the
machine before servicing.
WARNING
!
BD0324a01
32Q1934
Always notify machine operator of your
presence.
FALLING OBJECTS AND UNEXPECTED MACHINE
MOVEMENT CAN CAUSE SEVERE INJURY OR DEATH.
OPEN SERVICEWAY.
DO NOT ENTER WHEN MACHINE IS IN OPERATION.
Keep hands, body and clothing away from
machine.
Use pathways, hold handrails and watch
your step.
POTENTIAL ARC-FLASH HAZARDS.
Wear proper personal
protective equipment while
working inside energized
cabinet (see NFPA 70E).
R57305D1
ES04423a01
BD0325a01
HAZARDOUS
VOLTAGE.
WILL CAUSE SEVERE
INJURY OR DEATH.
Insure that all
high voltage is
removed from the
machine before
servicing.
32Q1937
51
(32Q1939)
This WARNING sign alerts
personnel of an open ser-
viceway.
Falling objects and unex-
pected machine move-
ment can cause severe
injury or death.
Do not enter when
ence.
clothing way from
machine.
Use pathways, hold hand-
rails and watch your step.
52
(32Q1942D1)
This WARNING decal
rotating parts and haz-
death.
Keep fingers clear of
rotating machinery.
circuits before opening
covers.
ing.
54
(32Q1930)
personnel that hazard-
ous voltage will cause
severe injury or death.
Insure that all high volt-
age is removed from the
machine before servicing
switch.
ES03028a01
FALLING OBJECTS AND UNEXPECTED MACHINE
MOVEMENT CAN CAUSE SEVERE INJURY OR DEATH.
OPEN SERVICEWAY.
DO NOT ENTER WHEN MACHINE IS IN
OPERATION.
ALWAYS NOTIFY MACHINE OPERATOR OF YOUR
PRESENCE.
KEEP HANDS, BODY AND CLOTHING AWAY
FROM MACHINE.
USE PATHWAYS, HOLD HANDRAILS AND
WATCH YOUR STEP
32Q1939
ES02930a01
ROTATING PARTS AND HAZARDOUS VOLTAGE INSIDE.
CAN CAUSE SEVERE INJURY OR DEATH.
Use lockout and tagout procedures before servicing.
Keep fingers clear of rotating machinery.
Disconnect power to all circuits before opening covers.
R42190D1
DL0116a01
32Q1930
HAZARDOUS
VOLTAGE.
WILL CAUSE SEVERE
INJURY OR DEATH.
DO NOT SERVICE
UNLESS QUALIFIED
AND AUTHORIZED.
Insure that all
high voltage is
removed from the
machine before
servicing switch.
55
(32Q1945D1)
This WARNING decal
exposure to harmful silica
dust during rock drilling
can cause serious respi-
ratory disease, cancer or
death.
Use respiratory protec-
tion during drilling.
Avoid dust contamination
from work clothes, eat-
ing or drinking.
Follow mine procedures
for air monitoring, expo-
sure limitations and pro-
tection methods.
58
(32Q1949D1)
This DANGER sign alerts
personnel of fan blades.
Fan may start without
warning.
or death if contacted.
60
(R12771D1)
Climbing onto mast from
ladder can cause falls
resulting in severe injury
or death.
Always use fall protec-
tion when climbing a lad-
der without cage or
ladder rings.
Mast ladder is for inspec-
tions of mast or mast
equipment. lower mast
for service or mainte-
nance.
BD183a01
EXPOSURE TO HARMFUL SILICA DUST
DURING ROCK DRILLING CAN CAUSE
SERIOUS RESPIRATORY DISEASE, CANCER
OR DEATH.
USE RESPIRATORY PROTECTION
DURING DRILLING.
AVOID DUST CONTAMINATION
FROM WORK CLOTHES, EATING
OR DRINKING.
FOLLOW MINE PROCEDURES FOR AIR
MONITORING, EXPOSURE LIMITATIONS
AND PROTECTION METHODS.
32Q1945D1
FAN BLADES
FAN MAY START
WITHOUT WARNING
Will cause severe
injury or death
if contacted.
32Q1949
BD326a01
BD185a01
CLIMBING ONTO MAST FROM
LADDER CAN CAUSE FALLS
RESULTING IN SEVERE INJURY
OR DEATH.
ALWAYS USE FALL PROTECTION
WHEN CLIMBING A LADDER
WITHOUT CAGE OR LADDER
RINGS.
MAST LADDER IS FOR
INSPECTIONS OF MAST OR
MAST EQUIPMENT. LOWER MAST
FOR SERVICE OR MAINTENANCE.
R12771D1
62
(R12773D1
This WARNING decal
alerts personnel of a fall-
ing load hazard.
Maximum winch capacity
not to exceed 15000#
with bare drum.
Maintain a minimum of 3
to 4 wraps of wire rope
on the drum at all times.
63
(R30729D1)
This CAUTION decal
improper use of stairway
can cause tripping or fall-
ing resulting in injury.
Always face stairway
while using.
64
(R30809D1)
This CAUTION sign alerts
personnel that improper
use of stairway can cause
tripping or falling result-
ing in injury.
Always face stairway
while using
FALLING LOAD HAZARD
MAXIMUM WINCH CAPACITY
NOT TO EXCEED 15000#
WITH BARE DRUM.
Maintain a minimum of
3 to 4 wraps of wire
rope on the drum at
all times.
R12773
BD0327a01
ES03057a01
IMPROPER USE OF
STAIRWAY CAN CAUSE
TRIPPING OR FALLING
RESULTING IN INJURY.
ALWAYS FACE STAIRWAY
WHILE USING.
R30729D1
ES03058a01
IMPROPER USE OF STAIRWAY CAN
CAUSE TRIPPING OR FALLING
RESULTING IN INJURY.
ALWAYS FACE STAIRWAY WHILE USING.
1.4.3.2 Description
Safety Hazard Decals and Signs are located throughout the drill in various locations. Figure 1-2 through Figure 1-16
illustrate the location of safety decals and signs on the drill. An index of the figures are shown in the bulleted list
below. The callout numbers can be cross referenced to the item numbers in Table 1-1.
Mast and Drilling Deck, Figure 1-2
Mast Hoist Cylinder Boots, Figure 1-3
Machinery House Exterior Panels, Figure 1-4
Machinery Deck Layout (Overview), Figure 1-5
Operators Cab Door (Drill Deck), Figure 1-6
Oil Separator, Figure 1-7
Main Transformer (right side), Figure 1-8
Main Transformer (front view), Figure 1-9
Fan Room Door, Figure 1-10
Machinery House Door (front) (outside), Figure 1-11
Lube Room Door (outside), Figure 1-12
Power Skid (typical both sides), Figure 1-13
PLC Cabinet, Figure 1-14
65
(R49498D1)
This CAUTION decal
alerts personnel that this
machine can be remote
controlled.
Only one operator shall
control the machine and
the remote control box at
the time.
66
(R49499D1)
This CAUTION decal
alerts personnel that this
machine can be remote
controlled.
Only one operator shall
control the machine and
the remote control box at
the time.
BD187a01
THIS MACHINE CAN BE REMOTE CONTROLLED.
ONLY ONE OPERATOR SHALL CONTROL THE MACHINE
AND THE REMOTE CONTROL BOX AT THE TIME.
R49498D1
BD188a01
THIS MACHINE CAN BE REMOTE CONTROLLED.
ONLY ONE OPERATOR SHALL CONTROL THE MACHINE
AND THE REMOTE CONTROL BOX AT THE TIME.
R49499D1
Solenoid Junction Box, Figure 1-15
Machinery House Door (rear) (outside), Figure 1-16
Operators Cab Door (front) (outside), Figure 1-17
Machinery Deck Layout (electrical cabinets), Figure 1-18
Auxiliary Cabinet, Figure 1-19
Hoist/Rotary Junction Box, Figure 1-20
DC Hoist Drive Cabinet, Figure 1-21
DC Rotary Drive Cabinet, Figure 1-22
High Voltage Junction Box, Figure 1-23
460V Load Center, Figure 1-24
120V Load Center, Figure 1-25
High Voltage Cabinet (side view), Figure 1-26
High Voltage Cabinet (front view), Figure 1-27
Operators Cab (Inside), Figure 1-28
Figure 1-2: Mast and Drilling Deck
23
33
30 a
(575VDC)
34
34
23
(575VDC)
24
52
24
23
34
52
34
45
45 55
e 34
BD0328
LEGEND
Inside of door/panel/cover
Inside or facing inside
Outside or facing outside
Eye level
Both sides
b
a
c
d
e
Figure 1-3: Mast Hoist Cylinder Boots
Figure 1-4: Machinery House Exterior Panels
5
5
34 34 51 b b 51 51 b
55 d
47 d
34
e
63
51 c 64 c 41 e 43 47 d 55 63 60 64 c d 51 51 41 e b c 45
LEGEND
Inside front door/panel/cover
Inside or Facing Inside
Outside or Facing Outside
Eye Level
Both Sides
a
b
c
d
e
Figure 1-5: Machinery Deck Layout (Overview)
01
02
03 04
05
06
07
08
09
10
11
12
23 d
LEGEND
01. Operators Cab Door (Drill Deck), Figure 1-6
02. Oil Separator, Figure 1-7
03. Main Transformer (right side), Figure 1-8
04. Main Transformer (front view), Figure 1-9
05. Fan Room Door, Figure 1-10
06. Machinery House Door (front) (outside), Figure 1-11
07. Lube Room Door (outside), Figure 1-12
08. Power Skid (typical both sides), Figure 1-13
09. PLC Cabinet, Figure 1-14
10. Solenoid Junction Box, Figure 1-15
11. Machinery House Door (rear) (outside), Figure 1-16
12. Operators Cab Door (front) (outside), Figure 1-17
FOR ALL FIGURES:
Eye Level
Both Sides
a
b
c
d
e
Figure 1-6: Operators Cab Door (Drill Deck)
Figure 1-7: Oil Separator
62
46 d
d
LEGEND
Eye Level
Both Sides
a
b
c
d
e
40
Figure 1-8: Main Transformer (right side)
Figure 1-9: Main Transformer (front view)
a 50
21
23
a
50
21
23 23 a 50 21
a
50
21
23
a
30
c
21
Figure 1-10: Fan Room Door
58*
35
d 46
55
47
*on fan duct
Figure 1-11: Machinery House Door (front) (outside)
Figure 1-12: Lube Room Door (outside)
d 46
a
36
38
Figure 1-13: Power Skid (typical both sides)
Figure 1-14: PLC Cabinet
52 22 24 23 22 22 40
a
57
A-A*
30
21
23
32
*A-A refers to the constant voltage transformer inside the PLC cabinet.
Figure 1-15: Solenoid Junction Box
Figure 1-16: Machinery House Door (rear) (outside)
Figure 1-17: Operators Cab Door (front) (outside)
a 30 23 21 42*
*on back
wall
d 46
c 51
46 d
Figure 1-18: Machinery Deck Layout (electrical cabinets)
01
02
03 04
05
06
07 08 09
10
37
LEGEND
01. Auxiliary Cabinet, Figure 1-19
02. Hoist/Rotary Junction Box, Figure 1-20
03. DC Hoist Drive Cabinet, Figure 1-21
04. DC Rotary Drive Cabinet, Figure 1-22
05. High Voltage Junction Box, Figure 1-23
06. 460V Load Center, Figure 1-24
07. 120V Load Center, Figure 1-25
08. High Voltage Cabinet (side view), Figure 1-26
09. High Voltage Cabinet (front view), Figure 1-27
10. Operators Cab (Inside), Figure 1-28
FOR ALL FIGURES:
Eye Level
Both Sides
a
b
c
d
e
* In
Figure 1-19: Auxiliary Cabinet
Figure 1-20: Hoist/Rotary Junction Box
50*
31
a
23
21
30
31
a
23
21
30
* On Back
Wall
23
33
a 30
Figure 1-21: DC Hoist Drive Cabinet
Figure 1-22: DC Rotary Drive Cabinet
21
a 30
31
23
21
a 30
31
23
Figure 1-23: High Voltage Junction Box
BD0986a01
33
50
23
48
a
Figure 1-24: 460V Load Center
23
Figure 1-25: 120V Load Center
Figure 1-26: High Voltage Cabinet (side view)
23
20
Figure 1-27: High Voltage Cabinet (front view)
Figure 1-28: Operators Cab (Inside)
a 54
54
23
62
39
43
66
44
BD120149 Mechanical Systems Manual Introduction
Sec02Intro.fm -2.1- Section 2, Version 00 - 03/06
Section 2
Introduction
2.1 General
This manual provides the information required to repair and maintain the P&H Mining Equipment Model 120A
Rotary Blasthole Drill.
2.1.1 Part Numbers
Repair parts information is provided in the LinkOne electronic parts manual that is prepared for your drill. The drill
serial number is located inside the operator's cab.
Part numbers are sometimes shown in this manual to identify specific assemblies and the information and proce-
dures that apply to that specific assembly. Since this book is not updated on a continuous basis, do not use these
part numbers to order repair parts.
NOTICE
Always obtain the part numbers from the up-to-date LinkOne electronic parts manual.
Figure 2-1: P&H Model 120A Rotary Blasthole Drill
Introduction BD120149 Mechanical Systems Manual
Section 2, Version 00 - 03/06 -2.2- Sec02Intro.fm
2.1.2 Applicability
All information in this manual, including descriptions, specifications, and illustrations is for P&H model 120A Rotary
Blasthole Drill, Serial Number BD120149, at the time of publication. Product improvements, owner modifications,
or other changes introduced after this manual was published are not covered.
2.2 Questions concerning the drill or this manual should be referred to your P&H MinePro Services representative.
2.3 Description
2.3.1 General
The rotary blasthole drill is designed to drill blast holes. These holes are then filled with explosives, which fracture
the material for most efficient removal. The drill can be equipped for single-pass drilling or multiple-pass drilling by
coupling additional lengths of drill pipe to form a drill string. This drill only drills vertical holes.
All drill motions use electric motors with the exception of the propel motion, which uses hydraulic power. Power for
the drill is provided by a double-shafted electric motor, coupled on one end to the air compressor and on the other
end to the hydraulic pump drive transmission (PDT).
2.3.2 Drill Description
The Model 120A rotary blasthole drill (hereafter, the drill) produces pulldown bit load up to 150,000 lbs and has
been optimized to drill single-pass or multi-pass holes up to 22" (55.88 cm) in diameter (see Figure 2-2). The total
machine weight is approximately 365,000 lbs (165,564 kg). The standard pipe rack provides storage for one 65-
foot (19.8-meter) pipe with 2-inch (50 mm) pipe wall thickness and up to 10.75 inches (273 mm) diameter. A sec-
ond pipe rack is available as an option. Refer to Figure 2-3 for the drill deck plan.
Figure 2-2: Model 120A Rotary Blast Hole Drill
01
02
03
04
05
06
07
08
09
10
BD00356b01
LEGEND
01. Mast
02. Rotary Carriage
03. Back Braces
04. Vent
05. Cable Reel
06. Machinery House
07. Crawler Assembly
08. Operators Cab
09. Drilling Deck
10. Left Rear Levelling Jack
Figure 2-3: Model 120A Deck Plan
01
BD0378f01
02
03
04
05
06
07
08
09
10
11
12
13
14
16 15 17
18
19
20
21
22
23
24
25
26
27
28
LEGEND
01. Valve Bank 3
02. Valve Bank 2
03. Valve Bank 1
04. Auxiliary Cabinet
05. Water Tank
06. PLC Cabinet
07.T-Tank
08. DC Hoist Cabinet
09. DC Rotary Cabinet
10. High Voltage Cabinet
11. Main Transformer
12. Control Load Center
13. Auxiliaries Load Center
14. Compressor Oil Cooler
15. Hydraulic Tank
16. Hydraulic Oil Cooler
17. Grease Reservoir
18. Lube Control Panel
19. Valve Bank 4
20 Valve Bank 5
21. Low Pressure/Head Brake
Pumps
22. Propel Pumps
23. Auxiliary Hydraulic Pump
24. Main Motor
25. Main Air Control Panel
26. Compressor
27. Mast Cylinder (2)
28. Operators Cab
2.3.3 Power Unit R10433F1
The Model 120A is powered by the 700HP main AC electric motor, which is configured for the voltage and fre-
quency available at the mine site. The electrical system remains operational even when the mine voltage fluctuates
up to plus 10% or minus 15% from nominal.
The hydraulic pump drive transmission (PDT) and the main air compressor are both driven by the main AC motor
rotating at 1,800 RPM (at 60 Hz; at 50 Hz, the motor rotation is 1500 RPM). The motor is designed to function well
within the voltage fluctuation level specified.
Figure 2-4: Main Drive Motor
2.3.4 Main Air Compressor 51U165D4
The main air compressor is a rotary screw type which provides a rated output of 3,600 scfm. It is coupled to the
main electric motor by means of a flexible coupling to ensure smooth operation. The main motor, air compressor
and PDT are mounted on a skid to isolate the assembly from mainframe distortion that may occur while leveling or
propelling the drill.
2.3.5 Undercarriage and Propel 100J6626F4
The two crawler frames are attached to the underside of the main frame by a fixed rear axle and an oscillating front
axle. This arrangement tends to increase stability and also to isolate the main frame from excessive loading when
propelling over rough terrain. The heavy duty crawler units are rated for a drill weight of over 200 tons.
The crawler shoes are of lug-and-tumbler design. There are 58 crawler shoes per crawler, approximately one-third
of which are cleated, and two-thirds uncleated. The two crawlers are independently driven by drive tumblers with
Figure 2-5: Main Air Compressor
Figure 2-6: Undercarriage and Propel
planetary transmissions directly bolted to the crawler frame. An individual plug-in hydrostatic motor powers each
planetary transmission. The transmissions are nested within the drive tumbler for protection from travel damage in
rough areas.
Each planetary transmission has an integral spring-set, hydraulically released wet-type multiple disc parking brake.
The propel motor can be manually disengaged from the transmissions to allow towing the drill with the optional
towing package installed.
The crawlers can be counter-rotated to provide maximum maneuverability for tight turns and rapid travel from point
to point.
2.3.6 Rotary Carriage R54410F4
Two electric drive motors drive the rotary driveshaft through the rotary gearcase (see Figure 2-8). The rotary drive
shaft protrudes from the bottom of the rotary gearcase for connection to the drill string.
The rotary motor output shaft fits into the rotary gearcase first reduction pinion shaft, which is supported by bear-
ings on both the top and the bottom. An oil pump on the bottom of the first reduction shaft provides lubrication for
the upper bearings in the gearcase.
A rotary air swivel ensures sealed air flow through the rotary drive shaft. The rotary air seal also prevents water
from entering the rotary gearcase oil when the drill is configured with water injection for dust suppression.
2.3.7 Pulldown Mechanism 916J204F1
Pulldown is accomplished by means of a rack and pinion drive (see Figure 2-8). The rack is mounted vertically on
the mast and the drive pinion on the rotary carriage shipper shaft.
Figure 2-7: Rotary Carriage
Figure 2-8: Rotary and Pulldown Mechanisms
BD0574a01
01
02 04 05
06
09 08
07
10
03
LEGEND
01. Pulldown Gearcase
02. Pulldown Brake
03. Shipper Shaft
04. Pulldown Motor
05. Pulldown Motor Blower
06. Drive Pinion
07. Guide Roller
08. Idler
09. Rotary Drive Motor
10. Rotary Gearcase
The rotary carriage guide rollers are provided with an eccentric arrangement for adjustment of rack/pinion gear
backlash and alignment with the mast. An electric DC motor drives the hoist/pulldown pinions through the pulldown
transmission.
2.3.8 Drill Pipe Storage
Drill pipe can be stored in the parallelogram-style pipe rack. The drill features two pipe racks. The main rack is 11.3
meters in length, while the additional rack is 8.4 meters. The racks are hydraulically controlled to move inward or
outward. A mechanical mechanism is used to lock the drill pipe into place while stored.
2.3.9 Mast and Back Braces R14102F6
The mast chords utilize structural steel members. The mast safety sling ensures retention of a falling drill pipe with-
out structural damage to the mast.
The mast is raised and lowered by two hydraulic cylinders and is locked in the vertical position by two hydraulically
actuated mast lock pins located below
the drilling deck. The position of these pins is monitored by the Programmable Logic Controller (PLC).
The back braces fold and unfold automatically when the mast is raised and lowered. Two back brace locking col-
lars slide over the folding knee joints between the upper and lower back braces to keep the back braces rigid, lock-
ing the mast in the vertical drilling position.
2.3.10 Winch 23U52D1
A hydraulic motor driven winch is mounted on the machinery deck, between the mast hoist cylinders and generally
below Valve Bank 2. The winch is used to handle tools and lift loads on the drilling platform. It features a one-way
clutch, so that the winch will hold a load, yet will automatically release when the load is hoisted. The winch has a
11,000 lb. (5443 kg) lifting capacity. Winch wire rope feeds through guide sheaves mounted on a support bar on the
mast crown. Either of two remote pendant controls (one outside the operators cab, the other inside) can be used to
operate the winch.
2.3.11 Deck Wrenches GH5007463
The drill is equipped with opposing hydraulic ram type deck wrenches which are used to hold the drill string and
prevent counter-rotation while adding or removing items from the drill string.
2.3.12 Operators Controls
The controls are arranged in functional groupings with frequently used controls located more closely to the opera-
tor. Refer to the Operators Manual for details. A Graphical User Interface (GUI) provides continuous information
for the operator.
2.3.13 Hydraulic Systems
The hydraulic systems are electric-over-hydraulic.
2.3.13.1 Main Hydraulic System R57531
Two identical axial piston pumps with crossover-center variable displacement provide speed and direction control
for the hydraulic motors that drive the propel motion. These two hydraulic circuits are closed-loop.
2.3.13.2 Auxiliary Hydraulic System R57351
The double vane auxiliary pump controls the many auxiliary cylinders, e.g., jacks, mast raise, deck wrenches, mast
locks, deck hatch, back brace locks, etc.
2.3.14 Automatic Lubrication System 944J461F5
The automatic lubrication system is powered by a hydraulically driven pump controlled by the PLC. The system
delivers lubricant from an on-board tank to injectors, which measure and deliver lubricant to selected points around
the drill at regular intervals. The operator can manually initiate a lubrication cycle from the GUI when required.
2.3.15 Bailing Air System R45797
The purpose of the bailing air system is to blow drill cuttings out of the drill hole and to cool the rock bit bearings.
The compressor output is adjustable to allow for optimum bailing air velocity.
Compressor inlet valves control the air draw into the rotary screws. These valves are hydraulically closed during
start-up. During operation, the inlet valves modulate air intake by means of pneumatic controls.
2.3.16 Towing System
The drill can be towed. The final drive is designed to allow the propel brakes to be released and the propel motors
to be disengaged from the transmission while towing the drill. Refer to for details.
2.3.17 Hydraulically Operated Dust Curtains R6349F1-F2
Dust curtains surround the area beneath the drilling platform to contain the dust and chips created by drilling. The
optional hydraulically operated rear dust curtains are operated from the operators cab. Along the sides of the drill,
the curtains are fixed.
2.3.18 Serial Number Location
The drill serial number is located inside the operators cab.
2.4 Sign Maintenance
Signs of various types are located wherever required on the drill to warn personnel of potential hazards, identify
controls and components, and to provide useful information.
Because these signs aid in the safe and efficient operation of the drill, inspection of all signs must be a part of the
inspection program.
If signs are dirty, missing, or illegible, clean or replace them.
2.5 Reader Comment Form
Self addressed comment forms have been included at the rear of this manual. Please use them to communicate
questions, suggestions, or comments regarding this manual.
2.6 Material Safety Data Sheets (MSDS)
In order to transfer MSDS information from our suppliers to our customers, P&H Mining Equipment will provide this
service upon customer request. All customer requests must be specific because of the volume and complexity of
the MSDS system.
To identify the appropriate MSDS, one of the following must be included: P&H part number, vendor trade name, or
vendor name.
Address inquiries concerning MSDS to your P&H MinePro Services representative.
2.7 Warranty
The terms of warranty for your drill are defined in the warranty document which accompanies each drill, including
any special vendor operating or maintenance instructions.
The warranty does not cover any damage caused by failure to follow operating instructions, abuse (including oper-
ation of the drill in excess of rated capacity), improper maintenance, accident, or unauthorized modification of the
equipment.
The warranty will be voided (in whole or part) if the drill is operated under any of the following conditions:
1. With hydraulic pressure in excess of the maximum allowable pressure limits. The maximum allowable pres-
sures are provided in the Maintenance Manual.
2. Under unsafe operating conditions.
3. With accessories not designed, furnished, or approved by P&H Mining Equipment.
4. With modifications which affect the operation or capacity of the blasthole drill.
2.8 Drill Terminology
Certain commonly used drill terms are defined below.
AIR SYSTEM (BIT OR MAIN). The sole function of the main air system is to supply a large volume of compressed
air to the drill bit for cooling and to blow drill cuttings out of the drill hole.
AUXILIARY HYDRAULIC SYSTEM. The auxiliary hydraulic system supplies pressure and controls to operate most
of the open loop hydraulically operated equipment, including the leveling jacks, pipe racks, breakout wrench, deck
hatch, mast hoist cylinders, anchor pin cylinders, deck wrench cylinders, winch, back brace locks, and the optional
hydraulically operated dust curtain.
AUTOMATIC GREASE LUBRICATION SYSTEM. Hydraulic oil is supplied from the auxiliary hydraulic system to
operate a hydraulic oil powered grease pump. The grease pump supplies all of the automatic grease lubrication
points on the drill.
BACK BRACES. The back braces are jointed tubular steel supports which support the mast in the drilling position.
BACK BRACE LOCKING COLLARS. The locking collars slide over the back brace knee joints to prevent the back
braces from folding when the mast is in the raised position.
BREAKOUT WRENCH (Optional). The breakout wrench is mounted on the lower portion of the mast. It is a
hydraulically operated pipe wrench controlled from the operators cab and used to loosen pipe joints.
CABLE REEL (Optional). The function of the cable reel is to wind in or spool out the stored high-voltage trail cable
when propelling the drill.
COLLARING. Collaring is the procedure used to pilot a new drill hole. The pilot hole helps to center the drill string
and minimizes material break-out and fall-in.
CRAWLER TRACK. The crawler track is an assembly of crawler shoes and pins which provides a continuous path
on which the drill is propelled.
DECK WRENCHES. Deck wrenches are mounted on the deck on opposite sides of the deck bushing. They consist
of a pair of opposed hydraulic rams that extend to grip and support drill pipe while adding or removing drill bits, sta-
bilizers, or an additional section of drill pipe.
DRILL BIT. The drill bit is a rotated tool used to penetrate rock formations. It is driven by drill pipe(s) in the drill
string via the rotary carriage.
DRILL PIPE. Drill pipe is a section of steel pipe, threaded male on one end and female on the other, on which the
drill bit, stabilizer, or another drill pipe is mounted.
DRILL STRING. The drill pipe, stabilizer, drill bit, and other components comprise the drill string.
DRY DUST CONTROL SYSTEM (Optional). This system is designed to vacuum dust and small debris from inside
the dust curtain area into a hopper which is dumped away from the drilling area.
DUST CURTAIN. A standard fixed dust curtain encloses the area around the drill string immediately below the drill-
ing platform. It restricts the travel of flying rock chips and dust which result from drilling. Available as an option, a
hydraulic cylinder can raise a portion of the dust curtain to prevent it from pushing cuttings into the blasthole when
relocating the drill.
FRONT/REAR. The front of the drill is the end opposite the operators cab. The rear of the drill is the operators cab
end.
HOIST/PULLDOWN SYSTEM. An electric motor which powers a rack and pinion drive through the hoist/pulldown
transmission. It provides continuous drill bit loading when drilling and lifts the drill string from the hole when done.
HOIST BRAKE. The dual-disc, spring-set, hydraulic-released hoist brake is mounted on the pulldown gearcase
intermediate shaft. It is used to stop and hold vertical movement of the rotary carriage.
JACK PADS. Jack pads are metal plates attached to the lower end of the leveling jack spud. The jack pads provide
a large surface area on which the leveling jack can bear.
LEVELING SYSTEM. Four leveling jacks are located at the four corners of the main frame. They are controlled
from the operators cab or the optional remote propel controller. The two rear jacks (closest to the operators cab)
are independently adjustable. The two front jacks are connected in parallel and operate as a self-equalizing pair.
The optional auto-leveling system, when activated, automatically raises the drill to the lowest possible level operat-
ing plane.
MACHINERY HOUSE. The machinery house is the enclosed room in which the power unit, electrical cabinets, and
the majority of the hydraulic system and air system components are located. The machinery house is pressurized
and filtered (standard) and can be heated by thermostatically controlled fans (optional).
MAIN HYDRAULIC SYSTEM. The main hydraulic system propels the drill. It primarily consists of two closed-loop
hydrostatic pumping systems with hydraulic motors, valves, filters, strainers, and propel motion controls. The sys-
tem also provides pressure to release the propel parking brakes and to control propel motor speed/torque setting.
MAST. The mast is a welded structural steel assembly that supports and guides the rotary carriage. The pipe
racks, winch, and breakout wrench are also secured to and supported by the mast. The mast is raised or lowered
by two hydraulic cylinders.
MAST ANCHOR PINS. The mast anchor pins are hydraulic cylinder-operated locking pins used to secure the mast
in the vertical position. They are located on the frame beneath the drilling deck.
MAST CROWN. The mast crown is located at the top of the mast. It ties the mast legs together and supports the
winch sheaves.
MAST RAISING CYLINDERS. These two cylinders are deck mounted and are used to raise and lower the mast.
MAST PIVOT PINS. The mast pivot pins are the pins about which the mast rotates when it is being raised or low-
ered.
OPERATORS CAB. The operators cab contains the operating controls, indicators, gauges and the Graphic User
Interface (GUI). All drill operations are controlled from the operators cab.
PIPE RACK. The pipe rack is a mechanism located within the mast which can store a 65 ft. (19.8 m) length of drill
pipe.
PIPE SLING. The pipe sling is a permanent frame mounted part way up the mast to restrain pipe sections from fall-
ing if one should become uncoupled from the rotary carriage or pipe rack.
POWER SUPPLY CABLE (TRAIL CABLE). The trail cable is the power conductor located between the front of the
drill and the power sub-station. All electrical energy is supplied to the drill via this cable.
POWER UNIT. The hydraulic pump drive transmission (PDT) and the main air compressor are mounted on oppo-
site ends of the main AC electric motor, on a common sub-base. The motor provides the power to drive all of the
drill functions. For purposes of this manual, the power unit is defined as the AC motor and the PDT. The air com-
pressor is not considered to be part of the power unit.
PROPEL BRAKES. Each crawler drive has a spring-set, hydraulically released parking brake that automatically
releases when pressure is applied to the hydraulic propel motor. The brakes are integral with the propel transmis-
sions.
PROPEL SYSTEM. The drill is mounted on and propelled by individually powered and controlled crawlers. The
rear axle is stationary and is bolted rigidly to the main frame. A floating equalizer axle at the front enables the crawl-
ers to maintain footing over rough terrain. Steering is accomplished by individual control of the speed and direction
of travel of the left and right crawlers.
PROPEL DIRECTION. The drill is propelled forward when the drilling platform and operators cab trail the drill in
the direction of travel. The drill is propelled to the rear when the drilling platform and operators cab lead in the
direction of travel.
PULLDOWN. Pulldown is the downward force applied to the rotary bit by the hoist/pulldown motor while drilling.
PUMP DRIVE TRANSMISSION (PDT). All of the pumps that power the main and auxiliary hydraulic systems,
except the hoist brake pump and the low pressure pump, are mounted on and driven by the PDT. The PDT is a
gear reducer having multiple output shafts, all driven from a common input shaft. Each hydraulic pump is flange
mounted and direct coupled to a PDT output drive shaft. The PDT is coupled to the main AC drive motor as one of
the components of the POWER UNIT.
ROTARY CARRIAGE. The rotary carriage provides rotary and vertical motion to the drill string. Reversible DC
motors drive the rotary gear reducer to impart bi-directional rotary motion to the drill string. A DC pulldown motor
provides vertical motion to lift or lower the drill string.
SINGLE-PASS DRILLING. Single-pass drilling is the process of drilling a blasthole to a depth no greater than the
distance the rotary carriage can travel from top to bottom of the mast, using a single length of drill string. The drill
string does not have to be removed from the drill while traveling to the next drill hole location.
WATER INJECTION SYSTEM (Optional). The water injection system supplies an adjustable flow of water into the
bailing air stream to control dust created by drilling.
WINCH. A winch is provided for tool handling on the drilling platform. The winch is mounted inside the machinery
house beneath the A Frame; wire rope feeds upward, passes over two guide sheaves mounted on the mast crown
and back down to the drilling platform. The winch has a built-in clutch designed so that when hydraulic power is
removed, the clutch will engage and the load will stop. When hydraulic power is applied, the clutch releases, allow-
ing the drum to rotate in a controlled manner.
BD120149 Mechanical Systems Manual Auxiliary Hydraulic System
Sec03AuxHyd.fm -3.1- Section 3, Version 00 - 03/06
Section 3
Auxiliary Hydraulic System
3.1 General
This section describes the auxiliary hydraulic system and provides information for adjustment, removal, and instal-
lation of the major hydraulic components.
Only the hydraulic portions of the various subsystems are described in this section. The mechanical components
that take their movement from the auxiliary hydraulic system will be discussed in the mechanical sections that per-
tain to them. For example, the hydraulic circuit that moves the mast anchor pins is discussed here; discussion of
the mast anchor pins themselves is in the mast section.
3.2 Theory of Operation
The auxiliary hydraulic system provides controlled hydraulic pressure and flow to the following assemblies:
Back brace locks
Dust curtain
.Deck wrench
.Mast anchor pins
Mast hoist cylinders
Pipe racks
Pipe rack gates
Pipe rack holdbacks
Deck Hatch
Breakout Wrench
Levelling jacks
Auxiliary winch
All directional valves on the three valve banks in this system are operated by electrical solenoids, which receive
operating signals from a programmable logic controller (PLC) located in a dedicated cabinet inside the machinery
house. See Figure 2-3.
Auxiliary Hydraulic System BD120149 Mechanical Systems Manual
Section 3, Version 00 - 03/06 -3.2- Sec03AuxHyd.fm

Figure 3-1: .Auxiliary Hydraulic Schematic, R57351
R
5
7
3
4
9
-
1
Numbers in the circles refer to the Bill of Material (Subtopic 3.2.6).
Numbers in the triangles refer to the System Data Sheet (Table 3-1).
3.2.1 Hydraulic Tank R6908D1
The auxiliary tank, located in the lubrication room on the forward right portion of the machinery deck, provides oil
for all hydraulic functions on the drill, including both the main hydraulic system and the auxiliary hydraulic system.
The hydraulic tank is partitioned by a baffle to separate the suction lines from the return lines. The baffle plate is
ported to permit cross-flow of oil from the return side to the suction side of the tank.
Refer to Subtopic 3.3.2 for maintenance information regarding the hydraulic tank.
Figure 3-2: Hydraulic Tank
01
03
04
06
09
08
BD0361a01
02
05
07
10
11
LEGEND
01. Suction Filters
02. Temperature Probe
03. Hydraulic Tank
04. Low Level Switch
05. Breather
06. Return Filters
07. OIl Level Gauge Placard
08. Oil Level Sight Glass
3.2.1.1 Suction Filters R16280D1
The pump suction filters are located at the rearward end of the hydraulic oil tank.They feature a Handwell Valve
which serves as a shut-off valve for the suction line of the auxiliary hydraulic pump. To shot off the oil flow, turn the
knob anticlockwise until it stops. The Handwell Valve includes a limit switch to prevent the start-up of the drill when
the valve is closed.
The suction filter is equipped with a vacuum by-pass valve that permits oil to flow around the filter element if the
element becomes excessively fouled. The indicator switch is not a visual switch. When the filter goes into bypass,
the switch will inform the PLC, which will issue a fault on the GUI.
Refer to Subtopic 3.3.3 for maintenance information regarding the suction filters.
3.2.1.2 Temperature Probe 89Z724D2
The temperature probe is a resistive temperature device (RTD) that detects the temperature of the hydraulic oil in
the tank and transmits that information to the PLC. It is installed on the rearward side of the hydraulic tank above
Figure 3-3: Handwell Valves and Suction Filters
Figure 3-4: Hydraulic Tank Temperature Probe
the Handwell valves. The temperature probe controls the operation of the oil cooler fans. When the oil temperature
reaches 140F (60C), the fans turn on.
Refer to Subtopic 3.3.4 for maintenance information regarding the temperature probe.
3.2.1.3 Low Level Switch R16982D1
The low level switch is located on the top of the hydraulic tank. The unit is a float type switch that detects when the
oil level has reached the allowable minimum. Functionally, the switch provides input to the programmable logic
controller (PLC). When a low hydraulic oil level condition is indicated, the PLC shuts down the main drive motor to
the pump drive transmission and records a fault on the GUI.
Refer to Subtopic 3.3.5 for maintenance information regarding the low level switch.
Figure 3-5: Hydraulic Tank Oil Level Switch
3.2.1.4 Hydraulic Tank Breather 1046Z994
The hydraulic tank breather is mounted at the top of the tank. The breather is fitted with a synthetic 3-micron filtra-
tion medium to filter out contaminants when the oil cools and air is drawn through the breather into the tank.
The breather should be replaced during each Preventive Maintenance period.
3.2.1.5 Magnetic Rod R17038D1
A magnetic rod is installed into the top of the tank. The rod extends into the tank and attracts metal contaminants,
holding them in suspension and preventing them from entering more sensitive hydraulic components.
The magnetic rod should be cleaned at each Preventive Maintenance period.
Figure 3-6: Hydraulic Tank Breather
Figure 3-7: Magnetic Rod
3.2.1.6 Return Filters 46Z529
The two return line filters for the hydraulic systems are flange-mounted on top of the hydraulic tank. The two filters
are identical, and can be serviced without removal from the tank.
The filters are rated at 80 gpm (303 lpm) and contain two 3-micron filter elements, mounted in tandem. Return oil
flows through the center of the element and exits the outside to tank. The filter is equipped with a bypass valve that
begins to bypass unfiltered oil at 25 psi (1.7 bar). A dirt alarm gauge is mounted to the body of each filter to indicate
the operating condition of the filter elements. The gauge faces are marked with red and green areas. Red indicates
the need to replace the filter elements.There is also a bypass indicator that informs the operator via the GUI that
the filters are in a bypass condition.
Refer to Subtopic 3.3.8 for maintenance information regarding the return filters.
Figure 3-8: Hydraulic Return Filters
BD0781b01
3.2.1.7 Level and Temperature Gauge R16998D1
The level gauge is a sight glass used in conjunction with the associated placard to determine the appropriate level
based on the condition of the drill (i.e., mast up or down, jacks up or down, etc.). At the lower end of the sight glass
is a thermometer that indicates oil temperature.
Figure 3-9: Level and Temperature Gauge
| | | | | | | | | | | | | | | | | | | | | | | | | | | | | |
BD0560a01
JACKS RETRACTED
MAST DOWN
- 250 GALLONS -
- (946 LITERS) -
MAX OIL LEVEL
** DO NOT OVERFILL **
JACKS EXTENDED
MAST VERTICAL
- 215 GALLONS -
- (814 LITERS) -
HYDRAULIC TANK FILL REQUIREMENTS
6.25 GALLONS PER INCH
MAXIMUM OF 250 GALLONS
(946 LITERS)
- 130 GALLONS -
- (492 LITERS) - LOW LEVEL FAULT
3.2.1.8 Filter Panel R34567F2
An additional oil reservoir and filter panel is mounted to the right of the PDT. This additional oil reservoir contains
80 gallons (303 liters) that can be used to replenish the oil in the air compressor as well as in the hydraulic
tank.Three-micron filters provide additional filtration before the oil is returned to the reservoir.
Figure 3-10: Filter Panel
3.2.2 Auxiliary Hydraulic Pump 37U153D1
Hydraulic flow for the auxiliary hydraulic system is produced by a vane-type, double hydraulic pump. This pump is
driven by a mechanical pump drive transmission (PDT). The PDT is driven by the main AC electric drive motor.
Figure 3-11: Auxiliary Pump Location
Figure 3-12: Auxiliary Hydraulic Pump
01
LEGEND
01. Main Pumps
02. PDT
03. Auxiliary Pump
Oil for the auxiliary hydraulic pump comes from the hydraulic tank, through a suction filter and a Handwell valve.
The pump delivers 20 gpm (76 lpm) from the lower-volume cover-end pump, and 37 gpm (140 lpm) from the
higher-volume shaft-end pump. The pump shaft is driven at 2070 rpm via the gear ratio of the PDT.
The output flow from the lower-volume pump section is directed into the pressure inlet port of valve bank 1 and
valve bank 2.
The output flow from the higher-volume pump section is directed into the pressure inlet port of valve bank 3.
When the Auto Level System is operating, or when the operator manually operates all four of the leveling jacks
simultaneously, the oil supply to the pressure inlet port of valve bank 3 comes from two sources. The first source is
the full output from the low pressure/higher volume pump section. The second supply source is an interruptible flow
of high pressure oil from the B 1 port of valve bank 1.
In addition to valve banks 1 and 2, the lower-volume section of the pump also supplies flow to the hydraulic pipe
rack gate.
Oil discharged from the three valve banks combines with the pump and motor drain lines from the main hydraulic
system. This combined stream of hot oil flows through an air-blown heat exchanger for cooling, then returns to the
tank by way of a pair of low pressure filters. The oil cooler has a built-in check valve to allow for bypass of oil in the
event the cooler core oil flow were to be restricted.
3.2.2.1 Theory of Operation
Fluid enters the pumping cartridge through the inlet port and is discharged through pressure plates to the outlet
ports. The action of the pumping cartridge is illustrated in Figure 3-13 The rotor is driven within the cam ring by the
driveshaft, which is splined to the pump drive transmission. As the rotor turns, centrifugal force on the vanes, aided
by under-vane pressure fed from the outlet port, causes the vanes to follow the elliptical inner surface of the cam
ring.
Radial movement of the vanes and turning of the rotor cause the chamber volume between the vanes to increase
as the vanes pass the inlet section of the cam ring. This results in a low pressure condition which allows atmo-
Figure 3-13: Pump Cartridge Operation
01
02
03
04
05
06
07
BD0374a01
09
10
11
12
08
LEGEND
01. Rotor
02. Outlet
03. Vane
04. Cam Ring
05. Inlet
06. Rotation
07. Outlet
08. Inlet
09. Drive Shaft
10. Outlet
11. Rotation
12. Inlet
spheric pressure to force fluid into the chambers. This fluid is trapped between the vanes and carried past a sealing
land to the outlet section of the cam ring. As the outlet section is approached, the chamber volume decreases and
the fluid is forced out into the system. The intra-vane design provides a means of controlling the outward thrust of
the vane against the cam ring to maintain the tip loads within reasonable limits. In the intra-vane cartridge, full sys-
tem pressure is continuously applied for outward vane thrust only over the area between the vane and the insert.
This area is small, and thrust is correspondingly light. During vane travel through the pressure areas, full system
pressure is also applied against the bottom of the vane. The valving of pressure to and from the bottom area of the
vane is through holes drilled in the rotor, as shown in Figure 3-14. This selective application of pressure maintains
the vane in constant radial hydraulic balance in all positions.
The cam ring is shaped so that the two pumping chambers are formed 180 degrees apart (refer to Figure 3-13).
Thus, opposing hydraulic forces, which would impose side loads on the driveshaft, cancel each other out.The pres-
sure plate seals the pump chamber, as shown in Figure 3-15. System pressure is effective against the area at the
back of the plate, which is larger than the area exposed to the pumping cartridge. Thus, an unbalanced force holds
the plate against the cartridge, sealing the cartridge, and providing the correct running clearance for the rotor and
vanes. The pressure plate also contains passages for feeding pressure to the space between the vanes and
inserts.
Figure 3-14: Pressure Feed to the Vanes
Figure 3-15: Pressure Plate Operation
01 01
02 02
07
06
BD0375a01
05
04
03
LEGEND
01. Pressure to
Intra-Vane
02. Pressure to
Bottom of Vane
03. Vane
04. Rotor
05. Direction of
Rotation
06. Ring
07. Sharper edges
lead direction
of rotation
01 02 03 04
05
06
07
08
09
BD0377a01
LEGEND
01. Pressure Plate
02. Cover
03. Pressure Feed
under vanes
04. Vane
05. Rotor
06. Shaft
07. Wear Plate
3.2.3 Valve Bank 1 36R198D3
Valve Bank 1 is mounted between the two mast hoist cylinders inside the machinery house (see Figure 2-3). Seven
hydraulic circuits are controlled by the valve assemblies mounted on valve bank 1: the relief unload/oil diverter,
mast hoist, mast anchor pins, deck wrench, dust curtain, back brace lock, and the cable reel. Refer to Figure 3-17.
Figure 3-16: Valve Bank 1

Figure 3-17: Valve Bank 1(spares removed for clarity)
R
5
7
3
4
9
-
2
N
u
m
b
e
r
s

i
n

t
h
e

c
i
r
c
l
e
s

r
e
f
e
r

t
o

t
h
e

B
i
l
l

o
f

M
a
t
e
r
i
a
l

(
S
u
b
t
o
p
i
c

3
.
2
.
6
)
.

N
u
m
b
e
r
s

i
n

t
h
e

t
r
i
a
n
g
l
e
s

r
e
f
e
r

t
o

t
h
e

S
y
s
t
e
m

D
a
t
a

S
h
e
e
t

(
T
a
b
l
e

3
-
1
)
.
3.2.3.1 Relief/Unload Oil Diverter Valve
Figure 3-18: Relief/Unload/Oil Diverter Valve
R57349-2b
One of the primary functions of valve bank 1 is to control the maximum hydraulic pressure available to the three
valve banks, and to implement the timing of when high pressure is available for system operation. This function is
managed by the relief unload/oil diverter valve. The relief/Unload Oil Diverter Valve is a three-position, four way
valve. The valve is solenoid actuated with manual override in both directions. It is spring-centered, and the center
is open. When in the spring-centered open position, this valve allows oil from the auxiliary pump to bypass the sys-
tem pressure relief valve, flowing directly back to the tank without building pressure. This is an energy-saving pro-
vision for periods when the auxiliary hydraulic circuits are at rest.
Whenever the operator initiates movement for any of the devices controlled by the valves on either Valve Bank 1 or
on Valve Bank 2, the PLC causes the relief unload/oil diverter valve A solenoid to energize. This causes the valve
to shift so that oil from the P port of the valve flows to the A port and to the blocked port A1. Oil flow backs up
against the pressure relief valve and system pressure builds to the maximum setting of the relief valve (2900 psi
(200 bar)). This establishes the maximum pressure available to the equipment using the high pressure flow stream.
WARNING
!
Do not exceed the maximum relief valve setting of 2900 psi. Pump and hoses have a
maximum specified pressure of 3000 psi. Overpressurizing the system could result in
equipment failure, which could result in severe personal injury or death. Do not exceed
2900 psi.
When the operator activates the Auto Level System, or when all four leveling jacks are manually operated simulta-
neously, the PLC causes the B solenoid to energize. Oil flow from the P port of the valve flows to the B port and
through valve bank port B1, where the oil is diverted out of valve bank 1 and merges with the high volume flow
stream to valve bank 3.
3.2.3.2 Pressure Transducer and Pressure Switches
Mounted to the right of valve bank 1 on the bulkhead below valve bank 2 are the pressure transducer and pressure
switches that monitor pressures in the auxiliary hydraulic system.
The pressure transducer (Item 01, Figure 3-19) senses pump discharge pressure and indicates system operating
pressure to the PLC. The hydraulic pressure switch (Item 02, Figure 3-19) confirms that the auxiliary pump is oper-
Figure 3-19: Pressure Transducer and Pressure Switches
LEGEND
01. Hydraulic Pressure
Transducer
02. Hydraulic Pressure Switch
03. Relief Pressure Switch
ating at pressure. The relief pressure switch (Item 03, Figure 3-19) senses when system pressure is excessive,
and automatically shuts down the pump drive.
Refer to Figure 3-19.
3.2.3.3 Mast Hoist Valve
Figure 3-20: Mast Hoist Valve
R57349-2c
The mast hoist valve assembly controls the direction and flow rate of oil to and from the large-bore mast-raising
cylinders. It is a three-position, four way valve. The valve is solenoid actuated with manual override in both direc-
tions. It is spring-centered, and the center is open to tank. When in the spring-centered open position, this valve
blocks pressure from the pump and opens all other ports to tank. Flow control valves in both the hoist and lower cir-
cuit control the speed of cylinder movement.
Flow Control for the Extend (Raise) circuit is set for 20 GPM; this causes the mast cylinder to extend in 76.5 sec-
onds. Flow Control for the Retract (Lower) circuit is set for 13 GPM; this causes the mast cylinder to retract in 79.2
seconds.
CAUTION
Counterbalance valve pressures are pre-set at the factory. Changing the settings can
cause severe equipment damage. Do not adjust counterbalance valve pressure settings.
If adjustments are necessary, contact your local P&H MinePro Services.
Each mast cylinder circuit is equipped with dual counterbalance valves to prevent uncontrolled movement in either
the up or down direction should a malfunction disrupt oil flow. Counterbalance valve pressures are pre-set at the
factory and are not to be adjusted.
When the operator places the mast hoist button in the RAISE position, the PLC causes solenoid A to energize. The
valve spool shifts so that oil from the P port of the valve flows to the A port of the valve and out the A2 port of the
valve bank. Oil flows through the 20 GPM flow control valve and over the check valve portion of the directional flow
control valve into the head end of the hydraulic cylinders. As pressure increases, the crossover ports on counter-
balance valves cause the valve ports on the opposite line to open. Oil from the rod end of the cylinders is then able
to flow through the counterbalance valves, over the directional flow control valve and back to tank.
When the operator places the mast hoist button in the LOWER position, the PLC causes solenoid B to energize.
The valve spool shifts so that oil from the P port of the valve flows to the B port of the valve and out the B2 port of
the valve bank. Oil flows through the 13 GPM flow control valve and over the check valve portion of the directional
flow control valve into the rod end of the hydraulic cylinders. As pressure increases, the crossover ports on coun-
terbalance valves cause the valve ports on the opposite line to open. Oil from the head end of the cylinders is then
able to flow through the counterbalance valves, over the directional flow control valve and back to tank.
3.2.3.4 Mast Anchor Pins
The mast anchor pin valve controls the direction of oil flow to two anchor pin cylinders. It is a three-position, four
way valve. The valve is solenoid actuated with manual override in both directions. It is spring-centered, and the
center is closed. When this valve is in its centered position, the closed lines tend to keep the pins in their current
Figure 3-21: Mast Anchor Pins
R57349-2d
position. A limit switch on the rod end sends a signal to the PLC when the pins are in the engaged position. Pins
should extend in 1.8 seconds and retract in 1.0 second.
3.2.3.5 Deck Wrench
The deck wrench valve assembly controls the direction and maximum operating pressure of oil flow to the two deck
wrench cylinders.It is a three-position, four way valve. The valve is solenoid actuated with manual override in both
Figure 3-22: Deck Wrench
R57349-2e
directions. It is spring-centered, and the center is partially open. When this valve is in its centered position, pres-
sure from the pump is blocked and the remaining ports are open to the tank.
CAUTION
Dual counterbalance valve pressures are pre-set at the factory. Changing the settings
can cause equipment damage. Do not adjust counterbalance valve pressure settings. If
adjustment becomes necessary, contact your local P&H MinePro Services.
A dual counterbalance valve is used in the cylinder circuit to prevent the wrenches from extending into the drill
string when the control valve is in the spring-centered neutral position. It also provides a means to help hold the
drill pipe when the pipe is uncoupled from the rotary carriage (the cylinder pressure is maintained by the counter-
balance valve).
3.2.3.6 Dust Curtain Valve
Figure 3-23: Dust Curtain Valve
R57349-2f
The dust curtain valve assembly controls the oil flow direction, rate of flow, and maximum operating pressure avail-
able for operation of the dust curtain raising and lowering cylinder. It is a three-position, four way valve. The valve
is solenoid actuated with manual override in both directions. It is spring-centered, and the center is partially open.
When this valve is in its centered position, pressure from the pump is blocked. The remaining ports are open to the
tank.
Cross port relief valves protect the dust curtain raising system from damage. Adjust the relief valve on the raise
side of the circuit to 1000 psi and the lower side to 350 psi.
The pilot operated check valves in both raising and lowering circuits provide positive position locking for the dust
curtain cylinders.
Adjust flow control valves to achieve a raising and lowering time between 4 and 5 seconds.
3.2.3.7 Back Brace Lock
The back brace lock valve controls the direction of oil flow back brace lock cylinders. Each back brace has a lock
that slides over the articulating joint; each lock is controlled by three cylinders.
Figure 3-24: Back Brace Lock Valve
R57349-2g
3.2.4 Valve Bank 2 36R199D7
Valve Bank 2 is mounted between the two mast hoist cylinders inside the machinery house (see Figure 2-3). The
hydraulic circuits that are controlled by the valve assemblies mounted on valve bank 2 are the two pipe racks, the
deck hatch and the breakout wrench. The availability of high pressure oil to operate these circuits is dependent
upon the position of the relief unload/oil diverter valve on valve bank 1, as described under Subtopic 3.2.3.1. Refer
to Figure 3-26.
Figure 3-26: Valve Bank 2 (spares removed for clarity)
3.2.4.1 Pipe Rack
Figure 3-27: Pipe Rack Valve
FROM PIPE RACK
HOLDBACK VALVE
R57349-3b
The pipe rack valve assembly controls the direction and flow rate of oil to and from the pipe rack cylinder. It is a
three-position, four way valve. The valve is solenoid actuated with manual override in both directions. It is spring-
centered, and the center is partially open. When this valve is in its centered position, pressure from the pump is
blocked; the remaining ports are open back to the tank.
Flow control valves in both the extend (over hole) and retract (store) circuit control the speed of cylinder move-
ment. Flow Control for the extend circuit is set for 12.5 GPM; Flow Control for the retract circuit is set for 15.5 GPM.
CAUTION
Counterbalance valve pressures are pre-set at the factory. Changing the settings can
cause severe equipment damage. Do not adjust counterbalance valve pressure settings.
The pipe rack cylinder circuit is equipped with a dual counterbalance valve to prevent uncontrolled movement in
either the centering or storing direction should a malfunction disrupt oil flow. Dual counterbalance valve pressures
are pre-set at the factory and are not to be adjusted.
When the operator places the pipe rack button in the OVER HOLE position, the PLC causes solenoid B to ener-
gize. The valve spool shifts so that oil from the P port of the valve flows to the B port of the valve and out of the
valve bank. Oil flows through the 12.5 GPM flow control valve and over the check valve portion of the directional
flow control valve into the head end of the hydraulic cylinder. As pressure increases, the crossover port on counter-
balance valve causes the valve port on the opposite line to open. Oil from the rod end of the cylinders is then able
to flow through the counterbalance valve, over the directional flow control valve and back to tank.
When the operator places the pipe rack button in the STORE position, the PLC causes solenoid A to energize. The
valve spool shifts so that oil from the P port of the valve flows to the A port of the valve and out the A1 or A2 port of
the valve bank (depending on which rack is active). Oil flows through the 15.5 GPM flow control valve and over the
check valve portion of the directional flow control valve into the rod end of the hydraulic cylinder. As pressure
increases, the crossover port on counterbalance valve causes the valve port on the opposite line to open. Oil from
the head end of the cylinders is then able to flow through the counterbalance valve, over the directional flow control
valve and back to tank.
When the pipe rack is in the stowed position, a limit switch will cause indication on the operators console.
3.2.4.2 Pipe Rack Gate
The pipe rack gate valve is a two-position, four way valve. The valve is solenoid actuated with manual override and
Figure 3-28: Pipe Rack Gate
R57349-3c
Numbers in the circles refer to the Bill of Material (Subtopic 3.2.6). Num-
bers in the triangles refer to the System Data Sheet (Table 3-1).
spring return. It is mounted on the bulkhead to the right of valve bank 2 and above valve bank 3.
Oil to operate the pipe rack gate is provided by the low-volume side of the auxiliary hydraulic pump. The line pro-
viding oil to the pipe rack gate valve connects to the line between Valve Bank 1 and Valve Bank 2. See Figure 3-1.
WARNING
!
When short pipes are used in the drill string, the shorter sections may not reach up to
the point where the pipe rack gate will hold them in the rack. The short pipe could fall out
and cause severe personal injury or death. Always be sure that the length of pipe in the
pipe rack is sufficient to allow the pipe rack gate to hold the pipe in the rack.
The pipe rack gate is located at the top of the pipe rack. It consists of a curved rod, or gate arm, that rotates down
and in front of the drill pipe when it is stored in the pipe rack, protecting the drill pipe from falling out of the pipe
rack.
When a loaded pipe rack is moved into the OVER HOLE position and the pipe is lifted from the rack by the rotary
carriage machinery, the pipe rack gate arm rotates up and out of the way. This permits rack to return to the STORE
position.
When the pipe rack is back in the STORE position, the gate arm rotates back down.
When the empty pipe rack moves out of the STORE position, the gate arm rotates up, allowing the rack to be
placed in position to receive the pipe. When the pipe is placed into the pipe rack, the gate arm rotates back down
and prevents the pipe from falling out.
Figure 3-29: Pipe Rack Gate Valve
LEGEND
01. Main Pipe
Rack Gate
Valve
02. Secondary
Pipe Rack
Gate Valve
3.2.4.3 Pipe Rack Holdback
When the drill is started, the head brake motor and pump turn on. At the same time, the pipe rack holdback sole-
noid energized. Oil pressure is provided to the pipe rack circuit, and acts to maintain the pipe rack cylinder in the
retracted position. This is to prevent the pipe rack from drifting into the drill string during normal drilling operations.
When the operator energizes the pipe rack solenoid, the pipe rack holdback solenoid is de-energized and the pipe
rack circuit can cause the pipe rack cylinder to extend or retract as required.
Figure 3-30: Pipe Rack Holdback Circuit
To Pipe
Rack Valves
R57349-3d
3.2.4.4 Deck Hatch
Figure 3-31: Deck Hatch
R57349-3e
The deck hatch valve assembly controls the oil flow direction, rate of flow, and maximum operating pressure avail-
able for operation of the deck hatch raising and lowering cylinder. It is a three-position, four way valve. The valve is
solenoid actuated with manual override in both directions. It is spring-centered, and the center is partially open.
When this valve is in its centered position, pressure from the pump is blocked; the remaining ports are open back
to the tank.
A pair of connected pilot-to-open check valves maintain the deck hatch in the desired position.
Adjustable flow control valves determine raising and lowering speed for the deck hatch.
3.2.4.5 Breakout Wrench Engage/Disengage
The Breakout Wrench Engage/Disengage Valve is used after the breakout wrench has been moved out to the drill
pipe. It is a three-position, four way valve. The valve is solenoid actuated with manual override in both directions. It
is spring-centered, and the center is closed. When this valve is in its centered position, all ports are blocked.
Figure 3-32: Breakout Wrench Engage / Disengage
R57349-3f
When the operator places the breakout wrench control button in the ENGAGE position, the PLC causes the A sole-
noid to energize and the valve spool shifts. Oil from the P port passes through the A port on the valve, out the A7
port on the valve bank and to the head end of the jaw cylinder. When the jaw cylinder extends, the jaws of the brea-
kout wrench close around the pipe. Oil from the rod end of the cylinder returns unrestricted to the valve (port B to
port T) and back to tank.
Once the jaws are in contact with the pipe and cannot move anymore, hydraulic pressure builds. When hydraulic
pressure reaches the setting of the sequencing valve (2400 psi), the sequencing valve opens. Oil flows to the head
end of the break cylinder, causing the cylinder to extend. As the cylinder extends, the breakout wrench jaws rotate
anticlockwise to break the pipe joint. Oil from the rod end of the cylinder passes through the check valve on the
sequencing valve to the low pressure line, from there to the valve (port B to port T) and back to tank.
When the operator places the breakout wrench control button in the DISENGAGE position, the PLC causes the B
solenoid to energize and the valve spool shifts. Oil from the P port passes through the B port on the valve, out the
B7 port on the valve bank and to the rod end of the jaw cylinder. When the jaw cylinder retracts, the jaws of the
breakout wrench open. Oil from the head end of the cylinder returns unrestricted to the valve (port B to port T) and
back to tank.
Once the jaws are completely open and cannot move anymore, hydraulic pressure builds. When hydraulic pres-
sure reaches the setting of the sequencing valve (2400 psi), the sequencing valve opens. Oil flows to the rod end
of the break cylinder. When the cylinder retracts, the breakout wrench jaws rotate back to their original position. Oil
from the head end of the cylinder passes through the check valve on the sequencing valve to the low pressure line,
from there to the valve (port B to port T) and back to tank.
3.2.4.6 Breakout Wrench In / Out
Figure 3-33: Breakout Wrench In / Out
R57349-3g
The Breakout Wrench In/Out Valve causes the breakout wrench to move to and away from the drill pipe.
When the operator places the breakout wrench control button in the OUT position, the PLC causes the A solenoid
to energize and the valve spool shifts. Oil from the P port passes through the A port on the valve, out the A8 port on
the valve bank, over the directional flow control valve and to the head end of the cylinder. When the cylinder
extends, the breakout wrench moves outward toward the pipe. Oil from the rod end of the cylinder returns through
the flow control valve. The oil then travels to the valve (port B to port T) and back to tank. Set the flow control valve
so that the time to fully extend is between 5 and 6 seconds.
When the operator places the breakout wrench control button in the IN position, the PLC causes the B solenoid to
energize and the valve spool shifts. Oil from the P port passes through the B port on the valve, out the B8 port on
the valve bank, over the directional flow control valve and to the rod end of the cylinder. When the cylinder retracts,
the breakout wrench moves back inward to the stowed position. Oil from the head end of the cylinder returns
through the flow control valve. Set the flow control valve so that the time to fully retract is between 4 and 5 seconds.
The oil then travels to the valve (port A to port T) and back to tank.
3.2.5 Valve Bank 3
Valve Bank 3 is mounted between the two mast hoist cylinders inside the machinery house (see Figure 2-3). All of
the leveling jack circuits are controlled by the valve assemblies mounted on valve bank 3, as well as the auxiliary
winch.
Oil to operate these circuits is provided by the 37GPM cartridge of the auxiliary hydraulic pump (see Figure 3-1)
during normal operation. When the drill is in Auto Level mode, or when the operator is manually operating all four
leveling jacks simultaneously, oil from the 20 GPM cartridge is diverted from Valve Bank 1 and is also provided to
Valve Bank 3.
Figure 3-35: Valve Bank 3 (spare removed for clarity)
R
5
7
3
4
9
-
4
3.2.5.1 Solenoid Relief/Unloading Valve
Figure 3-36: Relief Unloading Valve
R57349-4
The function of the solenoid relief/unloading valve is to reduce system pressure during periods when high volume
portion of the auxiliary pump is not needed to support operation. This function conserves energy and prevents
overloading of the high volume pump.
This is a four-position, four way valve. It is solenoid actuated with a manual override. The valve is spring centered,
and the center is open. When in the spring-centered open position, this valve allows oil from the high volume sec-
tion of the auxiliary pump to bypass the high flow relief valve, flowing directly back to the tank without building pres-
sure. This is the energy-saving provision for periods when the auxiliary hydraulic circuits are at rest.
Whenever the operator initiates movement for any of the devices controlled by the valves on Valve Bank 3, the
PLC causes the solenoid relief/unloader valve A solenoid to energize. This causes the valve to shift so that oil from
the P port of the valve flows to the A port, which is blocked. Oil flow backs up against the pressure relief valve and
system pressure builds to the maximum setting of the relief valve (2850 psi (169 bar)). This establishes the maxi-
mum pressure available to the equipment.
When the operator activates the Auto Level System, or when all four leveling jacks are manually operated simulta-
neously, the PLC causes the B solenoid to energize. Oil flow from the P port of the valve flows to the B port, which
is blocked. Oil flow backs up against the pressure relief valve and system pressure builds to the maximum setting
of the relief valve (2850 psi (169 bar)).
The difference between the A solenoid position and the B solenoid position is that in B position, oil returning from
the leveling jacks is ported to the A port of the unloading valve, which causes the oil to go through a .040" orifice
before returning to tank.
3.2.5.2 Auxiliary Winch Circuit
Figure 3-37: Auxiliary Circuit
R57349-4c
The auxiliary winch valve controls the direction and maximum pressure of the oil flow to the auxiliary winch hydrau-
lic motor. This is a proportional, three-position, four way valve.The valve is spring centered, and the center is open.
When in the spring-centered open position, this valve blocks pressure from the pump. All other circuits are open
back to the tank.
An adjustable, pressure-compensated flow control valve in the valve bank manifold controls the flow rate of oil
through the winch motor, thereby controlling the maximum speed of the winch. Set the flow control valve at 17 gal-
lons per minute (64 lpm), which should provide a maximum drum rotation speed of 8.5 rpm.
Two pressure relief valves determine the maximum pressure in the circuit. One is active in the hoisting direction,
and the other is active in the lowering direction. Set both relief valves for 2200 psi. A setting of 2200 psi on the relief
valves results in a 12,000 pound (9,072 kg) line pull.
3.2.5.3 Front Jack Valve
The front jack valve controls the direction of oil flow to the front jacks. This is a four-position, four way valve. It is
solenoid actuated with a manual override. The valve is spring centered, and the center is open.
The jacks are hydraulically connected in parallel so that the pressure will tend to equalize between the cylinders
during the machinery leveling procedure, and also while drilling. The flow rate is determined by a fixed flow control
valve which allows a flow of 27 gallons per minute (102 lpm). The circuit includes regeneration and dual counter-
balance valves, described in the following paragraphs.
Figure 3-20: Front Jack Valve Assembly
R57349-4d
3.2.5.4 Rear Jack Valves
The rear jack valves are identical in form and function to that of the front jacks; however, the circuit differs in three
respects.
Figure 3-21: Left or Right Rear Jack Valve
R57349-4e
1. The front jacks are joined hydraulically, whereas the two rear jacks are controlled independently. Each of the
rear jacks has its own valve and associated circuit components.
2. There is only one pressure switch on each of the circuits. This is the pressure switch that determines that the
jack pads have come in contact with the ground. Adjust these pressure switches (one on each jack) to 950 psi
50 psi.
3. The flow control valves are fixed at 15 gallons per minute (57 lpm).
For more detailed information on the jack operation, refer to Subtopic 3.2.5.3. For a representation of the circuit
schematic, refer to Figure 3-21.
A valve block is mounted on the jack housing. This block contains the regeneration valve and the dual counterbal-
ance valve.
Regeneration Valve
The regeneration circuit is used to permit fast cylinder movement when the jacks are being lowered. The regenera-
tion circuit is actuated when the jack is being extended, but not yet lifting the weight of the drill. It functions by circu-
lating the oil being displaced from the rod end of the jack cylinder back into the head end of the cylinder (hence
regeneration). This causes the jack to extend at a faster rate than it would if the oil from the cylinder rod end were
directed back to the tank.
Figure 3-22: Regeneration and Dual Counterbalance Valves
Since the regeneration has only about one-half the force necessary to lift the drill, the regeneration circuit must turn
off once the jacks begin to lift the drill. A Pressure Switch in each circuit detects when the jack pads have reached
the ground, and have started to pick up the weight of the drill. Once the pressure switch is actuated, the regenera-
tion circuit is shut off.
Dual Counterbalance Valve
The dual counterbalance valve prevents the jack cylinder from drifting, either under load or from the retracted posi-
tion, when the control valve is in the neutral position.
CAUTION
Dual counterbalance valve pressures are pre-set at the factory. Changing the settings
incorrectly can cause severe equipment damage. Follow correct procedures.
Refer to Figure 3-20. When the operator places the levelling jack button in the RAISE DRILL position (or during
Auto Level operation), the PLC causes solenoid A to energize. The valve spool shifts so that oil from the P port of
the valve flows to the A port of the valve and out the A2 port of the valve bank. Oil flows over the counterbalance
valve check valve into the head end of the hydraulic cylinders. As pressure increases, pressure through the cross-
over ports on the head end counterbalance valve causes the valve port on the rod side of the cylinder to open. Oil
from the rod end of the cylinders is then able to flow through the counterbalance valve, and either regenerates (if
the jacks are not both on the ground) or returns to the B port to tank.
When the operator places the levelling jack button in the LOWER DRILL position (or during Auto Level operation),
the PLC causes solenoid B to energize. The valve spool shifts so that oil from the P port of the valve flows to the B
port of the valve and out the B2 port of the valve bank. Oil flows through the regeneration valve, over the counter-
balance valve check valve, and into the rod end of the hydraulic cylinders. As pressure increases, the crossover
pressure through the ports on the rod side of the counterbalance valve causes the valve ports on the head end to
open. Oil from the head end of the cylinders is then able to flow through the counterbalance valve and back to tank.
3.2.5.5 Pressure Switch
The front jack circuit features two pressure switches.
The Front Pressure Switch detects when the jacks are on the ground so that the regeneration circuit can be turned
off. Adjust the Front Pressure Switch to 950 psi 50 psi.
The Front Over Pressure Switch will cause an immediate shutdown of the drill when it is activated. To adjust, attach
a 3000 psi gauge to port GA2 on the front regeneration valve and record the pressure required to support the front
of the machine on jacks (mast down with cable reel is worst case). Adjust the Front Over Pressure Switch to 1750
psi 50 psi.
Figure 3-23: Pressure Switch
3.2.5.6 Limit Switches
Limit Switches at the upper end of the jack housing indicate when the jack cylinders are fully retracted and the
jacks are in their stowed positions.
Figure 3-22: Jack Limit Switch
3.2.5.7 Hydraulic Oil Cooler R6907D1.
The cooler for the hydraulic oil is mounted on the forward wall of the lubrication room on the front right area of the
machinery deck. The two electric fans, controlled through the PLC by the temperature probe in the hydraulic tank,
draw air from the outside over the cooler fins.
Only oil from the auxiliary hydraulic circuit is routed through the cooler. The main hydraulic system oil from the main
pumps uses the cool oil from the tank but is not a part of the cooler circuit.
The cooler has a rated operating pressure of 300 psi with built-in 60 psi relief bypass.
Figure 3-23: Hydraulic Oil Cooler
3.2.5.8 Return Filters 46Z529
These by-pass type filters are rated at 80 gpm (303 lpm) and contain two 3-micron filter elements, mounted in tan-
dem. The bypass opens at 25 psig (1.7 bar). A visual-type dirt gauge is mounted to the body of each filter to indi-
cate the operating condition of the filter elements. The gauge faces are marked with red and green areas. Red
indicates the need to replace the filter elements. Oil returns to the tank via the return filters mounted on top of the
tank.
Figure 3-25: Return Filter Location
01
03
04
06
09
08
BD0361a01
02
05
07
10
11
LEGEND
01. Suction Filters
02. Hydraulic Tank
03. Breather
04. Return Filters
05. OIl Level Gauge
Placard
06. Oil Level Sight
Glass
3.2.6 Bill of Material
On the engineering drawings, numbers in circles refer to the Bill of Material, which provides component name, part
number, and quantity. The list below, extracted from the Bill of Material, identifies components by name.
1. Double vane pump
2. Pressure Switch
3. Pressure Transducer
4. Pressure Switch
5. Oil Cooler
6. Return Filter
7. Valve Bank #1
8. Cylinder
9. Cylinder
10.Dual Counterbalance Valve
11.Cylinder
12.Cylinder
13.Cylinder
14.Cylinder
15.Cylinder
16.Valve Bank #2
17.Cylinder
18.Cylinder
19.
20.Directional Valve
21.Cylinder
22.Valve Bank #3
23.Winch
24.Regeneration Valve
25.Cylinder
26.Dual Sequence Valve
27.Proportional Valve
28.Tapping Plate
29.Cylinder
30.Manifold Pressure Tap
31.Manifold Pilot Operated Check Valve
32.Manifold Transition
33.Manifold Pressure Tap
34.Manifold Pressure Reducing valve
35.Solenoid Valve
36.Pressure Compensated Flow Control Valve
37.Pressure Compensated Flow Control Valve
38.Cylinder
3.2.7 System Data Sheet
On the engineering drawings, numbers in triangles refer to the System Data Sheet, which provides expanded or
clarifying information regarding the item or function to which it applies.
TEST
POINT
ITEM/FUNCTION
CHECKED
SETTING
Limit Switch Pipe rack gate limit switch indicates gate closed
Item #20:
Directional Valve,
2 position, 4 way
Pipe rack gate solenoid controlled by pope rack limit switch (test point
18) and pope rack seal limit switch (not shown)
3
Item #6:
Return Filter
Verify visual bypass indicator pointer is in acceptable range (green area
of dial). Replace filter element if necessary.
4
Solenoid Relief/
Unload Diverter
Valve,
solenoids A and B
Solenoid A is activated when required by Valve Bank 1 or 2 operations.
Solenoid B is activated when required by Valve Bank 3 operations.
5
Relief/Unload
Diverter Valve
Verify low flow relief pressure setting of 2900 psi. Adjust accordingly.
6
Item #4:
Relief Pressure
Switch
Set relief pressure switch to 2825 psi. Used in auto-level program to
detect full cylinder extension.
Item #4:
Hydraulic Pressure
Switch
Set hydraulic pressure switch to 100 psi. Used to detect hydraulic back
pressure. No hydraulic controls will operate unless switch has been
tripped.
Mast Hoist
With rotary head in lowered position, verify raising and lowering times of
2.5 to 3 minutes. Adjust flow controls on Valve Bank One accordingly.
Items #8, 10, 17
and 24:
Cylinders, Dual
Counterbalance
Valves, and Regen-
eration Valves
FACTORY SET: DO NOT ADJUST!
Limit Switch Mast Anchor Pin limit switch indicates mast is pinned or unpinned
Table 3-1: System Data Sheet, Auxiliary Hydraulic System
1
2
3
4
5
6
7
8
9
10
Deck Wrench
Verify work port pressure relief setting of 2000 psi when fully extended
or retracted. Adjust relief valve accordingly.
Dust Curtains
Verify work port relief valve settings of 350 psi to lower and 1000 psi to
raise. Adjust accordingly.
Dust Curtains
Verify times of 4.0 - 5.0 seconds to raise and lower dust curtains. Adjust
flow control accordingly.
Pipe Rack
Verify in and out travel times of 8.0 - 12.0 seconds. Adjust flow control
accordingly.
Limit Switch Pipe rack limit switch indicates pipe rack stowed in mast.
Solenoid Relief/
Unloading Valve
Solenoid A is activated for auto-level or when all three jack controls are
manually operated.
Solenoid B is activated for manual operation of the winch or manual
operation of individual jacks.
Solenoid Relief/
Unloading Valve
Verify high flow relief pressure setting to be 2850 psi. Adjust relief valve
accordingly.
Item #24:
Regeneration Valve
Solenoid controlled by auto-level program.
Limit Switch
Pressure switch and limit switch produce feedback signals for auto-level
program sequence.
Item #4:
Front Overpressure
Switch
Attach 3000 psi gauge to port GA on front regen valve (Item #24) and
record pressure required to support front of machine on jacks. Adjust
front over pressure switch to trip at approximately 150% of recorded
pressure.
Item #4:
Front Pressure
Switch
Adjust pressure switch to trip when jack pad comes in contact with the
ground.
TEST
POINT
ITEM/FUNCTION
CHECKED
SETTING
11
12
13
17
18
24
25
26
27
28
29
3.3 Auxiliary Hydraulic System Maintenance
3.3.1 General
P&H recommended general maintenance practices can be found in Appendix A P&H recommended maintenance
practices for hydraulic systems can be found in Appendix B. The paragraphs that follow provide information regard-
ing installation, adjustment, lubrication, periodic maintenance, repair and replacement that are appropriate for gen-
eral field maintenance of the auxiliary hydraulic system for this drill. For information on repair procedures not
covered in this manual, contact your local P&H MinePro Services representative.
The inspections that follow are not intended to dictate constant and tedious inspection of every component on the
drill on a daily basis; however, when appropriate, these are areas that should not be overlooked when other main-
tenance services are being performed. In other words, whenever the opportunity arises, check the items indicated.
CAUTION
!
Pressurized fluid escaping from a hydraulic system can penetrate the skin causing seri-
ous injury. Always relieve pressure by connecting a microbore hose from the appropri-
ate test port to the tank test port before disconnecting hydraulic lines. Tighten all
connections before reapplying pressure. Keep hands and body away from pinholes and
nozzles which eject fluid under high pressure. Use a piece of paper to search for leaks.
Do not use your hands. If any fluid is injected into the skin, it must be surgically removed
within a few hours by a medical doctor or gangrene can result.
3.3.1.1 lnspect Hoses And Hydraulic Lines
Visually inspect hydraulic and lubrication hoses and tubing for abrasion, damage, kinks, or other signs of wear or
decay. Report any problems that are found. Damaged hoses and piping must be replaced prior to continued oper-
ation of the drill.
Technician Tip
The types of hoses and associated fittings and adapters specified for use on P&H drills provide
the best performance to withstand the high pressures of the hydraulic system. Always replace
hoses, fittings and adapters in accordance with P&H specifications.
Breakout Wrench
Verify work port pressure relief setting to be 1500 psi. Adjust accord-
ingly.
Breakout Wrench
Verify extend time of 5 to 6 seconds, and 4 to 5 seconds to retract.
Adjust flow control accordingly.
TEST
POINT
ITEM/FUNCTION
CHECKED
SETTING
30
31
3.3.1.2 lnspect Hydraulic Fittings For Leaks
Inspect hydraulic and lubrication connections, and use the appropriate tightening sequence to secure the connec-
tion if necessary. Refer to Appendix B for further guidance if these appropriate tightening procedures are unfamiliar
to you.
3.3.1.3 lnspect Hydraulic System Components
Visually inspect each hydraulic component for damage and leaks. Operate control valves and solenoids to check
for correct component operation. Repair or replace damaged or malfunctioning hydraulic components. Inspections
should include, but not be limited to, the following components:
hydraulic control valves and connections.
hydraulic hoses, fittings and adapters.
drive-to-pump couplings.
hydraulic pumps.
suction filters/return filters.
cylinders, pins, and bushings.
hydraulic motors.
3.3.2.1 Installation
The hydraulic tank is located in the lubrication room on the front right portion of the drill. It is bolted to the machin-
ery deck, with the drain tube extending downward to the underside of the deck.
3.3.2.2 Services
Daily or 8 hours
Check hydraulic fluid level. Check the sight glass daily and/or at the beginning of each shift. The placard next to the
sight glass provides minimum and maximum oil levels depending on the physical condition of the drill (mast up or
down, jacks up or down). Replenish the oil level using supplemental oil tank mounted near the air compressor. The
hydraulic tank holds approximately 64 gallons (242 liters) of Dexron ATF.
Two weeks or 250 hours
P&H Mining Equipment recommends that a sample of oil be drawn from the hydraulic tank during every
PM inspection. This sample should be about two quarts and should be taken when the oil is warmed
through normal operation. The sample should be analyzed by a qualified lubrication specialist to deter-
01
03
04
06
09
08
BD0361a01
02
05
07
10
11
LEGEND
01. Suction Filters
03. Hydraulic Tank
05. Breather
06. Return Filters
07. Lube Room
08. Top Cover
09. Oil Level Gauge Placard
10. Oil Level Sight Gauge
11. Auxiliary Pump
mine whether it is suitable for continued use. The interval between oil changes as defined below may be
extended based upon the operating conditions and on the care used in the handling oils and keeping
them clean during the handling process.
Annually or 2000 hours
Drain the hydraulic system.
Remove the top cover and observe the condition of the inside of the tank. If there is a heavy deposit of
debris, flush the tank.
Refill the hydraulic system with approximately 64 US gallons (242 liters) of Dexron ATF.
3.3.2.3 Repair
WARNING
!
Hydraulic oil is flammable and could explode if exposed to welding heat and/or sparks,
resulting in serious injury or death. Always be certain that the tank is properly cleaned of
any flammable material before welding.
The hydraulic tank is made of mild steel. Any repairs can be accomplished by draining the tank and welding in
accordance with accepted welding practices.
3.3.3 Suction Filters R16280D1
Two suction filters are flange-mounted at the rearward end of the hydraulic oil tank.
3.3.3.2 Service
It is normally unnecessary to remove the filter assembly from the pump suction line to service the filter unit. To
replace the filter element, refer to Figure 3-28 and proceed as follows:
Figure 3-27: Handwell Valves and Suction Filters

WARNING
!
Inadvertent machine movement can cause serious injury or death. Do not perform main-
tenance work on a machine without first disabling the operator controls. Lock out and
tag the operator controls to prevent inadvertent machine start-up during maintenance
work.
Step 1: Lock out and tag the operator controls to prevent inadvertent machine start-up during maintenance activ-
ities.
Step 2: Close the Handwell Valve to shut off the suction line valve by turning the knob anticlockwise.
Step 3: Remove the six capscrews and lockwashers from the filter cover, then remove the cover assembly from
the filter body.
Step 4: Inspect the seal and O-ring between the cover and the body. Replace as required.
Step 5: Remove and discard the filter element. Replace with a new element.
Step 6: Install the cover assembly on the filter body. Confirm the correct arrangement of seals and be certain that
the seals are properly seated.
Step 7: Install the six capscrews and lockwashers to secure the filter cover.
Step 8: Open the Handwell Valve and remove locks and tags from the operator controls.
Figure 3-28: Suction Filter
01 02 03 04 03
05 06
BD0563a01
LEGEND
01. Limit Switch
02. Knob
03. Seals
04. Filter Element
05. Valve
06. Indicator Switch
3.3.3.3 Cleaning, Inspection, and Repair
1. Check the filter weekly, or every 50 hours of operation, for visible damage, leaking seals, and leaking connec-
tions.
2. Clean and inspect all auxiliary hydraulic pump suction filter components in accordance with the general clean-
ing and inspection procedures described in Appendix A of this manual. Replace any worn or damaged compo-
nents. See the LinkOne electronic parts manual for component identification.
3.3.4 Temperature Probe 89Z724D2
The probe threads into the side of the hydraulic tank. When installing the probe, pack the well with grease. The
grease will act as a thermal conductor.
3.3.4.2 Service and Repair
No service is required, and the temperature probe is not repairable. If the unit fails, it must be replaced.
3.3.4.3 Replacement
WARNING
!
Electric current can cause burns, injury, or even death. Disconnect, lock open, and tag
the power source which feeds this device to prevent power from being applied while
inspection and repairs are being performed. Before beginning repairs, try the operational
controls to verify that the intended power source is disconnected.
Step 1: Lock out and tag out the controls to the hydraulic pumps to prevent activation while the temperature probe
is being serviced.
Step 2: Tag and disconnect the electrical wiring to the temperature probe, if not already disconnected.
Figure 3-29: Hydraulic Tank Temperature Probe
Step 3: Remove the temperature probe from the hydraulic tank.
NOTICE
The temperature probe assembly is not repairable, and must be replaced if damaged or inoper-
able. Refer to the LinkOne electronic parts manual for temperature probe identification.
Step 4: Pack the well with grease. The grease will act as a thermal conductor. Thread the probe into the well.
Step 5: Install the electrical wiring to the probe in accordance with the identification tags placed during removal.
3.3.5 Low Level Switch R16982D1
The oil level switch is threaded into a fitting on the top of the hydraulic tank.
3.3.5.1 Testing the Switch
NOTICE
Thoroughly clean the top of the hydraulic tank before disconnecting or removing any of the
hydraulic components.
To check the function of the switch, unthread the float switch assembly from the tank and pull the float rod about 2
feet ( meter) out of the tank. The GUI should register a fault. If it does not register a fault, replace the float.
3.3.5.2 Service and Repair
No service is required, and the low level switch is not repairable. If the unit fails, it must be replaced.
Figure 3-30: Hydraulic Tank Oil Level Switch
3.3.5.3 Replacement
WARNING
!
Electric current can cause burns, injury, or even death. Disconnect, lock open, and tag
Step 1: Lock out and tag out the controls to the hydraulic pumps and the level switch to prevent activation while
the level switch is being serviced.
Step 2: Tag and disconnect the electrical wiring to the level switch, if not already disconnected.
Step 3: Remove the level switch from the hydraulic tank.
NOTICE
The level switch assembly is not repairable, and must be replaced if damaged or inoperable.
See the LinkOne electronic parts manual for switch identification.
Step 4: Apply a thin film of pipe sealant to the male pipe threads on the level switch, then install the switch in the
tank.
Step 5: Install the electrical wiring to the switch in accordance with the identification tags placed during removal.
Add oil as necessary to attain the correct operating level.
3.3.6 Hydraulic Tank Breather 1046Z994
The hydraulic tank breather is threaded onto a stud mounted at the top of the tank.
Figure 3-31: Hydraulic Tank Breather
3.3.6.2 Service
Replace the breather at every PM.
3.3.6.3 Replacement
Remove the old breather by spinning it off the stud. Coat the new gasket (O-ring) with oil and install the new gasket
into the new breather. Install the new breather onto the stud until the gasket makes contact, then turn the breather
another 1/4 turn.
3.3.7 Magnetic Rod
The magnetic rod is threaded into a fitting in the top of the tank. The rod extends into the tank and attracts metal
contaminants.
3.3.7.2 Service
Each PM, remove the magnetic rod and inspect it. Determine the source and severity of the contaminants captured
by the rod. Record these findings for follow-up analysis. Wipe the rod clean and reinstall it into the fitting in the top
of the tank.
Figure 3-32: Magnetic Rod
3.3.8 Return Filters 46Z529
BD0781b01
3.3.8.2 Inspection, Service and Repair
1. Check the filter indicators weekly to ensure that the filters are still operating in the green zone of the indicator.
Also check filter status at the GUI.
2. Check the filters for visible damage, leaking seals, and leaking connections.
3. If the filter indicators are in the red zone, or after six months or 2000 hours of operation the filter elements must
be replaced.
Replace the hydraulic return line filter elements as follows:
DISASSEMBLY. Disassemble the return line filters for replacement of filter elements as follows:
WARNING
!
tenance work on a machine without first disabling the operator controls. Follow lockout
and tagout procedures to prevent inadvertent machine startup during maintenance.
Figure 3-34: Return Filter
LEGEND
01. Filter Cap
02. O-ring
03. Head
04. Square O-ring
05. Dirt Alarm Gauge
06. Bypass Indicator Switch
07. Filter Element
08. Filter Elements Connector
09. Bowl
10. Filter Mounting Gasket
11. Check Valve
1. Lock out and tag the operator controls to prevent inadvertent machine startup during maintenance activities.
2. Clean all dirt from the filter housings and fittings.
WARNING
!
Hot hydraulic oil can spray with extreme force and volume causing injury or death. Use
lockout and tagout procedures to guard against inadvertent hydraulic system or
machine start up during service or maintenance. Allow the hydraulic system to cool
before maintenance or repair. Slowly release pressure or vent circuits before discon-
necting hydraulic lines. Wear appropriate face and body protective devices while care-
fully loosening any connection or fitting.
3. Be sure that no pressure exists in any of the hydraulic system circuits before opening the filter assembly.
4. Remove the four capscrews from the filter cap, then remove the cap assembly and O-ring from the filter body.
5. Remove the two filter elements and the intermediate connector from the bowl.
6. Inspect the filter element for signs of damage or heavy buildup of debris collected on the inside of the element.
Note the type of debris found; debris can be a clue to potential component failures.
7. Inspect the element for damage. Damage can warn that there is or has been a high pressure spike, or a surge
of return oil. Spikes would indicate a potential problem with a pump or hydraulic motor.
8. Inspect the filter bowl. Note any damage as well as the presence and type of debris buildup.
9. Discard the filter elements, but do not discard the element connector.
10. Cover the opening of the filter body to prevent dirt or other small items from inadvertently falling into the bowl or
tank.
CLEANING AND INSPECTION. Clean and inspect all of the return filter components in accordance with the gen-
eral cleaning and inspection procedures described in Appendix A of this manual. Replace any worn or damaged
components. The cap assembly including the spring and element retainer must be replaced as a unit. See the
LinkOne electronic parts manual for component identification.
ASSEMBLY. Assemble the new filter elements in the return filter assembly as follows (refer to Figure 3-34):
1. Install the two new filter elements and element connector in the filter bowl.
2. Lightly oil the O-ring, then position it with the cover assembly on the filter head. Be certain that the spring-loaded
element retainer is correctly positioned on the top filter element, and the O-ring is accurately positioned under the
filter cap to prevent leakage during operation.
3. Install the four capscrews and lockwashers into the cap assembly, and torque them securely.
3.3.8.3 Service
Replace the filter elements when:
indicators are in the red zone and/or the GUI is registering a fault
after 6 months or 1000 hours of operation
when the hydraulic oil is changed
Refer to Figure 3-34 and replace the filter elements as follows:
Step 1: Lock out and tag out the operator controls to prevent inadvertent machine startup during maintenance
activities.
Step 2: Clean all dirt from the filter housings and fittings.
CAUTION
!
Hot hydraulic oil can burn. Use lockout and tagout procedures to guard against inadvert-
ent hydraulic system or machine startup during service or maintenance. Allow the
hydraulic system to cool before maintenance or repair. Wear appropriate face and body
protective devices while changing filter elements.
Step 3: Remove the four capscrews from the filter cap, then remove the cap assembly and O-ring from the filter
body.
Step 4: Remove the two filter elements and the intermediate connector from the bowl. Discard the filter elements,
but do not discard the element connector.
Step 5: Cover the opening of the filter body to prevent dirt or other small items from inadvertently falling into the
bowl or tank.
Step 6: Clean and inspect all of the return filter components in accordance with the general cleaning and inspec-
tion procedures described in Appendix Z of this manual. Replace any worn or damaged components. The
cap assembly including the spring and element retainer must be replaced as a unit. See the LinkOne
electronic parts manual for component identification.
Step 7: Install the two new filter elements and element connector in the filter bowl.
Step 8: Lightly oil the O-ring, then position it with the cover assembly on the filter body. Confirm that the spring-
loaded element retainer is correctly positioned on the top filter element, and the O-ring is accurately posi-
tioned under the cover to prevent leakage during operation.
Step 9: Install the four capscrews and lockwashers into the cap assembly, and torque them securely.
3.3.9 Auxiliary Hydraulic Pump 37U153D1
3.3.9.1 Location
The auxiliary hydraulic pump is flange-mounted to the back side of the PDT.
3.3.9.2 Maintenance and Repairs
No periodic maintenance is required. Repairs in the field are not recommended. If the pump requires service,
remove it and send it to a qualified repair facility.
3.3.9.3 Removal
Remove the pump from the system as follows:
WARNING
!
work.
1. Lock out and tag the operator controls to prevent inadvertent machine start-up during maintenance activities.
2. Clean all dirt away from the pump, hose assemblies, and fittings.
3. Turn the Handwell valve on the tank suction filter assembly fully counterclockwise to the closed position.
Figure 3-35: Auxiliary Pump
WARNING
!
Hot hydraulic oil can spray, causing injury or death. Use lockout and tagout procedures
to guard against inadvertent hydraulic system or machine start up during service or
maintenance. Allow the hydraulic system to cool before maintenance or repair. Slowly
release pressure or vent circuits before disconnecting hydraulic lines. Wear appropriate
face and body protective devices while carefully loosening any connection or fitting.
4. Check to be certain that the hydraulic pressure is completely vented from the high-pressure and control pres-
sure circuits.To vent system pressure, attach a Microbore hose from the hydraulic test kit between the appro-
priate test port and the test port that is open to the tank.
5. Tag and remove the hydraulic hoses from the pump. Cap plug all hose fittings and pump ports to prevent the
entry of foreign material into the pump or hydraulic system.
6. Support the pump (pump weighs approximately 30 lbs (14 kg)) so that its entire weight will not be supported by
the shaft when the mounting capscrews are removed. Remove the two capscrews and lockwashers that
secure the pump to the pump drive transmission. Slide the pump back from the pump drive until the driveshaft
is clear of the pump drive, and remove the pump.
CAUTION
Exercise care when installing the pump on the pump drive transmission to prevent mis-
alignment, which can lead to premature pump failure.
Install the pump on the pump drive as follows:
1. Check the mounting flange on the pump drive, the pilot diameter on the pump, and the splined shaft and bore
for burrs and imperfections that would prevent the pump from seating correctly on the pump drive. Carefully
remove any imperfections by lapping.
2. Apply a light coat of grease to the pilot diameter and driveshaft splines. Position the gasket on the pump.
3. Carefully install the pump on the drive, and install the mounting capscrews and lockwashers. Be careful to pre-
vent misalignment when tightening the capscrews.
4. Install the suction and outlet lines, then turn the suction line valve to the open position.
5. Start the pump drive with no load applied to the pump to prime the pump. Operate the system at moderate
loading (such as the deck wrenches or the deck hatch) for a short period of time.
6. Check the reservoir oil level, and add oil if required.
3.3.10 Valve Banks
3.3.10.1 General
Valve banks 1, 2 and 3 control the operation of the auxiliary hydraulic system. They are located at the rear of the
machinery house, between the mast hoist cylinders. Refer to Figure 2-3.
01 02 03 04 05 06 07 08
BD0380a01
LEGEND
01. Relief Unload/Oil Diverter consists of four stacked valves. The top valve is a double solenoid, spring centered, 3
position/4 way directional valve with manual override. The second valve down is a single check valve that pre-
vents backflow from the low pressure discharge of the auxiliary hydraulic pump.The third valve down is a shut-
tle valve that connects externally to the auxiliary hydraulic system pressure transducer and two of the auto level
pressure switches.The bottom valve is a single, adjustable pressure relief valve.
02. Mast Hoist. Top valve is a double solenoid, spring centered, 3 position/4 way directional valve with manual over-
ride. Bottom valve contains a pair of one-way flow control valves.
03. Mast Anchor Pins. A double solenoid, spring centered, 3 position/4 way directional valve with manual override.
04. Deck Wrench. Top valve is a double solenoid, spring centered, directional valve with manual control. Bottom
valve is a double, adjustable pressure relief valve.
05. Dust Curtain. Top valve is a double solenoid, spring centered, 3 position/4 way directional valve with manual
override. The second valve down contains two pilot check valves. The third valve down is a double, adjustable
pressure relief valve. Bottom valve contains a pair of one-way flow control valves.
06. Back Brace Lock. A double solenoid, spring centered, 3position/4 way directional valve with manual override.
07. Spare
08. Spare
01 02 03 04 05 06 07 08
BD0397a01
LEGEND
01. Pipe Rack. Top valve is a double solenoid, spring centered, 3 position/4 way directional valve with manual
override.The bottom valve contains a pair of one-way flow control valves. Set the flow control valves to
achieve a travel time in both directions of 8.0 - 12.0 seconds (typically 12.5 - 15.5 gpm).
02. Pipe Rack. Top valve is a double solenoid, spring centered, 3 position/4 way directional valve with manual
override.The bottom valve contains a pair of one-way flow control valves. Set the flow control valves to
achieve a travel time in both directions of 8.0 - 12.0 seconds (typically 12.5 - 15.5 gpm)
03. Pipe Rack Holdback. Top valve is a single solenoid, spring return, 2 position/4 way directional valve with
manual override.The second valve contains a pressure relief valve. Set the pressure relief valve to 400 psi
(27.6 bar)
04. Spare
05. Spare
06. Deck Hatch. Top valve is a double solenoid, spring centered, 3 position/4 way directional valve with manual
override.
The second valve down is a dual pilot-to-open check valve with a 15 psi crack pressure.
The third valve down is a dual relief valve. Each relief valve is to be set at 150 psi (10.35 bar).
The bottom valve is a dual flow control valve. Outflow is metered to 3 GPM on the A side and 4 GPM on the
B side.
07. Spare
08. Spare
01
02
03 04 05 06
BD0382a01
LEGEND
01. Solenoid Relief Unloading Valve. Top valve is double solenoid, spring centered, 3 position/4 way
directional valve with a manual override. The second component down is a special porting block to
provide a means to install pilot line between the solenoid relief unloading valve and the three jack
control valves, also on valve bank #3. The third valve down contains a single adjustable, pilot oper-
ated pressure relief valve, which function as a pilot stage relief valve. Bottom valve is a pressure
relief valve, which operates as the main stage relief valve for the valve bank #3 circuits.
02. Auxiliary Winch. Top valve is a double solenoid, spring centered, 3 position/4 way proportional
directional valve with manual override. Bottom valve is a double counterbalance valve. A flow con-
trol valve installed in the valve bank manifold regulates the inflow rate to the directional valve.
03. Right Rear Jack. A double solenoid, spring centered, directional valve with manual control. A flow
control valve installed in the valve bank manifold regulates the inflow rate to the directional valve.
04. Left Rear Jack. Valve configuration is identical to the right rear jack valve.
05. Front Jacks. Valve configuration is identical to the right rear jack valve.
3.3.10.2 Removal
Under normal circumstances, it is unnecessary to replace an entire valve bank assembly for maintenance or repair
of its control circuits. Each individual control valve block can be removed from its position in a stacked valve
assembly without need for removal of the manifold, hydraulic hoses, or fittings.
NOTICE
The following contains procedures for replacement of the hydraulic valve assembly compo-
nents mounted on manifolds. These procedures are typical, and apply to all of the hydraulic
system valve banks.
3.3.10.3 Solenoid Replacement
Figure 3-42 illustrates the components of a typical solenoid-operated directional valve. It is unnecessary either to
remove the valve from the manifold or to disassemble its hydraulic components in order to replace a valve solenoid
coil.
1. Remove the solenoid from the directional valve as follows:
WARNING
!
work.
A. Lock out and tag the operator controls to prevent inadvertent machine start-up during maintenance activi-
ties.
B. Tag the electrical connector(s) on the solenoid, or solenoids, to be removed.
Figure 3-42: Solenoid Operated Directional Valve
01
02
03
05
06
07
08
09
11
04 04
10
LEGEND
01. Name Plate Screw
02. Valve Body Capsrew (under body)
03. Connector Screw
04. Seal
05. Name Plate
06. Electrical Connector
07. Solenoid Cap
08. Solenoid Core
09. Solenoid
10. Locating Pin
11. Valve Body
C. Loosen the retainer screw on the electrical connector, then remove the connector from the solenoid. Be cer-
tain to remove the seal as well.
D. Unthread the solenoid cap, then remove the cap and O-ring from the solenoid core. Save the O-ring for re-
assembly.
E. Slide the solenoid assembly from the end of the solenoid core.
2. Clean and inspect the exterior of the directional valve and the solenoid in accordance with the general proce-
dures provided in Appendix A.
3. Install the solenoid on the directional valve as follows:
A. Position a solenoid assembly over the end of the core, and locate it against the directional valve body.B.
Lightly lubricate the O-ring, and install it over the core and against the end of the solenoid housing.
B. Install the solenoid cap, and tighten it firmly by hand.
C. Install the electrical connector and seal onto the solenoid in accordance with the identification tag, and fas-
ten securely with the retaining screw.
3.3.10.4 Directional Valve Replacement
Depending on the specific circuit configuration, the solenoid-operated directional valves are mounted either as a
single unit assembly on the manifold, or as the top valve in a stacked valve assembly. Refer to Figure 3-42 and
proceed as follows:
1. Prepare the drill for hydraulic system maintenance as follows:
A. Move the drill to firm level ground.
B. If not already in position, lower the drill until it is supported completely by the crawler tracks.
C. Position the leveling jacks until the jack pads are resting on the ground without pressure.
D. Be certain that the mast is either fully up and locked in position, or that it is in the down position and resting
completely on its supports.
E. Have adequate lighting available.
F. Have tools and replacement parts with you before starting the job.
CAUTION
!
Hydraulic fluid can enter water supplies and cause illness. Never drain hydraulic fluid
onto the ground.
G. Since some minor leakage of hydraulic fluid is unavoidable, keep a good supply of cleaning materials on
hand.
H. Be sure that the auxiliary winch is not supporting any load, and that its hook is secured to the mast.
WARNING
!
work.
3. Tag, loosen and remove the electrical connector(s) from the valve solenoid(s). It is not necessary to remove
the solenoid(s) from the valve at this time.
WARNING
!
4. Make certain that no control pressure exists in any of the auxiliary hydraulic system circuits.
5. Remove the four round head machine screws from the valve identification plate on top of the valve body, then
remove the plate.
6. Remove the four valve body capscrews, previously hidden by the identification plate, and carefully remove the
valve from the manifold or intermediate valve (if part of a stacked valve subassembly). The valve is located on
its mounting surface by a pair of dowel pins. Use care to avoid scratching or nicking the mounting surfaces dur-
ing the removal process.
7. Remove and discard the used O-rings from the valve body.
8. Clean and inspect the exterior of the directional valve in accordance with the general procedures for cleaning
and inspection in Appendix A. Replace any faulty valve, and all O-rings.
9. Install the directional valve as follows:
CAUTION
Always use O-rings specified by P&H Mining Equipment. Using the wrong material or
size of O-ring may cause the O-ring to fail under high pressure.
A. Lubricate the new O-rings with hydraulic oil and insert them into the seats in the valve body.
B. Make sure that the locating pins are correctly seated, then carefully position the valve body on the manifold
mounting surface, or on top of the intermediate valve in the valve assembly.
C. Insert the pins into the pin holes to correctly align the valve. Install the four body retaining capscrews to fas-
ten the valve body to the manifold. Torque the capscrews uniformly using a crosswise pattern.
D. Position the identification plate on top of the directional valve and fasten securely with four round head
machine screws.
E. Install the electrical connector(s) and seal(s) onto the valve solenoid(s) in accordance with the identification
tags, and fasten securely with the retaining screw.
F. Start the power unit, and bleed all air from the auxiliary hydraulic system.
3.3.10.5 Intermediate Stacked Valve Replacement
All valve bodies that are sandwiched between the solenoid-operated directional valves and the manifold are
replaced using the following typical procedure.
1. Remove the solenoid-operated valve from the valve assembly as described above.
2. Loosen the four body retaining capscrews that fasten the valve body to the adjacent valve or manifold, and
carefully remove the valve body. The valve body is located on its mounting surface by a pair of dowel pins. Use
care to avoid scratching or nicking the mounting surfaces during the removal process.
3. Remove and discard the used O-rings from the valve body.
4. Clean and inspect the exterior of the directional valve in accordance with the general procedures provided in
Appendix A. Replace any faulty valves, and all O-rings. See the LinkOne electronic parts manual for valve and
seal kit information.
5. Lubricate the new O-rings with hydraulic oil and insert them into the seats in the valve body.
6. Make sure that the locating pins are correctly seated, then carefully position the valve body on the manifold
mounting surface. Insert the pins into the pin holes to correctly align the valve.
7. Install four special capscrews to fasten the valve body to the manifold. Torque the capscrews uniformly using a
crosswise pattern.
8. Install the solenoid-operated valve from the valve assembly as described under Subtopic 3.3.10.4.
Figure 3-43: Valve Ports
9. Start the power unit, and bleed all air from the auxiliary hydraulic system.
3.3.11 Dual Counterbalance Valves R6268D1
Dual counterbalance valves are used in several auxiliary hydraulic system branch circuits. Figure 3-44 illustrates a
typical application on one of the jack cylinders. The function of dual counterbalance valves is to prevent the flow of
fluid in a hydraulic circuit when the circuit is not sufficiently pressurized. This function prevents components, such
as jack cylinders, from drifting under load when the hydraulic systems have been turned off or there is an unex-
pected loss of hydraulic pressure.
All dual counterbalance valves on this drill are cartridge type, which means that the valve bodies do not need to be
removed from the circuits to enable replacement of the working components of the valve. The circuits using dual
counterbalance valves as shown in Table 3-2.
Figure 3-44: Dual Counterbalance Valve

Cartridge type counterbalance valve assemblies consist of a valve body that is drilled, tapped, and counter-bored
to accept one or more valve cartridges, the valve cartridge assemblies, and the O-rings and back-up rings that seal
the land areas of the valve cartridge.
3.3.11.2 Service
Counterbalance valves should not be serviced, except for two conditions:
Valve Leakage. Remove the cartridge and replace the O-ring seals.
Valve Malfunction. Replace the cartridge as a unit.
3.3.11.3 Cartridge Removal
To remove a counterbalance valve cartridge from a valve body, proceed as follows:
Step 1: Position the drill in a flat, level area. The ground must be stable and the area must be safe from hazards.
WARNING
!
work.
ities.
WARNING
!
Circuit Valve Description
Pipe Rack In/Out One Dual CB Valve per pipe rack
Mast Hoist One dual CB Valve per cylinder
Deck Wrench One Dual CB Valve
Right Rear Jack One Dual CB Valve
Left Rear Jack One Dual CB Valve
Front Jacks One Dual CB Valve
Table 3-2: Counterbalance Valve Locations
Step 3: Be sure that no pressure exists in any of the auxiliary hydraulic system circuits.
A. Position the components so that there is no load being held by the cylinder.
B. If test ports directly into the cylinder are available, connect a microbore hose to both sides of the cylinder. If
no ports are available, proceed slowly and with caution.
NOTICE
Clean any dirt away from the valve assembly and hydraulic hose fittings before loosening any of
the hydraulic components.
Step 4: Cover the cartridge with a shop rag. With a wrench, use the wrench flats provided for removal. Do not
attempt to loosen the cartridge by turning on the pressure adjustment assembly. Loosen and slowly
unscrew the cartridge; any trapped pressure will be released before the cartridge is fully unscrewed. Plug
the hole in the valve body to prevent entry of loose or airborne dirt.
Clean and inspect the valve assembly in accordance with the general procedures for cleaning and inspection in
Appendix A.
Repair is limited to replacing O-rings and back-up rings. The cartridge valves are not field repairable. Replace any
faulty valve cartridges.
Replace O-rings and back-up rings as follows:
Step 1: Remove and discard the O-rings and back-up rings from the O-ring grooves on the outside diameter of
the valve cartridge.
Step 2: Replace all O-rings and back-up rings in the order indicated in Figure 3-45. Refer to the LinkOne elec-
tronic parts manual for cartridge and seal kit information.

Figure 3-45: Cartridge Service
F7357
03
04
05
04
06
07
06
08
09
08
02
01
10
13
14
13
15
16
17
18
17
18
17
13
14
13
15
16
17
18
17
18
17
11
12
12
11
10
21
22
23
24
25 20
19
26
LEGEND
01. Directional Valve
02. Seal Kit
03. O-Ring
04. Backup Ring
05. O-Ring
06. Backup Ring
07. O-Ring
08 Backup Ring
09. O-Ring
10. Test Port Connector
11. Counterbalance Valve
12. Seal Kit
13. Backup Ring
14. O-Ring
15. Backup Ring
16. O-Ring
17. Backup Ring
18. O-Ring
19. Directional Solenoid Valve
20. Seal Kit
21. O-Ring
22. O-Ring
23. Backup Ring
24. O-Ring
25. Backup Ring
26. Solenoid Coil
3.3.11.5 Cartridge Installation
To install the counterbalance valve cartridge into the valve body, proceed as follows:
Step 1: Lightly lubricate the O-rings and back-up rings for the cartridge valve, and install them in the grooves on
the outside diameter of the valve cartridge.
Step 2: Carefully install the valve cartridge into its seat in the manifold. Avoid displacement or cutting of the O-ring
seals during installation. Torque the valve 150-160 ft-lbs (203 - 217 Nm).
3.3.12 Main Hydraulic Pressure Transducer 36Q549
3.3.12.1 Location
One pressure transducer is used in the auxiliary hydraulic system. It is mounted on the wall behind and below
valve bank 2 (refer to Figure 3-46), and is connected to a shuttle valve installed as part of the relief/unload oil
diverter valve assembly on valve bank 1. The pressure transducer has a 1/4" NPT female pipe thread for connec-
tion to the hydraulic circuit. It is connected to the electrical system with a four prong DIN electrical connector.
3.3.12.2 Removal
To remove the pressure transducer from the system, proceed as follows:
WARNING
!
Figure 3-46: Auxiliary Hydraulic System Pressure Components
LEGEND
01. Main Hydraulic
Pressure Transducer
02. Hydraulic Pressure Switch
03. Relief Pressure Switch
work.
Step 2: Lock out and tag out the operator controls to prevent inadvertent machine start-up during maintenance
activities.
Step 3: Clean all dirt away from the pressure transducer and pipe fittings before loosening any components.
Step 4: Remove the signal wire connector from the connector on the transducer.
WARNING
!
Step 5: Confirm that hydraulic pressure is completely vented before loosening the pressure transducer.
Step 6: Unthread and remove the transducer from the 1/4" high pressure pipe fitting.
Clean and inspect the pressure transducer in accordance with the general procedures for cleaning and inspection
in Appendix A. The pressure transducer is non-repairable, and therefore must be replaced with a new unit if dam-
aged. See the LinkOne electronic parts manual for pressure transducer information.
Install the pressure transducer as follows:
Step 1: Apply a coating of pipe thread sealant to the 1/4" male pipe threads, and install the transducer in the shut-
tle valve circuit.
Step 2: Install the signal wire connector and seal to the connector on the transducer.
3.3.13 Hydraulic Pressure Switch R24844D1
3.3.13.1 Location
The hydraulic pressure switch (Item 02, Figure 3-46) is mounted on the wall behind and below valve bank 2, and is
connected to a shuttle valve installed as part of the relief/unload oil diverter valve assembly on valve bank 1. The
pressure transducer has a 1/4" NPT female pipe thread for connection to the hydraulic circuit. It is connected to the
electrical system with a 1/2 NPT conduit connection.
Figure 3-47: Hydraulic Pressure Switch
3.3.13.2 Adjustment
Adjust the hydraulic pressure for 100 psi as follows:
Step 1: Remove cover (01) to gain access to the self-locking adjustment screw (04).
Step 2: Use a screwdriver to adjust the setting on the pressure switch. Observe the indicator (02) to determine
the switch is set to 100 psi (6.9 bar).
Step 3: Electrical testing can confirm that the switch closes when hydraulic pressure reaches 100 psi, and
remains closed until pressure drops below 80-95 psi.
3.3.13.3 Maintenance and Repair
Clean and inspect the pressure switch in accordance with the general procedures for cleaning and inspection in
Appendix A. The pressure switch is non-repairable, and therefore must be replaced with a new unit if damaged.
See the LinkOne electronic parts manual for pressure switch information.
3.3.13.4 Removal
To remove the pressure switch from the system, proceed as follows:
Figure 3-48: Hydraulic Pressure Switch Adjustment
LEGEND
01. Cover
02. Indicator
03. Pressure Setting
Gauge
04. Self-Locking
Adjustment Screw
05. Screwdriver
WARNING
!
work.
activities.
Step 3: Clean all dirt away from the pressure switch and pipe fittings before loosening any components.
Step 4: Remove the wire connector from the switch.
WARNING
!
Step 5: Confirm that hydraulic pressure is completely vented before loosening the pressure switch.
Step 6: Unthread and remove the switch from the 1/4" high pressure pipe fitting.
Install the pressure switch as follows:
Step 1: Apply a coating of pipe thread sealant to the 1/4" male pipe threads, and install the transducer in the shut-
tle valve circuit.
Step 2: Attach the wire connector to the switch.
3.3.14 Leveling System Pressure Switches 79Z2750D2
3.3.14.1 Location
The relief pressure switch (Item 03, Figure 3-46) is mounted on the wall behind and below valve bank 2, and is
connected to a shuttle valve installed as part of the relief/unload oil diverter valve assembly on valve bank 1. The
pressure transducer has a 3/8" SAE connector for connection to the hydraulic circuit. It is connected to the electri-
cal system with a 1/2 NPT conduit connection.
Jack pressure switches are located on the upper jack housing. Pressure switches for the front jacks are mounted
on the upper housing of the right front jack. Pressure switches for the rear jacks are mounted on each jack housing.
Figure 3-49: Hydraulic Pressure Switch
LEGEND
01. Setting Adjustment
02. Lock Nut
03. Range Scale
04. Setting Indicator
05. Operation Indicator
06. Differential
Adjustment
3.3.14.2 Adjustment
Levelling system pressure switches and their settings are described in Table 3-3:
Relief Pressure Switch
The relief pressure switch indicates to the PLC that all of the leveling jacks have reached the ground. Refer to Fig-
ure 3-49 and adjust the relief pressure switch for 2825 psi as follows:
Step 1: Loosen lock nut (02) to allow movement of the adjustment screw (01).
the switch is set at 2825 psi (195 bar).
Step 3: Electrical testing can confirm that the switch closes when hydraulic pressure reaches 2825 psi.
Overpressure Switch
Step 1: Attach a 3000 psi gauge to Port GA on the front regeneration valve.
WARNING
!
Contact with rotating machinery and live electrical circuits can cause personnel injury or
death. Before starting the drill be sure all personnel are clear of drill mast, moving
machinery, rotating shafts, electrical cabinets and other areas that may be hazardous.
Step 2: Start the drill.
Step 3: Actuate the front jack raise sequence until the front jacks are supporting the weight of the drill.
Circuit Location Function Setting
Relief Pressure Switch Near Valve Bank 2
Indicates that all jacks
are in contact with the
ground and starting to lift
the drill.
2825 psi
Overpressure Switch Right Front Jack Housing
Indicates that pressure is
significantly higher than
normal.
150% of recorded lifting
pressure (refer to Over-
pressure Switch)
Front Jack
Pressure Switch
Right Front Jack Housing
Indicates that the front
jacks are in contact with
the ground.
Set to trip when jack pad
comes in contact with the
ground
Left Rear Jack
Pressure Switch
Left Rear Jack Housing
Indicates that the left
rear jack is in contact
with the ground.
Right Rear Jack
Pressure Switch
Right Rear Jack Housing
Indicates that the right
rear jack is in contact
with the ground.
Table 3-3: Valve Bank Pressure Switch Settings
Step 4: Record the pressure required to support the front of the drill on jacks.
Step 5: Actuate the front jack lower sequence until the jacks are fully retracted.
Step 6: Turn off the drill.
WARNING
!
work.
activities.
Step 8: Refer to Figure 3-49. Loosen lock nut (02) to allow movement of the adjustment screw (01).
the switch is set to approximately 150% of the pressure recorded in Step 4 above.
Jack Pressure Switches
The jack pressure switches indicates to the PLC that the associated leveling jack(s) have reached the ground.
Refer to Figure 3-49 and adjust all three jack pressure switches to close when the jack has reached the ground as
follows:
Step 1: Loosen lock nut (02) to allow movement of the adjustment screw (01).
Step 2: Use a screwdriver while observing the indicator (04) to adjust the setting on the pressure switch to
approximately 200 psi (13.8 bar).
WARNING
!
Contact with rotating machinery and live electrical circuits can cause personnel injury or
death. Before starting the drill be sure all personnel are clear of drill mast, moving
machinery, rotating shafts, electrical cabinets and other areas that may be hazardous.
Step 3: Start the drill.
Step 4: Actuate the jack raise sequence for the front jacks circuit until the jacks contact the ground.
Step 5: Confirm that the pressure switch closes when both jacks contact the ground. If it does not, note that the
pressure setting must be decreased.
Step 6: Actuate the jack raise sequence for the left rear jack circuit until the jack contacts the ground.
Step 7: Confirm that the pressure switch closes when the jack contacts the ground. If it does not, note that the
Step 8: Actuate the jack raise sequence for the right rear jack circuit until the jack contacts the ground.
Step 9: Confirm that the pressure switch closes when the jack contacts the ground. If it does not, note that the
Step 10: Turn off the drill.
Step 11: For any switch that did not close when the jack(s) came in contact with the ground, adjust the pressure
switch to a lower pressure and re-test.
3.3.14.3 Maintenance and Repair
Inspect the pressure switch in accordance with the general procedures for cleaning and inspection in Appendix A.
Test the switch for satisfactory hydraulic pressure and electrical function. The pressure switch is non-repairable,
and therefore must be replaced with a new unit if damaged. Refer to Figure 3-50 and pre-adjust the replacement
switch on a test bench to the pressure setting specified in Subtopic 3.3.14.2. See the LinkOne electronic parts
manual for pressure switch information.

3.3.14.4 Removal
To remove the pressure switch from the system, proceed as follows:
WARNING
!
work.
activities.
Step 3: Clean all dirt away from the pressure switch and pipe fittings before loosening any components.
Step 4: Remove the wire connector from the switch.
Figure 3-50: Bench Test Set-up
01 02 04 05 06 03
BD0575a01
LEGEND
01. Port-a-Power
02. Gauge
03. Tee Fitting
04. Hose
05. Adapter
06. Pressure Switch
WARNING
!
Step 5: Confirm that hydraulic pressure is completely vented before loosening the pressure switch.
Step 6: Uncouple the 3/8" SAE fitting and remove the switch.
Install the pressure switch as follows:
Step 1: Couple the 3/8" SAE fitting to install the transducer in the shuttle valve circuit.
Step 2: Attach the 1/2 wire connector to the switch.
3.3.15 Regeneration Valve 36U437D1
3.3.15.1 Description
One regeneration valve is used in each of the three jack circuits. Figure 3-51 illustrates one of the valves installed
on a jack housing. These valves are cartridge type valves, and, therefore, do not require removal from the piping to
replace a cartridge or the seals.
3.3.15.2 Service
Remove a regeneration valve cartridge assembly as follows:
Step 1: Position the drill so that it is supported on the crawler tracks, and the jack pads are resting on firm ground
with no applied load.
WARNING
!
work.
ities.
Step 3: Tag and disconnect the electrical connector from the solenoid valve operator.
Figure 3-51: Regeneration Valve
Step 4: Remove the nut that retains the solenoid coil, and remove the coil from the valve.
WARNING
!
Step 5: Confirm that no pressure exists in any of the auxiliary hydraulic system circuits.
CAUTION
Clean any dirt away from the valve assembly and hydraulic hose fittings before loosen-
ing any of the hydraulic components.
Step 6: With a wrench, loosen and remove the valve cartridge from the valve body. Be sure to use the wrench
flats provided for removal. Do not attempt to loosen the cartridge by turning on the pressure adjustment
assembly. Plug the hole in the valve body to prevent entry of loose or airborne dirt.
Step 7: Inspect the O-rings and back-up rings on the outside diameter of the valve cartridge. Remove and dis-
card them if they are damaged.
Clean and inspect the valve assembly in accordance with the general procedures for cleaning and inspection in
Appendix A. The cartridge valves are not field repairable. Replace any faulty valve cartridges, all O-rings. and
back-up rings. See the LinkOne electronic parts manual for cartridge and seal kit information.
3.3.15.4 Cartridge Installation
To install the valve cartridge into the valve body, proceed as follows:
Step 1: Lightly lubricate the new O-rings and back-up rings for the cartridge valve, and install them in the grooves
on the outside diameter of the valve cartridge.
Step 2: Carefully install the valve cartridge into its seat in the manifold. Avoid displacement or cutting of the seals
during installation. Torque the valve to 225 12 ft-lbs (305 16 Nm).
Step 3: Install the solenoid coil on the valve with the solenoid nut.
Step 4: Connect the electrical connector to the valve solenoid.
Step 5: Start the hydraulic systems, bleed the air from the jack circuit, and test the function of the replaced regen-
eration valve.
3.3.16 Troubleshooting
Problem Possible Cause Remedy
System fails to build
pressure
Control valve does not shift cor-
rectly
Replace the Relief/unload/oil diverter valve
System oil level is low Replenish tank supply
External leak in system
Tighten components and bleed air from sys-
tem
dirty filters Replace the filters
clogged inlet line Clean the inlet line
clogged tank breather Clean or replace the breather
fluid is too cold Heat the fluid
main drive motor is not operating Repair or replace the main drive motor
pump drive coupling failed Repair or replace the coupling
relief or unloading valve set too low Adjust the valve to the correct setting
pump is damaged Repair or replace the pump
Excessive hydraulic
pump noise
pump is cavitating Refer to System fails to build pressure
air in the fluid
Leak in the inlet line to the pump.
Tighten the fittings
Faulty pump shaft seal. Replace the seal
Excessive system heat
air in the fluid
contaminated fluid Change filters and replace the fluid
Drill pipe racks operate
too slow or too fast
the needle valve is out of adjust-
ment or faulty
Adjust the needle valve for correct operating
speed. If unable to adjust, replace the nee-
dle valve
Leveling jacks and winch
move slowly
ment or faulty
dle valve
The unloading relief valve is faulty
Adjust the unloading relief valve to operate
at 1100 psig (75.9 bar). If unable to adjust,
repair or replace valve
Breakout Wrench moves
too fast or too slow
faulty flow control valves Adjust or replace the flow control valves
Table 3-4: Auxiliary Hydraulic System Troubleshooting
BD120149 Mechanical Systems Manual Main Hydraulic System
Sec04MainHyd.fm -4.1- Section 4, Version 00 - 03/06
Section 4
Main Hydraulic System
4.1 General
The Main Hydraulic System provides fluid power to operate the propel function of the drill. Two main pumps supply
hydraulic flow, one to each of the side frames. This section describes the theory of operation of the main hydraulic
system and provides information for adjustment, removal, and installation of the major components.
The system consists of two independent closed loop hydrostatic drives, which provide the torque to operate the
propel transmissions. The major components include: a hydraulic tank, two identical variable-displacement hydrau-
lic pumps, two variable-displacement hydraulic motors, system control valves, and hydraulic oil filters. The propel
motors and brakes are an integral part of the propel transmission.
Each of the propel circuits is an independent closed loop system. The system is pressurized by a small-volume
charge pump, which is tandem mounted on the main piston pump drive shaft. In addition to maintaining the basic
loop system pressure, the charging pump provides pressure for the pump servo controls, motor displacement con-
trol, and the brake release circuits.
When the drill is operating in propel mode, and the operator moves the joystick controller away from the NEUTRAL
position, the electro-hydraulic servo control on the pump is energized. Energizing the servo control causes the
pump pistons to begin to stroke. The direction and amount of movement of the joystick away from NEUTRAL posi-
tion determines the direction of oil flow from the pump main ports (through A or B) and establishes the volumet-
ric displacement of the pump pistons. When the displacement of the pistons is increased, the flow rate of oil
discharging from the pump into the motor circuit increases, causing the propel motor to turn faster.
Main Hydraulic System BD120149 Mechanical Systems Manual
Section 4, Version 00 - 03/06 -4.2- Sec04MainHyd.fm
The block diagram at Figure 4-1 demonstrates system operation.
The oil for the main hydraulic system comes from the hydraulic tank. The main hydraulic system and the auxiliary
hydraulic system share a common oil tank. The tank is located in the lubrication room on the forward right portion
of the machinery deck.
For a detailed description of the hydraulic tank and its components, refer to Subtopic 3.2.1.
Figure 4-1: Main Hydraulic System Block Diagram
R57531-2
4.2.2 Main Hydraulic Pumps R51924D1
4.2.2.1 Description
The two main hydraulic pumps, mounted on the forward side of the pump drive transmission (PDT), are identical.
They are axial piston pumps with a rotary servo, trimmer, adjustable volume stops, and a neutral bypass with
detent (not spring or pressure centered). The pumps are configured to supply hydraulic fluid to the hydraulic motors
and brakes for the propel system. The pumps also provide braking for the propel motors when the controls are
placed in neutral position. Servo pressure from the right pump is used to release the hoist brake and to adjust the
displacement of the propel motors.The pumps contain: an axial piston crossover-center variable pump which con-
trols the speed and direction of the motor actuator; the auxiliary gerotor pump which supplies servo pressure (for
controlling the displacement of the variable pump) and replenishment pressure; the servo pressure relief valve; the
replenishment pressure relief valve; and the replenishment check valves for legs A & B.
When the main motor starts, the PDT causes the pump to turn; however, during normal start-up, the pump is in the
neutral position and oil pressure does not develop in the main hydraulic circuit.
When the operator places the drill in PROPEL mode and moves the joystick, a signal is provided to the electrohy-
draulic stroker. The stroker (or servo) causes the swash plate within the motor to rotate. The movement of the
swash plate causes oil to move through the main hydraulic circuit. The movement of the servo determines the rate
of oil flow through the circuit as well as the direction.
Figure 4-2: Main Pump
Figure 4-3: Main Hydraulic Pump
R57531-3a
4.2.3 Propel Motors 41U100D2
Motors receive oil flow from the main pump. The variable displacement motors can be controlled for either high
speed and low torque, or low speed and high torque, through the operators speed control.
The propel motors are integral components with the propel transmissions; brakes are internal to the component.
Brakes are hydraulically released and spring set. In order for the brakes to release, the switch on the operators
console must be in the RELEASE position, and the joystick must be moved off neutral. This permits oil to flow from
the pilot control valve bank to cause the brakes to release.
Figure 4-4: Propel Motor
Figure 4-5: Propel Motor Schematic
R57531-3b
4.2.4 Pilot Control Valve Bank 36U435D4
The pilot control valve bank is in the lubrication room, between the hydraulic tank and the low pressure valve stand.
It contains three valves: the speed control valve, the left brake valve and the right brake valve.
4.2.4.1 Speed Valve
In its de-energized state, the speed valve directs oil from the pumps H port to a blocked port on the pilot control
valve bank. The motor then receives no pressure through its X port, and the motor is fully stroked (low speed, high
torque).
When the operator places the speed switch in the high speed position, this causes the propel speed solenoid to
energize. When the valve spool shifts, oil from port B of the speed valve enters the motor through port X and
destrokes the motors swash plate, providing higher speed and lower torque.
Figure 4-6: Pilot Control Valve Bank
LEGEND
01. Propel Speed Valve
02. Left Brake Valve
03. Right Brake Valve
4.2.4.2 Brake Valve
WARNING
!
Uncontrolled drill movement can cause severe personal injury or death. Always confirm
that the tow bar is attached to both the drill and the tow vehicle before using the hand
pump to release the propel brakes.
The brake valve solenoids energize when the operator presses the brake release switch on the operators console.
Oil is not provided to release the brakes, however, until the joystick is moved, which causes the pumps internal
porting to open and allows oil to flow through the Z port to the brake valve.
4.2.4.3 Towing System
CAUTION
Excessive speed can cause substantial damage to propel system components. Never
tow the drill faster than the drill can propel itself.
When the drills motor is not running, the pumps that supply the oil to release the propel brakes cannot perform that
function. When it is necessary to tow the drill, the propel brakes must be released by hydraulic pressure provided
by a hand pump located near the front right corner of the drill. The hand pump also includes an accumulator and a
pressure gauge to assist with maintaining pressure to the brake during long moves. Spring-loaded breakaway
valves are provided to allow the brakes to set if the tow vehicle should separate from the drill.
4.3 Main Hydraulic System Maintenance
4.3.1.1 Description
The auxiliary hydraulic system and the main hydraulic system share a common oil tank. The tank is located in the
lubrication room on the forward right portion of the machinery deck. For detailed description about maintaining the
hydraulic tank and its components, refer to Subtopic 3.2.1.
Figure 4-8:
01
03
04
06
09
08
BD0361a01
02
05
07
10
11
LEGEND
01. Suction Filters
03. Hydraulic Tank
05. Breather
06. Return Filters
07. OIl Level Gauge Placard
08. Oil Level Sight Glass
4.3.2 Main Hydraulic Pumps R51924D1
4.3.2.1 Pump Start-up, Adjustment and Functional Testing
This procedure is to be used for start-up and functional testing of the main hydraulic pumps and propel system after
installation on the drill. The procedure is suitable for periodic testing of the pumps to confirm normal operation. On-
the-drill testing of these pumps is limited to a few basic pressure measurements, observations and adjustments.
However, more thorough testing can be done only by removing the pumps from the system, installing them on a
hydraulic test stand, and implementing complete pressure, flow, and controls functional tests to rated design
capacity.
Figure 4-9: Main Pump
Refer to Figure 4-10 and proceed with pump start-up and functional checkout as follows:
Step 1: Fill the hydraulic oil tank to the correct level with oil as specified in Topic 16.5.
Step 2: Confirm that all of the main hydraulic system suction and pressure filters are clean.
Step 3: Confirm that there is hydraulic oil present at drain port D. If oil is present, the pumps are primed. Add if
necessary.
Step 4: Back out the compensator adjustment on the pump valve block assembly (behind the acorn nut) until
there is no spring resistance.
CAUTION
Do not over-tighten the compensator adjustment screw assembly when making adjust-
ments, or damage to the screw may result.
Figure 4-10: Pump Start-up and Functional Check
05
01
BD0051b03
06
07
02
03
08
04
LEGEND
01. Valve Block
02. Port V
03. Port D
04. Indicator
05. Port VA (Port VB opposite)
06. Port A
07. Port B
08. Compensator Adjustment
Step 5: Disconnect the electrical connectors from the right and left propel brake solenoid valves on the Propel
Control Valve Bank in the lubrication room. Refer to Figure 4-11.
NOTICE
With the electrical connectors disconnected from the brake valves, the propel brakes should not
be able to release and the propel drive should not be able to rotate.
Step 6: Install a 0 - 1500 psi (103.5 bar) gauge onto the pressure taps, one for each charge filter.
Step 7: Install a 5000 psi (345 bar) (minimum) pressure gauge on the A port of each pump.
CAUTION
Operating the pump with low charge pressure could cause substantial damage to the
pump. If the gauge does not register specified pressure within a few seconds, shut down
the drill and determine the cause. Do not operate the drill if charge pressure is low.
BD0577a01
02
03
05
01
04
LEGEND
01. Electrical Connectors
02. Propel Brake Valves
04. Spare
05. Pilot Valves (towing system)
Step 8: Start the main drive motor.
Step 9: Confirm the charge pressure reading on the 0 - 1500 psi gauges registers 250 - 350 psi (17.5 - 24 bar).
Step 10: Raise and level the drill on the jacks. The drill must be raised until the crawler belts are completely clear
of the ground.
Step 11: Allow the hydraulic systems to operate until normal operating temperature is reached (usually about 15
minutes).
Step 12: Set the propel mode normal/maintenance switch to MAINTENANCE position.
WARNING
!
Unexpected machine movement or operation can cause serious injury or death. When
necessary to operate the drill to make an adjustment or perform a check on the propel
drive system, position a person to watch the crawler mechanism and to keep personnel
at a safe distance from the drill. Always use the cab horn (in accordance with local pol-
icy) to signal that the drill is about to move.
Step 13: Set the mode select propel/hoist/drill switch to PROPEL position.
Step 14: Assign someone to watch the crawler mechanism for motion, and to keep others away from the drill dur-
ing the propel drive adjustment and testing.
Step 15: Have the operator move the propel joystick to the FORWARD position, and turn the compensator adjust-
ment screw on the pump inward until the pump port A pressure reads 4200 psi (283 bar).
NOTICE
The indicator should remain on, or very near, the zero position.
Step 16: Confirm that there is no rotation of the crawler tumblers.
Step 17: Move the gauges to the B port of each pump.
Step 18: Move the propel joystick to the REVERSE position. Pressure in the pump port B circuit should now be
4200 psi (283 bar).
NOTICE
The indicator should remain on, or very near, the zero position.
Step 19: Confirm that there is no rotation of the crawler tumblers.
Step 20: Return the propel joystick to NEUTRAL position, and confirm that the pressures at ports A and B are
equal. If they are not, adjust the NULL of the pump as follows:
a. Turn the spring stop adjustment in or out until it just contacts the spring and there is no free play.
Lock in place. Then proceed with step 2 below.
b. Turn the trimmer screw to place the input shaft in the zero stroke position. Check for positive center-
ing. Lock in place. For cross-center pumps, set maximum volume stops so that the servo shaft link
touches stop pins when the handle is stroked each side of center. For one side of center pumps, set
maximum stop so that the servo shaft link touches the stop pin. Set the minimum stop to prevent
crossing over center. Lock the stops in place.
c. Apply signal current to one proportional valve. Adjust current from minimum to maximum.
Note the pressure and current values at which the pump just starts to stroke and at which
the pump reaches full stroke. These must be within the values shown in Table 4-1.
d. If control pressure is off the same amount at the start and end of the stroke, the control may be dis-
assembled and the spring adjusted. One flat (1/6 of a turn) of adjustment will change the pressure
by 4.6 psi (0.31 bar).
e. If the change in pressure from start to end of stroke is incorrect, the spring is incorrect and must be
replaced.
f. If pressures are correct but current is incorrect, then either the coil is incorrect or the proportional
valve is bad.
g. With minimum signal, the pump must return to zero stroke within 200 psi (13.8 bar) maximum.
h. For cross-center pumps, repeat the test on the opposite side of center.
i. Increase and decrease current between minimum and maximum several times. Pump stroke should
follow control pressure smoothly and proportionally. Full stroke to zero or zero to full stroke should
be achieved in no more than two seconds. Adjust stroke from zero stroke up to approximately 50%
stroke and then adjust down from full stroke to the same current value. The flow at the two settings
must not vary more than 25%.
Step 21: Check the propel brake set/release switch to be sure it is in the SET position.
Step 22: Connect the electrical connectors to the right and left brake solenoids Propel Control Valve Bank in the
lubrication room.
Step 23: Move the propel brake set/release switch to RELEASE position.
Step 24: Check the hydraulic pressure on the gauges at pressure test points G1 and G2 on the Propel Control
Valve Bank in the lubrication room.
COIL CONT PR
MIN DISPL
MA MIN
DISPL
CONT. PR
MAX. DISPL
MA MAX
DISPL
12V 75 15 psi 360 60 250 25 psi 650 110
5.17 1 bar 17.2 1.7 bar
24V 75 15 psi 180 30 250 25 psi 325 55
5.17 1 bar 17.2 1.7 ba
Table 4-1: Pump Adjustment Data
NOTICE
Brake operating pressure must be at least 250 psi (18 bar) at pressure test points G1 and G2.
Step 25: Move the propel speed hi/low switch to the LOW position.
WARNING
!
Unintentional machine movement or operation can cause serious injury or death. When
necessary to operate the drill to make an adjustment or perform a check on the propel
drive system, position a person to watch the crawler mechanism and to keep personnel
at a safe distance from the drill.
Step 26: Be sure that someone is still positioned to watch the crawler mechanism for motion, and to keep others
away from the drill during the propel drive adjustment and testing.
Step 27: Move the propel joystick to the full FORWARD position and check the rotational speed and direction of
the left and right crawler drive tumblers. Both should rotate at 4 rpm in the forward direction.
Step 28: Return the propel joystick to the NEUTRAL position. There should be no movement of the crawler drives.
Step 29: Move the propel joystick to the REVERSE position and check the rotational speed and direction of the left
and right crawler drive tumblers. Both should rotate at 4 rpm in the reverse direction.
Step 31: Move the propel speed hi/low switch to the HIGH position.
Step 32: Move the propel joystick to the full FORWARD position and check the rotational speed and direction of
the left and right crawler drive tumblers. Both should rotate at 6.6 rpm in the forward direction.
Step 34: Move the propel joystick to the REVERSE position and check the rotational speed and direction of the left
and right crawler drive tumblers. Both should rotate at 6.6 rpm in the reverse direction.
Step 36: Move the propel brake set/release switch to the SET position.
Step 37: Lower the drill off the jacks, and raise the jacks to fully stored position.
Step 38: Check the pump compensator adjustment to be certain the locknut is tight and the acorn nut is securely in
place on the adjustment screw.
NOTICE
Over-tightening of the locknut can damage the compensator adjustment.
Step 39: Remove the test gauges from the pressure tap fittings, and check the entire system for leaks.
Technician Tip
When the main pumps and the propel motors are set up and functioning correctly, the appropri-
ate speeds will be achieved in the propel system. If the crawlers still do not track straight after
the pumps have been adjusted (and flow and pressure confirmed), refer to motor adjustment
procedure in Subtopic 9.3.1.4.
4.3.3 Removal
To remove either of the hydrostatic pumps from the pump drive transmission, proceed as follows:
WARNING
!
work.
ities.
Step 2: Clean all dirt away from the pump, hose, and electrical fittings.
WARNING
!
Step 3: Check to be certain that the hydraulic pressure is completely vented from the high-pressure and control
pressure circuits.
Step 4: Close the hydraulic tank Handwell valves.
Step 5: Tag and remove the hydraulic hoses from the pump. Cap or plug all hose fittings and pump ports.
Step 6: Tag and disconnect the electrical control wiring from the electrohydraulic stroker control on the pump.
Step 7: Attach a suitable hoist to the pump to prevent an overhung load on the shaft when the mounting bolts are
loosened. Protect the external tubing on the pump from being bent or crushed.
Step 8: Mark the pump, if more than one is being removed, to assure that it is remounted at the same shaft posi-
tion on the transmission.
Step 9: Remove the capscrews and lockwashers from the mounting flange of the pump, and pull the pump away
from the pump drive transmission. Use care to prevent binding of the shaft or damage to the spline teeth
when withdrawing the pump from its mounting.
Step 10: Inspect the pump and pump drive transmission splines for damage.
4.3.4 Installation
To install the pump on the pump drive transmission, proceed as follows:
CAUTION
!
Disassembling heavy components with inadequate hoisting apparatus can injure per-
sonnel and/or damage equipment. Use suitable rigging and hoisting equipment to stabi-
lize and lift heavy objects.
Step 1: Using a suitable hoist, lift the pump into position at the rear of the pump drive transmission. Be careful to
avoid bending or pinching the external tubing on the pump with the sling.
Step 2: Grease the female spline with lithium grease before inserting the splined pump shaft.
Step 3: Insert the shaft of the pump into the bore of the pump drive transmission. Be careful to avoid side loading
and/or binding of the shaft as the pump is moved into position against the transmission.
Step 4: Coat the threads of two
5
/
8
" capscrews with sealing grease (P&H Spec 499). Insert capscrews with lock-
washers to fasten the pump to the pump drive transmission.
Step 5: Fill the pump case with clean oil, then install the hydraulic hose assemblies in accordance with the identi-
fication tags placed during pump removal.
Step 6: Install the electrical wiring to the electrohydraulic stroker control in accordance with the identification tags
placed during pump removal.
Step 7: Open the Handwell valve.
Step 8: Install a 0 - 1500 psi (103.5 bar) gauge into the charge pump circuit (atop the charge filter).
Step 9: Start the pump and monitor charge pressure. Refer to the start-up procedure in steps 6 through 9 in Sub-
topic 4.3.2.1.
4.3.5 Pilot Control Valve Bank (Valve Bank 4) 36U445D4
The Pilot Control Valve Bank, also known as Valve Bank 4, contains three identical solenoid valves: Right Propel
Brake, Left Propel Brake, and Propel Speed. It also includes two pilot valves for the tow circuit. Each valve is a two-
position, four-way valve with solenoid and manual actuation with a spring return. Field repair of the valves is limited
to the replacement of the solenoid coil and O-rings.
BD0577a01
02
03
05
01
04
LEGEND
01. Electrical Connectors
02. Propel Brake Valves
04. Spare
05. Pilot Valves (towing system)
4.3.6 Charge Filter 46Z547
The charge filter assembly is mounted in-line between ports G and H on each of the two main hydraulic pumps,
mounted on a bracket over the PDT. The function of these filters is to ensure the cleanliness of the pressurized oil
stream from the control pressure (charge pressure) section of the main hydraulic pump, and to prevent fouling of
the main pump control valves. These by-pass type filters are rated at 30 gpm (113.6 lpm) maximum flow, and 2500
psi (172.5 bars). The by-pass is set to open when flow pressure differential across the filter exceeds 30 psid (2.1
bars differential). A single 3-micron element is used for oil filtration. The filter assembly includes a by-pass indicator
that sends a signal to the PLC, which will initiate a fault indicator on the GUI. It is not necessary to remove the filter
assembly from the line to replace the element or seals.
Inspect the filter units during PM for visible damage, leaking seals, or leaking fittings. If the GUI indicates that the
filter is bypassing, the element should be replaced. Replace the charge filter elements as follows:
WARNING
!
tag the operator controls to prevent inadvertent machine startup during maintenance.
A. Lock out and tag the operator controls to prevent inadvertent machine startup during maintenance activities.
WARNING
!
Figure 4-13: Charge Filters
B. Be sure that no pressure exists in any of the main hydraulic system circuits.
C. Remove the bleed plug located on bottom of the filter. Drain oil from the filter into a pail before removing the
filter element.
NOTICE
Clean dirt from the filter assembly before loosening the bleed plug and filter cap.
D. Loosen and remove the cap from the filter body.
E. Remove the old filter element and examine its condition for clues to potential problems. Discard the old filter
element only after it has been examined.
F. Inspect the bottom of the filter bowl for debris. Look here as well for clues to potential problems. Clean the
bowl if necessary.
G. Check the cap seal O-ring and back-up ring for nicks or damage. Replace these components as necessary.
H. install a new filter element into the body of the filter. Be sure the element is correctly located on the bottom
seat.
I. Apply a coating of hydraulic oil to the O-ring and back-up ring, and install with the filter cap. Torque the cap
securely.
J. Install the bleed plug securely in the filter.
Figure 4-14: Charge Filter Ports
01
02
03
BD0579a01
LEGEND
01. Pressure Test Port
02. Filter Cap
03. Bleed Port
K. Start the hydraulic pumps, and bleed the trapped air from the main hydraulic system. This can be done
using the Microbore hose in the hydraulic test kit. Attach to the pressure test port on the top of the charge fil-
ter and allow the discharge to shoot into a pail.
4.4 . Troubleshooting
Component problems and circuit problems are often interrelated. An incorrect 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.
Noisy Pump Air in fluid Repair leak in suction line
Repair leak at shaft seal
Fill tank to correct fluid level
Eliminate fluid turbulence in
tank
Cavitation in pump or motor
rotating group
Increase fluid temperature,
but do not exceed 180F
(82C)
Decrease fluid viscosity
Clean suction strainer
Misaligned shaft Check pump shaft for mis-
alignment
Check and relieve any axial
interference
Mechanical fault in pump Return the pump to P&H
MinePro Services for repair,
or replace the pump
Table 4-2: Main Hydraulic System Troubleshooting
High wear in pump or motor Contaminant in fluid Replace filters
Replace dirty hydraulic fluid
Keep all tank openings cov-
ered
Check tank breather
Clean fittings before replace-
ment
Incorrect fluid Use correct fluid for operat-
ing temperature
Replace fluid broken down
due to time/temperature/
shearing effects
Incorrect repair Return the pump to P&H
MinePro Services for repair,
or replace the pump.
Water in fluid Eliminate source of conden-
sation in tank
Replace faulty breather
Eliminate faulty clean-up
practices
Check for water in make-up
fluid
Erosion on barrel port and
port plate
Air in fluid Repair leak in suction line
Repair leak at shaft seal
Fill tank to correct fluid level
Eliminate fluid turbulence in
tank
Cavitation Increase fluid temperature,
but do not exceed 180F
(82C)
Decrease fluid viscosity
Clean suction strainer
Pressure shocks Clogged load Look for mechanical prob-
lems
Worn relief valve Repair as required
Worn compensator Repair as required
Slow response in check
valves
Replace valve
Servo pressure too low to
maintain firm control
Increase pressure and check
pressure drop through the
servo filter
Barrel low-off Re-check the pump hold-
down, rotating group and
drain pressure
Heating of Fluid Excessive pump or motor
leakage
Re-check case drain flow and
repair as required
Replace fluid that is too thin
Inspect for incorrect port
timing
Relief valve Adjust pressure that is set
too low
Eliminate instability caused
by back pressure, worn parts
Compensator Adjust pressure that is set
too high (compared to relief)
Replace worn parts
Heat exchanger Clean cooling fan
Remove mud or scale depos-
its from the heat exchanger
Eliminate cause of intermit-
tent fluid flow
Tank Maintain correct fluid level
BD120149 Mechanical Systems Manual Power Unit
Sec05PowerUnit.fm -5.1- Section 5, Version 00 - 03/06
Section 5
Power Unit
5.1 General
The power unit provides a single source of torque with which to drive the main air compressor and the three pumps
for the auxiliary and main hydraulic systems. Major components of the power unit include the electric main drive
motor, the hydraulic pump transmission, and the main air compressor. These are mounted on a rigid base as a
unitized assembly. The structural section of the base is sized to retain alignment of all components, regardless of
the mounting support. Refer to Figure 5-1.
5.1.1 Power Unit Assembly Alignment
The power unit components -- that is, the main AC drive motor, the main air compressor and the pump drive trans-
mission -- are mounted to a steel skid. This arrangement is intended to reduce the flexing between the motor and
Figure 5-1: Power Unit
06
05
07
04 03 01
09
10
11
02
BD0398b01
08
LEGEND
01. Charge Filter
02. Auxiliary Pump
03. Main Drive Motor
04. Compressor Air Cleaner
05. Main Air Compressor Inlet Valve
06. Main Air Compressor
07. Compressor Coupling
08. Base
09. PDT Coupling
10. Pump Drive Transmission (PDT)
11. Main Hydraulic Pump
Power Unit BD120149 Mechanical Systems Manual
Section 5, Version 00 - 03/06 -5.2- Sec05PowerUnit.fm
compressor and thus preventing premature failure of the coupling, and secondly to be used as a tool to keep re-
alignment adjustments to a minimum in field installations.
If any of these components is replaced in the field, first check to ensure that:
Shaft is concentric to the motor end cover pilot
Both pilots and faces of adapter mounting are concentric and parallel
Compressor input shaft is concentric to the bell housing pilot
The following steps needs to be carried out for either motor or compressor field installation:
1. Make sure the machine is level (use a spirit level).
2. Make sure that all mating surfaces and foot mounting pads are clean.
3. Remove adapter from motor or compressor.
4. Fit motor or compressor to respective mounting pads on the skid. Tighten mounting bolts. (Do not install cou-
pling at this stage.)
5. Use a magnetic base dial indicator to determine height difference between compressor and motor shaft. Add
shims to foot mountings on the lowest component. Max .015" (.381mm) TIR. If motor is lower than compressor,
motor base bolts must be loosened and shimmed accordingly. (If motor is lower, pump drive transmission will
have to be re-aligned.)
6. Loosen compressor foot mounting bolts and remove compressor.
7. Slide coupling hubs onto their respective shafts. Do not tighten.
8. Re-install adapter to motor. Install and tighten bolts. Torque to 266 ft-lbs (360 Nm) dry. Remove inspection cov-
ers.
9. Re-install compressor using shims as established in step 5. Install base mounting bolts, do not tighten.
10. Fasten adapter to compressor/motor foot mounting bolts and torque compressor bolt's 266ft-lbs (360Nm) dry,
motor bolt's 650 ft-lbs. (880 Nm) dry.
11. Remove adapter inspection cover to gain access to coupling.
12. Slide coupling hubs together. Inside gap should be a nominal 1/8" (3.175mm). Install flexible inserts into either
coupling half. Slide flexible insert retainer cover onto hub and fasten.
13. Insure that equal length of shaft extends into each hub, secure both hubs with set screws provided and torque
to 110 in-lbs. (12Nm)
14. Insert dowels on either end of mounting adapter.
NOTICE
If new or different compressor/motor is installed, new holes are to be drilled and reamed for
dowels in new locations. Do not use existing holes. Holes are to be drilled 29/64" (11.508mm)
then reamed with number 8 taper pin reamer.
15. Dowel both compressor and motor feet to base. If either the compressor or the motor is a new or service
exchange unit, new dowel holes are to be drilled in different locations. Holes are to be drilled .500" (12.7mm)
and reamed with a number 9 tapered pin reamer.
If pump drive transmission coupling has to be re-aligned then the following steps should be followed.
16. Loosen bolts on the PDT mounting plate. Do not remove.
17. Remove dowel pins from mount to skid and dowel pins from mount to PDT. Remove coupling guard.
18. Check and align coupling. Max TIR .008" (2.03mm)
19. Fasten bolts mounted to PDT and mount to skid. Torque to 266 ft-lbs (360Nm).
20. Confirm alignment within .008" (2.03mm). If alignment is within tolerance, lubricate the spacer with grease and
install the spacer between the coupling halves.
21. Drill one pilot hole, 15/32" (11.907mm) diameter, through the mounting plate and into PDT. Do not drill deeper
than 1" (25mm) into PDT. Drill one hole, 15/32" (11.907mm) in diameter, through the mounting plate into the
skid. Ream hole to .4996" (12.67mm) and install dowels. Do not use old holes.
22. 22. Install coupling guards.
5.2.1 Main Drive Motor 5100A1368F12
The drill is powered by a double-shafted, high-voltage AC electric motor. The motor is sized, at 700 HP (at 60 Hz),
to provide the total torque needed to operate the main air compressor and the pumps for both the main and auxil-
iary hydraulic systems.
5.2.2 Air Compressor 51U165D4
The air compressor is coupled to the motor drive shaft at one end of the motor. Compression of the air is accom-
plished by the main and secondary rotors synchronously meshing in a one-piece cylinder. The main rotor has four
helical lobes spaced 90 apart. The secondary rotor has five matching helical grooves 72 apart to allow meshing
with the main rotor lobes.
NOTICE
The Air Compressor is covered in Section 6, Bailing Air System.
5.2.3 Hydraulic Pump Drive Transmission (PDT) GH5829479
The hydraulic pump drive transmission is coupled to the motor shaft at the other end of the motor. The power unit
is mounted to the machinery house deck with four isolator mounts to minimize the effects of machinery vibration.
All four hydraulic pumps are flange-mounted to the output shafts of the pump drive transmission.
5.3 Main Hydraulic System Components
5.3.1 Main Drive Motor
5.3.1.1 General
The power unit is driven by a double-shafted, high-voltage AC electric motor. The motor operates the main air com-
pressor and the pumps for the main and auxiliary hydraulic systems. The motor is direct coupled to the compressor
and pump drive transmission with flexible couplings.
5.3.1.2 Removal
Remove the main drive motor from the power unit base as follows:
WARNING
!
Hazardous voltage can cause burns, injury, or death. Disconnect, lock open, and tag the
power source which feeds the main drive motor to prevent power from being applied
while inspection and repairs are being performed. Before beginning repairs, try the oper-
ational controls to verify that the intended power source is disconnected.
1. Disconnect, lock out, and tag the power source to the main drive motor to prevent power from being applied
while service being performed.
2. Clean all dirt from the pumps, hoses, and electrical fittings.
3. Tag and disconnect the electrical wiring and conduit from the main drive motor.
4. Tag and disconnect the electrical control wiring from the electrohydraulic stroker controls on the main hydraulic
pumps.
5. Refer to Figure 5-2 and remove the capscrews, lockwashers, and the two cover plates from the compressor-
motor mount adapter.
Figure 5-2: Power Unit, Exploded View
:
6. Remove the nuts, lockwashers, and capscrews from the motor and adapter flanges.
7. Remove the four dowel pins, nuts, lockwashers, and capscrews from the motor feet.
8. Open roof (if mast is vertical) to lift motor out.
CAUTION
!
9. Attach a suitable lifting device to the motor, and lift enough of the motor weight to enable sliding it away from
the compressor-motor adapter. Do not lift the motor off the base until the flexible coupling halves are sepa-
rated. Retain the coupling insert with to the compressor half of the coupling.
10. Lift the motor away from the power unit base and set it on wooden blocking to protect the mounting foot sur-
faces. Keep the motor shim set for re-use.
11. Clean and inspect the motor and power unit base components in accordance with the cleaning and inspection
procedures described in Appendix A of this manual.
12. Install the main drive motor as follows (refer to Figure 5-2):
A. Position the motor shim set on the power unit base.
Figure 5-3: Legend for Figure 5-2
LEGEND
01. Nut
02. Band
03. Capscrew
04. Air Cleaner
05. Service Indicator
06. Bracket
07. Hose Clamp
08. Hose
O9. tube
10. Capscrew
11. Lockwasher
12. Inlet Manifold
13. Gasket
14. Inlet Manifold
15. Capscrew
16. Lockwasher
17. Oil Filter
18. Filter Gasket
19. Nut
20. Capscrew
21. Shim Set
22. Filter
23. Adapter
24.tapered Pin
25. Cover
26. Lockwasher
27. Capscrew
28. Flexible Coupling
29. Key
31. Key
32. Guard
33. Capscrew
34. Capscrew
35. Dowel Pin
36. Base
37. Capscrew
38. Mounting Pad
39. Mounting Pad
40. Mounting Pad
41. Mounting Pad
42. Shim
43. Shim
44. Capscrew
45. Dowel Pin
46. Mount
47. Dowel Pin
48. Capscrew
49. Lockwasher
50. Nut
51. Lockwasher
52. Pipe Nipple
53. Drain Cock
54. Hex Nipple
55. Elbow
56. Hydraulic Pump
57. Capscrew
58. Pump Drive Trans.
59. Hydraulic Pump
60. Lockwasher
61. Capscrew
62. Capscrew
63. Cover Gasket
64. Cover
65. Electrical Indicator
CAUTION
!
Assembling heavy components with inadequate hoisting apparatus can injure personnel
and/or damage equipment. Use suitable rigging and hoisting equipment to stabilize and
lift heavy objects.
B. Attach a suitable lifting device to the motor, and position the motor on top of the shims. Continue to support
most of the motor weight with the lifting device until the motor is in final position.
C. Carefully slide the motor into position against the compressor-motor mounting adapter. Rotate the motor
shaft as necessary so the coupling halves mate correctly. Be certain that the flexible insert is installed in the
coupling. If the compressor has not been moved, the motor and compressor shafts should be correctly
aligned by the mounting adapter.
D. Position the shims as necessary under the motor feet, then install the dowel pins, capscrews, lockwashers,
and nuts. Torque the nuts securely.
E. Install the covers on the compressor-motor adapter with capscrews and lockwashers.
F. Install the hydraulic pump drive transmission on the gear box mounts, as described under Subtopic 5.3.2.6.
G. Install the electrical wiring to the main drive motor.
H. Confirm alignment in accordance with Subtopic 5.1.1.
5.3.2 Hydraulic Pump Drive Transmission GH5429879
5.3.2.1 Description
The pump drive transmission (PDT) is a multi-shafted gear reducer that distributes torque from the electric main
drive motor to the three attached hydraulic pumps. The output shafts to the pumps all rotate at the same speed.
The input shaft of the hydraulic pump drive is connected to the main drive motor shaft by means of a flexible cou-
pling. The hydraulic pumps are flange-mounted to the hydraulic pump drive transmission housing. A single pump
on the forward side of the pump drive provides flow and pressure to the auxiliary hydraulic system. The two hydro-
static pumps for the main hydraulic system are located on the rear side of the pump drive.
The pump drive transmission has a ventilated gear case. The gears are lubricated by a splash-type oil bath.
5.3.2.2 Removal
Removal. Remove the PDT as follows:
WARNING
!
work.
1. Lock out and tag the operator controls to prevent operation of the machine during maintenance work.
2. Open the drain cock located on the bottom front side of the pump drive housing and drain the lubricating oil into
a suitable container. The housing contains approximately 2 gallons (7.6 liters) of oil.
3. Remove the guard which encloses the flexible coupling between the main drive motor and the pump drive
transmission.
4. Disconnect the pump drive from the main drive motor at the flexible coupling by removing the capscrews,
washers, and locknuts which secure the pump drive to the coupling flange extension. Do not remove the
attaching capscrews, washers, or nuts from the motor end of the flexible coupling at this time. The hydraulic
pump drive can be removed from the power unit assembly with all pumps installed. The following procedure,
however, assumes that all of the hydraulic pumps have been removed from the pump drive as described under
the topics, Auxiliary Hydraulic Pump, Removal, and Main Hydraulic Pump.
CAUTION
!
5. Attach a suitable lifting device to stabilize the pump drive transmission.
6. Remove the pipe nipple, oil drain cock, hex nipple, and pipe elbow from beneath the pump drive housing.
7. Remove the four locating dowel pins from mount and the pump drive housing. Two dowel pins are on each side
of the pump drive housing.
8. Remove the four capscrews and lockwashers which secure the pump drive housing to mount.
9. Open roof (mast vertical only) to access pump drive with a crane.
10. Remove the pump drive from the power unit assembly.
5.3.2.3 Disassembly
Disassemble the hydraulic pump drive transmission as follows:
1. Remove the coupling hub and sleeve from the pump drive input shaft as follows (refer to Figure 5-4):
NOTICE
The following equipment is required: A suitable hydraulic puller with an adjusting assembly and
a crosshead leg assembly having SAE Grade 8 studs, two rosebud torches, heat resistant
gloves and a fire extinguisher.
A. Thoroughly clean the coupling hub to be removed to avoid combustion when heat is applied.
B. Place the pump drive housing on a support with the input shaft facing up.
Figure 5-4: Pump Drive Flexible Coupling
BD0371a01
01
02
03
04
05
06
07
08
09
010
LEGEND
01. Capscrew
02. Sleeve
03. Hub
04. Gasket
05. Coupling Extension
06. Gasket
07. Sleeve
08. Hub
09. Locknut
10. Washer
C. Drill and tap the face of the coupling hub for the appropriate puller leg thread size, as shown in Figure 5-5.
D. Assemble the puller as illustrated in Figure 5-5. Check to be sure the puller has enough stroke to pull the
hub off the input shaft.
SAFETY FIRST
Surfaces will be extremely hot. Be certain to wear all appropriate personal protective equipment
(PPE).
E. Heat the hub evenly with a rosebud torch to approximately 300 - 500F (150-260C) while applying pressure
with the puller. The temperature of the hub may be measured with a heat sensitive crayon.
CAUTION
Excessive heat can damage hub teeth. Avoid placing the heat directly on the hub teeth.
Apply the heat as shown in Figure 5-5.
F. Apply puller pressure until the hub clears the shaft.
2. Refer to Figure 4-5 and disassemble the pump drive housing as follows:
A. Thoroughly clean the split housing exterior using a suitable solvent. Make sure the disassembly area is
clean. Place the assembled pump drive so the oil drain side of the housing is facing down on the work sup-
port, and the input shaft facing up.
B. Remove the dowel pins which align the two housing halves.
Figure 5-5: Coupling Hub Removal
01
02
03
04
06
05
07
08
BD0372b01
LEGEND
01. Gauge
02. Adjusting Screw
03. Plate
04. Hydraulic Cylinder
05. Bar Stock
06. Shaft
07. Coupling Hub
08. Torch
C. Separate the housing halves using bolts as jacking screws in the tapped holes provided in the housing
flanges.
CAUTION
!
sonnel and/or damage equipment. Use suitable hoisting equipment to stabilize and lift
heavy objects.
D. Using a suitable lifting device, remove the upper housing half. Bearings will remain on the input shaft and
pump drive (output) shafts in the lower housing half. The bearing/seal carrier will remain with the upper
housing half along with seal, O-ring and snap ring.
E. Note the orientation of the seal lip and bearing seal carrier to ensure proper reassembly. Then, remove all
necessary parts from the upper housing. It is normally unnecessary to remove the pump adapters (14) from
the housings in order to disassemble the pump drive transmission.
NOTICE
The disassembly method for each pump drive (output) shaft is identical. The following proce-
dure will apply equally to each.
F. Remove snap ring and the splined adapter from each end of output shaft.
G. Press against the lower end of the output shaft and remove the shaft with bearings in place on the shaft.
H. Remove the bearings from the shaft using a puller which contacts only the inner race of the bearings.
I. Remove the gear spacers and the gear from the shaft.
5.3.2.4 Repair
Clean and inspect all of the pump drive transmission components in accordance with the general cleaning and
inspection procedures described in Appendix A of this manual. Replace all worn or damaged parts. Replace all
gaskets.
5.3.2.5 Assembly
Assemble the pump drive transmission as follows:
1. Reinstall the bearings on their respective shafts, being careful to press only on the inner race. Be sure the
bearings are pressed fully onto the shaft.
2. Lubricate bearings with light oil and install seal using Loctite Plastic Gasket 54931 on the outer diameter.
Assemble seal carrier with Loctite 609. Grease the seal surface before installing.
3. Install all pump drive shafts in the lower housing half and secure with snap rings.
4. Install all splined adapters and secure with snap rings.
5. Use SAF-T-LOK Silicone Sealant No. 732 to seal the pump drive housing halves and install the upper housing
half on the lower half.
6. Install the locating dowel pins in the housings.
7. Tighten bolts and nuts to 60 ft-lbs (81 Nm), following the bolting sequence illustrated in Figure 5-6.
8. Reinstall the coupling hub and coupling half on the input shaft as follows:
A. Place the sleeve on the input shaft with the flange facing away from the pump drive transmission housing.
B. Heat the hub to 275T (135C) using one of the following methods:
1). For oven heating, set the oven thermostat to 275F (135C) and heat the hub at least one hour for each
inch of wall thickness. Do not allow the hub teeth to come into contact with the heat source.
WARNING
!
Use of an open flame in a combustible atmosphere can ignite the atmosphere or cause
an explosion resulting in the injury or death of personnel and damage to equipment. Do
not use an open flame in a combustible atmosphere or near combustible materials.
2). For oxy-acetylene or blow torch heating, mark the hub with a 275T temperature sensitive crayon in
several places near the teeth. Direct the flame toward the hub bore and keep it in motion while heating
to avoid overheating an area. Do not apply heat directly to the hub teeth. When using an oxy-acetylene
torch, use an excess acetylene mixture.
C. Mount the hub on the shaft as quickly as possible to avoid heat loss. Make certain that the position of the
hub teeth relative to the shaft end is correct before assembling. Line up the bore with the shaft and slide the
hub onto the shaft until the hub face is flush with the end of the shaft.
NOTICE
If it is necessary to drive the hub into position, tap lightly with a soft brass or lead hammer. Do
not strike the hub teeth or pound hard enough to damage bearings.
Figure 5-6: Bolt Tightening Sequence
BD0399a01
D. Allow the hub to cool.
Install the pump drive transmission as follows (refer to Figure 5-2):
1. Using a suitable lifting sling, position the pump drive housing in mount on the power unit base, and secure it
lightly with the mounting capscrews and lockwashers. Do not tighten fully at this time.
2. Install the four dowel pins which accurately position the pump drive housing relative to the two gear box
mounts, then complete tightening of the mounting capscrews.
3. Using a dial indicator, check the alignment of the coupling hubs on the motor shaft and pump drive shaft. Align-
ment must be parallel within 0.002" TIR. Always rotate the hub on which the dial indicator is mounted and
mount the dial indicator on the most easily rotated hub.
NOTICE
The coupling extension will need to be removed from the coupling assembly to enable checking
overall hub-to-hub alignment.
4. Install the coupling extension with two new gaskets, capscrews, lockwashers and locknuts.
5. Lubricate the coupling using the lubricant specified in the Lubrication Chart. To do so, fill the front section with
lubricant until an excess appears at an open hole. Plug that hole. Continue with the rear section until lubricant
appears out the rear hole. Plug that hole.
6. Install the coupling guard between the motor and the pump drive housing with capscrews and lockwashers.
7. Install the pipe elbow, hex nipple, drain cock, and pipe nipple beneath the pump drive housing.
8. Confirm alignment in accordance with Subtopic 5.1.1.
9. Install the hydraulic pumps. Refer to Subtopic 4.3.4.
10. Fill the pump drive with 2 gallons (7.6 liters) of gear oil. Refer to Subtopic 17.3.2.
BD120149 Mechanical Systems Manual Main Air System
Sec06MainAir.fm -6.1- Section 6, Version 00 - 03/06
Section 6
Main Air System
6.1 General
In order to drill most effectively, the rock chips and dust generated by the drill bit at the bottom of the blasthole must
be removed. The main air system provides a large volume of air under pressure to blow these particles out of the
hole. An additional benefit to providing air through the drill bit is that it helps keep the drill bit cool.
Main Air System BD120149 Mechanical Systems Manual
Section 6, Version 00 - 03/06 -6.2- Sec06MainAir.fm
The main air compressor (Figure 6-2) is a single-stage, positive-displacement oil-flooded rotary screw compressor
using two meshing helical rotors to effect compression. The compressor is protected against dust contamination by
a pair of two-stage air filters, which are attached to the air inlet valves. The compressor is ported to accept an
external, re-circulating supply of oil for cooling and lubrication. Oil is supplied at the compressor inlet, and mixes
directly with the air being compressed. The compressed air-oil mixture flows from the compressor into the T tank (a
combination oil reservoir and air-oil separator) where the majority of oil separates from the air stream. The sepa-
rated oil, retained temporarily in the enlarged bottom of the T tank, is circulated through the oil temperature control
and filter circuit, then back to the inlet of the compressor.
Figure 6-2: Main Air Compressor and Main Motor
01
02
04
05
06
07
08
09
10
BD0384b01
03
LEGEND
01. Compressor Base
02. Isolation Mounts
04. Main Air Compressor Oil Filter
05. Inlet Valve Manifold
06. Inlet Valves
07. Air Cleaner Support Bracket
08. Air Cleaner Filters
09. Bearing Oil Filter
10. Main Motor
6.2.1.1 Compression Principle
The Compression Principle is demonstrated in Figure 6-3:
Compression of the air is accomplished by the main and secondary rotors synchronously meshing in a one-piece
cylinder. The main rotor has four helical lobes spaced 90 apart. The secondary rotor has five matching helical
grooves 72 apart to allow meshing with the main rotor lobes.
The air inlet port is located on top of the compressor near the center. The discharge port is near the bottom at the
opposite end of the compressor cylinder.
The compression cycle begins as the rotors unmesh at the inlet port and air is drawn into the cavity between the
main rotor lobes and the secondary rotor grooves (A, Figure 6-3). When the rotors pass the inlet port cutoff, air is
trapped in the interlobe cavity and flows axially with the meshing rotors (B). As meshing continues, more of the
main rotor lobe enters the secondary rotor groove, normal volume is reduced, and pressure increases.Volume
reduction and pressure increase continues until the air/oil mixture trapped in the inter-lobe cavity by the rotors
passes the discharge port and is released to the oil reservoir (C).
Each rotor cavity follows the same fill-compress-discharge cycle in rapid succession to produce a continuous,
smooth, and shock-free discharge air flow.
6.2.1.2 Air Flow
Air enters the compressor after first passing through the main compressor air cleaner and the inlet valves (refer to
Figure 6-2). After compression, the air/oil mixture passes into the oil reservoir in the bottom of the T-Tank, where
most of the entrained oil is removed by velocity change and impingement. The air and any remaining oil -- now a
mist -- then pass through the oil separator in the upper leg of the T-Tank; the separated oil is returned to the system
through tubing connecting the separator to the compressor. The air passes through the T-Tank discharge manifold,
discharge minimum pressure relief valve, and bailing air control (butterfly) valve.
6.2.1.3 Lubrication, Cooling, And Sealing
An oil circulation pump draws oil from the oil reservoir. Oil is pumped through the oil cooler, thermal control (ther-
mostatic mixing) valve, main oil filter, and bearing oil filter, and discharges into the main oil gallery of the compres-
sor. A portion of the oil flow is directed through internal passages to the bearings, gears, and shaft oil seal. The
Figure 6-3: Compression Principle
01 01 01
02 02 02
BD0388a01
LEGEND
01. Air In
02. Discharge Port
balance of the oil is injected directly into the compression chamber to remove heat of compression, seal internal
clearances, and to lubricate the rotors.
6.2.1.4 Turn Valve
The turn valve is a rotary helical valve located near the discharge port. The turn valve is locked in place at the fac-
tory to produce maximum output. The turn valve can be unlocked via a set screw, enabling the turn valve to be
turned to open and close cylinder ports that communicate with the inlet passage. This varies the compressor rotor
volume to match the demand for air required for drilling.
Figure 6-4: Turn Valve
6.2.2 Overview
Figure 6-5 shows the main air system schematic.
For the purposes of this manual, discussion will be broken into three groups:
Air Intake (green outline). Refer to Subtopic 6.2.3.
Oil Circulation (blue outline). Refer to Subtopic 6.2.4.
Bailing Air Control (orange outline). Refer to Subtopic 6.2.5.
Figure 6-5: Main Air System Schematic
BD0515a01
6.2.3 Air Intake
6.2.3.1 General
Air from atmosphere is filtered through a pair of dual-stage air cleaners and a pair of inlet valves prior to entering
the compressor. The inlet valves are closed at main motor start and modulated during operation by the subtractive
pilot valve.
Refer to Figure 6-6 as the functions of the components are described in the following subsections.
Figure 6-6: Air Intake
LEGEND
01. General
02. Vacuum Switches
03. Check Valve
04. Inlet Valves
06. Main Drive Motor
07. Subtractive Pilot Valve
08. Pilot Pressure Gauge
09. Compressor Inlet Pressure Switch
CIPS
BD0515b01
01
02
01
02
03
04 04
M
05
06
07
08
09
6.2.3.2 Main Compressor Air Cleaner 46Z534D1
Two double-element filters are installed, one in each air intake line. These filter the air going to the compressor.
6.2.3.3 Vacuum Switches R15628D1
A vacuum switch is plumbed between the air cleaner and the inlet valve in each of the two air intake lines. The vac-
uum switch indicates to the PLC when a filter needs to be changed.
Figure 6-7: Main Compressor Air Cleaner
Figure 6-8: Vacuum Switches
6.2.3.4 Inlet Valves
The inlet valves are piston-actuated devices. They close when the system is operating at full pressure, and the
degree of opening changes as the system pressure changes. Refer to Figure 6-10, views A, B, C, D and E, which
illustrate how the inlet valve assemblies operate
Figure 6-9: Compressor Inlet Valve Assembly
.
Inlet
Figure 6-10: Inlet Valve Modulation Operation
01
02
03
04
05
06 07 08
09 10
11 12 13 14 15
BD0527a01
A
16
17
B C
D E
LEGEND
01. Adjusting Screw
02. Subtractive Pilot
Valve
03. Spring
04. Poppet
05. Diaphragm
06. From Air Valve
07. Inlet Pressure Gauge
08. To Inlet Valve
09. From Low Pressure
Hydraulic System
10. Control Piston
11. Piston
12. Piston Spring
13. Inlet Valve Stem
14. Inlet Valve Spring
15. Inlet Valve
16. Air from Filters
17. Air to Compressor
A. COMPRESSOR IS OFF. Air pressure in line from air valve is zero. The subtractive pilot valve is closed, and
pressure on the inlet pressure gauge is zero. No air pressure is acting on the cylinder cap, and no hydraulic
pressure is acting on the cylinder cap. The piston spring holds the piston in the open position; however, the
small, weak valve spring is strong enough to keep the valve over the opening so that dust and other contam-
inants do not enter the compressor.
B. MAIN MOTOR STARTS. Air pressure in line from air valve is zero. The subtractive pilot valve is closed, and
pressure on the inlet pressure gauge is zero. No air pressure is acting on the cylinder cap. Until the motor is
running at normal speed, pilot hydraulic pressure from the low pressure hydraulic system moves the control
piston in the cylinder. The main piston compresses the piston spring and pushes against the inlet valve
stem, closing the valve.
C. NORMAL OPERATION, FULLY UNLOADED. When pressure at the air valve is between 0 and 58 psi, the
subtractive pilot valve is closed, and pressure on the inlet pressure gauge is zero. No air pressure is acting
on the cylinder cap, and no hydraulic pressure is acting on the cylinder cap. The piston spring holds the pis-
ton in the open position. As the compressor lobes turn, sufficient vacuum is created to pull the inlet valve
open against the small, weak inlet spring. Full air volume is available for compression.
D. NORMAL OPERATION, MODULATING. When pressure at the air valve is between 58 and 65 psi, the sub-
tractive pilot valve is partially open. Pressure on the inlet pressure gauge is between 0 and 21 psi.Air pres-
sure working on the piston causes the piston to move in the cylinder. This causes the inlet valve to partially
close off the flow of air through the inlet valve.
E. NORMAL OPERATION, FULLY LOADED. When pressure at the air valve is over 65 psi, the subtractive pilot
valve is fully open. Pressure on the inlet pressure gauge is 21 psi. Air pressure working on the piston causes
the piston to move to the fully closed position, causing the inlet valve to completely close off the flow of air
through the inlet valve.
In this way, the inlet valves control air going to the air compressor based on demand. The condition of the inlet
valves at various stages is recapped in Table 6-1
Drill State Control Mechanism Inlet Valve State
Shut down Valve spring Fully closed
Startup (5 seconds) Hydraulic pressure Fully closed
Running: fully unloaded Subtractive Pilot Valve Fully open
Running: partially loaded Subtractive Pilot Valve Partially open
Running: fully loaded Subtractive Pilot Valve Fully closed
Table 6-1: Inlet Valve States
6.2.3.5 Compressor Inlet Pressure Switch CIPS R7090D1
The compressor inlet pressure switch is mounted on the air control panel in the machinery house. It indicates to the
PLC that the low pressure hydraulic system is sending hydraulic fluid to the intake valves to keep the intake valves
closed during start-up. When the CIPS closes, it sends a signal to the PLC that pressure in the low pressure
hydraulic line reaches 275 psi, and the main motor can start.
Figure 6-11: Compressor Inlet Pressure Switch CIPS
6.2.3.6 Pilot Air Pressure
The pilot air pressure gauge is mounted on the air control panel, above the subtractive pilot valve. The pilot air
pressure is a function of main air pressure acting through the subtractive pilot valve. Refer to Table 6-2.
Figure 6-12: Pilot Air Pressure Gauge and Subtractive Pilot Valve
Inlet Valve State Main Air Pressure Pilot Pressure Gauge
Reading
Shut down: closed 0 psi 0 psi
Startup (15 seconds):
closed
0 psi 0 psi
Open: fully unloaded 0-58 psi 0 psi
Modulating: partially
unloaded
58-65 psi 0-21 psi
Closed: fully loaded over 65 psi 21 psi
Table 6-2: Inlet Pressure Gauge Readings
LEGEND
01. Inlet Pressure Gauge
6.2.3.7 Check Valve 36Z1245D1
When system air pressure is at or above 65 psi, inlet valves are closed and no air is allowed into the system; how-
ever, the compressor continues to turn. If a vacuum develops between the inlet valve and the air compressor, noisy
operation results. To avoid this undesired operation, a line with a check valve has been installed between the main
compressor air cleaner and the compressor that bypasses the inlet valve on the left side and permits a small
amount of air to enter the system. The check valve works in conjunction with the Air Pilot Valve to move some air
through the compressor, which also serves to keep the screws lubricated. Quiet, smooth operation results.
Figure 6-13: Inlet Valve Bypass Line Check Valve
Figure 6-14: Inlet Valve Lines
LEGEND
01. Oil line from low pressure hydraulic system (only functions at startup)
02. Air line from subtractive pilot valve
03. Oil return line from T-Tank oil separator (scavenger line)
04. Bypass air line (from check valve)
6.2.4 Oil Circulation
6.2.4.1 General
Oil is induced into the air compressor to lubricate the lobes and to act as an air seal. As the air moves through the
compressor, the oil is entrained with it. This oil is removed from the air before the air is sent out to the bit. The oil is
then cooled and filtered and returned to the compressor.
Figure 6-15: Oil Circulation
BD0515c01
01 01
02 03
M
04
05
06
07
10
08
09
12
13
14
15
16
17
18
11
19
LEGEND
01. Inlet Valve
03. Main Motor
04. Compressor Air Temperature Gauge
05. Compressor Air Temperature Probe
06. Compressor Oil Temperature Probe
07. T-Tank
08. Main Air Pressure Differential Gauge
09. Main Air Pressure Differential Switch
10. Oil Separator Element
11. Shut-off (Drain) Valve
12. Circulation Pump
13. Thermostatic Mixing Valve
14. Compressor Oil Cooler
15. Compressor Oil Flow Switch
16. Compressor Oil Pressure Switch
17. Compressor Main Oil Filter
18. Compressor Oil Pressure Differential Switch
19. Compressor Oil Pressure Differential Gauge
6.2.4.2 Compressor Air Temp Gauge 5826907
The Compressor Air Temperature Gauge is located on the discharge pipe exiting on the right side of the compres-
sor. It indicates the current temperature of the discharge air/oil mixture. During operation, the compressor should
maintain a normal operating temperature of 180-185F (82-85C).
6.2.4.3 Compressor Air Temp Probe 89Q136D1
The Compressor Air Temperature Probe is located on the discharge pipe exiting on the right side of the compres-
sor. It sends a signal to the PLC indicating the current temperature of the air discharge.
Figure 6-16: Compressor Air Temperature Probe and Gauge
6.2.4.4 T-Tank R55420F1
T-Tank is the common name for the oil separator/reservoir. It is mounted on the When the oil and air mixture enters
from the compressor, the majority of the oil falls out of the air by gravity and impaction. The oil is recirculated
through the cooler and the filter, then returned to the air compressor.
6.2.4.5 Compressor Oil Temp Probe 89Q136D1
The Compressor Oil Temperature Probe is inside the T-Tank, and sends a signal to the PLC indicating the current
temperature of the oil inside the T-Tank.
6.2.4.6 Oil Separator Elements 5010587, 5010588
Part of the T-Tank, the two oil separator filter sections extend upward from the main reservoir. Each contains a two-
stage oil remover, which removes oil that is still entrained as a mist in the main air flow. The oil removed by the sep-
arators returns by a different path from the path of the majority of the oil in the T-Tank. It returns to the compressor
through the scavenger lines, filtered but without going through the oil cooler.
Figure 6-17: T-Tank
6.2.4.7 Main Air Pressure Differential Switch 5000261 and Gauge 89Z559
This two-position manual switch is mounted on the air control panel. Changing the position of the knob causes the
associated gauge to read the air pressure either before the oil separators or after the oil separators, depending on
its position. Decisions regarding changing or cleaning the oil separator filter elements can be based on the differen-
tial between the two readings.
6.2.4.8 Shutoff Valve R6902D4
The shutoff valve is located on the underside of the T-tank. It is used to isolate system components during mainte-
nance.
6.2.4.9 Circulation Pump R56963D1
An oil circulation draws oil from the oil reservoir. Oil is pumped through the oil cooler, thermal control (thermostatic
mixing) valve, main oil filter, and bearing oil filter, and discharges into the main oil gallery of the compressor. A por-
tion of the oil flow is directed through internal passages to the bearings, gears, and shaft oil seal. The balance of
the oil is injected directly into the compression chamber to remove heat of compression, seal internal clearances,
and to lubricate the rotors.
Figure 6-18: Main Air Pressure Differential Switch and Gauge
Figure 6-19: T-Tank Shutoff Valve
The oil circulation pump is a self-contained assembly that incorporates a mounting frame, a 20 horsepower motor,
coupling and gear pump rated at 150GPM. The assembly mounts horizontally between the T-tank and the house
wall on the left hand platform next to the T-tank. Refer to Figure 6-20.
Pump discharge piping includes an in-line check valve to provide pump relief. A second in-line oil check valve is
included to limit T-tank back-pressure. These components are positioned below the left hand platform near the
pump package. Pump discharge piping parallels the outside of the house, then enters the cooler room and termi-
nates at the compressor cooler inlet. A bypass line plumbs off a tee connection to the check valve located inside
the cooler room. The cooler discharge piping re-enters the house and joins into the compressor oil filter.
Figure 6-20: Oil Circulation Pump and Motor
6.2.4.10 Thermostatic Mixing Valve R38039D2
The thermostatic mixing valve is mounted in the fan room at the front left corner of the drill. Access to the fan room
is only from the left-hand platform.
The thermostatic mixing valve has a 130F (54C) element. Oil moves through the valve and bypasses the cooler
until the fluid temperature reaches approximately 120F (49C). As the temperature of the oil continues to rise, the
valve slides farther open until it is fully open, porting all oil through the cooler, when oil temperature is 140F
(60C).
Figure 6-21: Thermostatic Mixing Valve
6.2.4.11 Compressor Oil Cooler R56899F1
The compressor oil cooler is mounted on the left front of the drill. Oil from the compressor is cooled by a fan draw-
ing air through cooling fins on the cooler. The fan is driven by an electric motor.
Figure 6-22: Compressor Oil Cooler
6.2.4.12 Compressor Oil Flow Switch COFS R29648D1
The compressor oil flow switch is mounted in the oil line just before the main compressor oil filter, to the right of the
compressor. Its primary function is to indicate to the PLC that oil is flowing through the lines. During the main motor
start-up sequence, the circulation pump is started. To confirm that the pump is on, the PLC monitors the flow
switch. Once the flow switch closes, the PLC issues a 2-seconds delay to allow time for the oil to build pressure
within the compressor. Then the main motor starts. The PLC continues to monitor the flow switch.
6.2.4.13 Compressor Oil Pressure Switch COPS 79Z5680D1
The compressor oil pressure switch is mounted on the air control panel. It indicates to the PLC that sufficient oil
pressure exists to ensure proper compressor operation. The switch is set at 15 psi with a 7 psi differential; that is,
the switch closes when oil pressure reaches 15 psi and stays closed until pressure drops below 8 psi (8 psi is the
minimum operating pressure). The pressure switch is not recognized during the initial start of the main motor; how-
Figure 6-23: Compressor Oil Flow Switch COFS (typical; for reference only)
Figure 6-24: Compressor Oil Pressure Switch COPS
ever, during the first 5 seconds of motor operation, the PLC monitors oil flow. If the initial 5 seconds has elapsed
and the pressure switch is not closed, the main motor will shut down and the GUI will register a fault.
6.2.4.14 Compressor Oil Filter R51071F1
The compressor oil filter, mounted to the right of the air compressor, removes contaminates from the recirculated
oil as it returns to the compressor.
6.2.4.15 Scavenger Oil Return Filter 5000348
Oil recovered from the T-Tank oil separator returns to the compressor through the scavenger lines. Scavenger oil is
filtered by a spin-on filter at the air control panel.
Figure 6-25: Compressor Oil Filter
Figure 6-26: Scavenger Oil Filter
6.2.4.16 Compressor Oil Pressure Differential Switch 5000261 and Gauge 89Z559
A two-position manual switch mounted on the air control panel causes the associated gauge to read the air pres-
sure either before the oil separators or after the oil separators, depending on its position. Decisions regarding
changing or cleaning the oil separator filter elements can be based on the differential between the two readings.
Figure 6-27: Compressor Oil Pressure Differential Switch and Gauge
6.2.5 Bailing Air Control
Figure 6-28: Bailing Air Control
BD0515e01
01
02
03
04
05
06
07
08
09
10
LEGEND
01. Moisture Removal Orifice
02. Main Air Pressure Switch MAPS
03. Bailing Air Pressure Transducer
BAPT
04. Main Air Pressure Transducer MAPT
06. Air Pilot Valve
07. Muffler
08. Relief Valve
09. Butterfly Valve
10. Dump Valve
6.2.5.1 General
Bailing air provides sufficient quantity of air at sufficient pressure to remove rock chips and dust from the blasthole.
Although the compressor is functioning the entire time the main motor is running, the air needs to be controllable
so that compressed air is permitted to flow through the drill string only when required.
6.2.5.2 Subtractive Pilot Valve 36Q577D1
After the main motor has been running for six seconds, the air compressor inlet valves open and air is compressed
until a pressure of the subtractive pilot valve setting (typically 65 psig) is achieved. At that point, the subtractive
pilot valve will cause the inlet valves to close again. The subtractive pilot valve continues to react to system pres-
sure, and the compressor will compress air when and only when it is needed.
The function of the subtractive pilot valve is described in greater detail in Subtopic 6.2.3.4.
Figure 6-29: Subtractive Pilot Valve
6.2.5.3 Main Air Pressure Transducer MAPT 44Q1536
The Main Air Pressure Transducer is mounted on the air control panel. Sensing before the butterfly valve, it indi-
cates to the PLC that sufficient air pressure exists and the bailing air system can be used.
6.2.5.4 Bailing Air Pressure Transducer BAPT 44Q1536
The Bailing Air Transducer is mounted on the air control panel. Sensing after the butterfly valve, it indicates to the
PLC the pressure of air going to the bit.
Figure 6-30: Main Air Pressure Transducer MAPT
Figure 6-31: Bailing Air Pressure Transducer BAPT
6.2.5.5 Main Air Pressure Switch MAPS R7090D1
The main air pressure switch is mounted on the air control panel. It closes when main air is 40 psi or greater, and
opens when air pressure is 34 psi or less. When closed, it allows the butterfly valve motor control to energize.
6.2.5.6 Air Pilot Valve R56220D1
The air pilot valve is mounted on the bailing air pipe after the T-Tank. When the butterfly valve opens, pressure
from the main line is piloted to the air pilot valve, which blocks the path to the muffler. When the butterfly valve
closes, the pilot valve opens, allowing approximately 350 CFM of air to pass through. This valve is required to allow
the compressor to still produce air flow, which is necessary to prevent the rotors inside the compressor from rum-
bling. The pilot valve works in conjunction with the bypass line and Check Valve to move some air through the com-
pressor.
Figure 6-32: Main Air Pressure Switch MAPS
Figure 6-33: Air Pilot Valve
6.2.5.7 Muffler 27U762D1
The muffler is clamped to the back brace support between the T-Tank and the machinery house. When the main air
compressor is running and the bailing air is turned off, approximately 350 CFM exhausts to atmosphere through
the muffler.
6.2.5.8 Relief Valve R6902D4
The relief valve is mounted in the T-Tank. The setting for the relief valve is calibrated at the factory. At that time, the
valve is preset and a tag is attached to the valve that contains the calibration numbers. No field adjustment is
required.
Figure 6-34: Muffler
Figure 6-35: Relief Valve
6.2.5.9 Butterfly Valve R51305D1
The butterfly valve is mounted in the bailing air pipe between the relief valve and the dump valve. It features an
electric actuator that is controlled through the PLC by a switch on the operators console. In order for the switch
signal to be active, the Main Air Pressure Switch must be closed (i.e., main air pressure must be at least 40 psi).
Figure 6-36: Butterfly Valve with Electric Actuator
6.2.5.10 Dump Valve GH5000369
This is a normally open, pressurize to close check valve. When pressure from the main air system acts on the
valve, the valve closes. When the pressure is removed, the valve opens to allow air to exhaust without going
through the drill string.
6.2.5.11 Water Injection
Water is injected into the air stream when the operator turns on the function on the operators console. The amount
of water varies from 0 to 5 GPM. Refer to Section 16, Water Injection System for a detailed description.
Figure 6-37: Dump Valve
6.3 Main Air System Components
6.3.1 Main Compressor Air Cleaner 46Z534
Service the main compressor air cleaner when necessary, as follows:
1. Shut down the main motor.
2. Remove primary element by removing attaching hardware.
3. Check the status of the safety element restriction indicator, which is part of the safety element retaining nut.
Replace the safety element only if the indicator on the wing nut shows red. Reset the wing nut indicator by
applying suction in accordance with the instructions on the wing nut.
4. Wipe out the filter housing with a damp cloth.
Figure 6-38: Main Compressor Air Cleaner
LEGEND
01. Housing
02. Filter
03. Wing Nut/Indicator
04. Primary Filter
05. Wing Nut
06. Cover
07. Gasket
08. Washer
09. Cotter Pin
10. Band Clamp
11. O-ring
12. Primary Body
13. Band Clamp
14. Cup
15. Restriction Adapter
CAUTION
Filter damage will result if the air pressure is too high or if the air nozzle is held too close
to the filter. Follow instructions to avoid damage to the filter element. Clean the elements
away from the compressor, such as outside the machinery house or in a shop, to avoid
contaminating the safety element (or the compressor inlet, if the safety element has
been removed).
5. Clean primary element using compressed air on the pleated paper inside the element. Keep the air nozzle at
least one inch from the pleated paper while rotating the element. Air pressure must not exceed 100 psi (6.9
bar).
6. Inspect the cleaned element by holding a light bulb inside it. Rotate the element slowly and inspect for damage.
If the element is ruptured or has holes or gasket damage, replace it. Primary element can be cleaned up to six
times if care is used. However, inner (safety) element should never be cleaned. Replace the safety element
instead of cleaning it. Always replace safety element after three cleanings of primary element, more often if
necessary.
7. Remove the primary body and clean either by using compressed air or by washing the tubes out with water.
8. Check the condition of the wing nut indicator. If the center has changed
9. Install parts in reverse order of removal, start the motor and see that the vacuum switches do not actuate.
The main air compressor (Figure 6-39) is a single-stage, positive-displacement rotary machine using two meshing
helical rotors to effect compression. The compressor is protected against dust contamination by a pair of two-stage
air filters, which are attached to the air inlet valves. The compressor is ported to accept an external, re-circulating
supply of oil for cooling and lubrication.
01
02
04
05
06
07
08
09
10
BD0384b01
03
LEGEND
01. Compressor Base
02. Isolation Mounts
04. Main Air Compressor Oil Filter
05. Inlet Valve Manifold
06. Inlet Valves
07. Air Cleaner Support Bracket
08. Air Cleaner Filters
09. Bearing Oil Filter
10. Main Motor
6.3.2.1 Removal
Refer to Figure 6-40 and remove the compressor from the compressor base for disassembly as follows:
Figure 6-40: Power Unit (exploded view)
WARNING
!
Working on or near rotating machinery while in operation is hazardous and can result in
the injury or death of personnel. Shut down the main air compressor, and use lockout/
tagout procedures prior to starting any service on the machinery.
1. Lock out and tag the high-voltage main circuit breaker switch to prevent operation of the main drive motor dur-
ing disassembly.
CAUTION
!
Pressurized oil will spray with extreme force from oil line fittings when being loosened,
and can cause severe injury. Slowly release air pressure or vent the T-Tank before loos-
ening any oil line fittings. Wear appropriate face, ear, and body protective devices while
opening pressurized systems.
2. Vent any residual air pressure from the T-Tank. The T-Tank will self-vent through the pilot air valve and out the
main air system muffler in approximately 2 minutes when the main air compressor is not operating and all con-
trols are in the OFF position.
3. Tag and disconnect the oil pressure hose that is connected to the main oil filter flanged connection port on the
compressor housing. This hose leads from the main oil filter element differential pressure test valve, which is
mounted on the air control panel.
4. Disconnect the wires from the oil filter indicator, air filter indictors, and temperature probe.
LEGEND
01. Nut
02. Band
03. Capscrew
04. Air Cleaner
05. Service Indicator
06. Bracket
07. Hose Clamp
08. Hose
09. Tube
10. Capscrew
11. Lockwasher
12. Inlet Manifold
13. Gasket
14. Inlet Manifold
15. Capscrew
16. Lockwasher
17. Oil Filter
18. Filter Gasket
19. Nut
20. Capscrew
21. Shim Set
22. Filter
23. Adapter
24. Tapered Pin
25. Cover
26. Lockwasher
27. Capscrew
29. Key
31. Key
32. Guard
33. Capscrew
34. Capscrew
35. Dowel Pin
36. Base
37. Capscrew
38. Mounting Pad
39. Mounting Pad
40. Mounting Pad
41. Mounting Pad
42. Shim
43. Shim
44. Capscrew
45. Dowel Pin
46. Mount
47. Dowel Pin
48. Capscrew
49. Lockwasher
50. Nut
51. Lockwasher
52. Pipe Nipple
53. Drain Cock
54. Hex Nipple
55. Elbow
56. Hydraulic Pump
57. Capscrew
58. Pump Drive Trans.
59. Hydraulic Pump
60. Lockwasher
61. Capscrew
62. Capscrew
63. Cover Gasket
64. Cover
65. Electrical Indicator
5. Disconnect the compressor oil filter from the compressor housing by removing the capscrews, lockwashers,
and gasket. Discard the used gasket.
CAUTION
Cap or plug all open oil lines to prevent entry of contaminants and dirt, and also to pre-
vent spillage of oil.
6. Tag and remove the oil return line from the air-oil separator to the housing of the compressor air inlet valve(s).
7. Tag and remove the two hydraulic hoses attached to each compressor inlet valve from the low pressure
hydraulic system.
8. Tag and remove the air pilot piping from the subtractive pilot valve and low-torque start-up circuits to the two
inlet air valves.
9. Disconnect the air discharge pipe from the compressor by removing the eight bolts holding the compressor and
pipe flanges together. Discard the used flange gasket.
10. Remove the two air inlet tubes that connect the air cleaner filters with the compressor inlet valves. Loosen
hose clamps and slide hose sections onto the air inlet tubes.
11. Open house roof (if the mast is vertical) to allow components to be hoisted in and out.
12. Attach suitable hoisting equipment to the air cleaner support bracket during its removal from the compressor
assembly. Unbolt and remove the bracket from the motor mount adapter flange and the inlet valve manifold
flange. The two air cleaner filters can remain assembled to the bracket.
13. Attach suitable hoisting equipment to the inlet valve manifold, remove the 12 capscrews and lockwashers from
the inlet manifold/compressor mounting flange, then remove the inlet manifold and manifold gasket from the
top of the compressor. The two inlet valves need not be disassembled from the manifold.
14. Remove the adapter cover from each side of the compressor motor adapter to expose the drive coupling.
15. Disconnect adapter from the compressor by removing the eight capscrews, nuts, lockwashers, and the two
taper pins from the compressor-side flange.
16. Disconnect the compressor from the power unit base by removing the four cap screws and lockwashers that
fasten the compressor feet and shims to the base. Match mark the shims for later re-assembly.
CAUTION
!
Incorrect lifting of the compressor can cause serious injury or property damage. Be cer-
tain lifting rigging is secure and the hoist is of sufficient capacity before attempting the
lift. (Weight of the bare compressor is approximately 4,000 pounds (1814 kg).
17. Using a suitable lifting device, lift the compressor enough to take most of the weight off the feet. Carefully slide
the compressor axially away from compressor motor adapter to disengage the two halves of motor drive cou-
pling.
18. Remove the flexible insert from motor drive coupling.
19. Lift the bare compressor from the power unit base, and place it on secure wooden supports.
20. Loosen the motor drive coupling set screw, and use a suitable gear puller to remove the coupling from the
compressor input shaft.
21. Remove the coupling key from the compressor input shaft with a soft drive plug.
6.3.2.2 Repair
Repair of the main air compressor requires special tools, test equipment, and experience to be performed correctly.
Whenever the main air compressor requires repair or overhaul, contact your P&H MinePro Services representa-
tive.
Install the compressor on the compressor base and interconnect it into the system as described below. Refer to
Figure 6-40 for identification and location of components.
1. Remove any nicks or burrs from the compressor input shaft keyway and drive coupling key, then install the key
into the keyway. Be certain that the key is firmly seated on the bottom of the keyway, and that the key fits
snugly in the keyway.
2. Heat the compressor half of drive coupling (refer to Figure 6-42) in oil, or an electric oven, to 350F (177C).
Allow sufficient time for the heat to thoroughly penetrate the half-coupling, then install it on the compressor
input shaft.
3. Position the end of the compressor input shaft even with the bottom of the counterbore in the half-coupling,
then tighten the set screw onto the key, and allow the half-coupling to cool.
4. When the half-coupling has cooled, remove the set screw, apply a coating of Loctite to the threads, then install
and tighten the set screw securely.
5. Install the flexible insert for drive coupling onto the motor half of the coupling.
6. Position the four shims on the power unit base where the compressor feet are to be located.
Figure 6-42: Flexible Coupling
WARNING
!
Incorrect lifting of the compressor can cause serious injury or property damage. Be cer-
tain that lifting rigging is secure and the hoist is of sufficient capacity before attempting
the lift. Weight of the bare compressor is approximately 4,000 pounds (1850 kg).
7. Attach a suitable lifting device, and move the compressor into approximate mounting position over the power
unit base.
8. Lower the compressor until it almost touches the shims, then push the compressor axially toward the motor
until the drive coupling halves engage.
NOTICE
The motor shaft may need to be rotated and the elevation of the compressor may need to be
adjusted with the hoist to accomplish engagement of the coupling halves.
9. Push the compressor mounting flange and compressor adapter flange together and fasten loosely with eight
capscrews, lockwashers, and nuts.
10. Install two taper pins in the compressor mounting/motor adapter flanges, then torque the capscrews and nuts
securely.
11. Install four capscrews and lockwashers through the compressor mounting feet and shims, then tighten
securely.
12. Working through the access openings in compressor motor adapter, check the axial position of the drive cou-
pling halves with a feeler gauge to confirm the 0.13" (3.302 mm) gap between faces (refer to Figure 6-42). If
the gap is not within 0.020" (0.508 mm) of 0.13" (3.302 mm), the compressor must be removed from the base,
and the half coupling position on the compressor input shaft must be adjusted accordingly. Then re-install the
compressor in accordance with Steps 7 through 12.
13. Install the two adapter covers on the compressor motor adapter with cap screws and lockwashers.
14. Attach suitable hoisting equipment to the inlet valve manifold, and install the compressor inlet valve manifold
and two inlet valves, as a subassembly, onto the top of the compressor. Install with a new flange gasket and
torque the 12 mounting bolts and lockwashers securely.
15. Attach suitable hoisting equipment to the air cleaner support bracket, including the two air cleaner filters, and
hoist the subassembly into place for installation. Install the bracket by bolting it to the compressor-side flange
of the compressor motor adapter and the inlet valve manifold flange on the compressor.
16. Close the roof after the last heavy piece has been placed.
17. Position one of the air inlet tubes between an inlet valve and an air cleaner filter and slide a hose onto the inlet
manifold. Slide the opposite hose onto the air filter. Adjust the engagement of hoses on the tube, manifold, and
air filter so there is sufficient overlap for clamping; Fasten hoses in position with hose clamps. Repeat this step
for the other tubing assembly.
18. Install main oil filter assembly to the mounting flange of the compressor with four capscrews and lockwashers.
Install the filter assembly with a new gasket.
19. Install the compressor air discharge pipe to the compressor with eight bolts, lockwashers, and nuts. Install a
new gasket in the flange assembly.
20. Install the air piping from the subtractive pilot valve and low-torque start-up circuits to the two inlet air valves.
21. Install the two hydraulic hoses from the low pressure hydraulic system to each compressor inlet air valve.
22. Install the oil return line from the air-oil separator to the housing of the compressor air inlet valve(s).
23. Install the oil pressure hose assembly from the main oil filter element differential pressure test valve onto the
flanged main oil filter connection port of the compressor.
24. Connect wires that were removed earlier.
CAUTION
Check that the oil level in the compressor T-Tank reservoir is at the correct fill level prior
to starting the main air compressor.
6.3.3 Compressor Inlet Valves
6.3.3.1 Removal
In most cases, it is possible to service the inlet valve assemblies without removing them from the compressor. If it
is desirable or necessary, either inlet valve assembly can be removed from the compressor as follows (refer to Fig-
ure 6-43):
Figure 6-43: Compressor Inlet Valve Assembly
03
04
05
08
09
10
12
13
14
BD0528b01
01
02
06
07
01
02
11
LEGEND
01. Lock Washer
02. Capscrew
03. Pilot Hydraulic Port
04. Pilot Air Port
05. Cylinder Cap
06. Gasket
07. Piston Rings
08. Piston
09. Piston Spring
10. Cylinder
11. Cylinder Gasket
12. Valve Spring
13. Inlet Valve Assembly
14. Housing
WARNING
!
the injury or death of personnel. Shut down the main air compressor, and use lockout/
tagout procedures prior to starting any service on the machinery.
1. Lock out and tag the high-voltage main circuit breaker switch to prevent operation of the main air compressor
drive motor during service on the machinery.
2. Remove the air inlet tube, which connects the air filter with the compressor inlet valve, and the other hose
assemblies connected to the inlet valves. Refer to Subtopic 6.3.3.1, for procedures.
CAUTION
!
Incorrect lifting of the valve assembly can cause serious injury or property damage. Be
certain lifting rigging is secure and the hoist is of sufficient capacity before attempting
the lift.
3. Attach a suitable hoist to the inlet valve assembly to be removed, then remove the capscrews, lockwashers,
and nuts holding the valve assembly onto the inlet valve manifold, and lift the valve assembly away from the
compressor.
6.3.3.2 Disassembly
Refer to Figure 6-43 and disassemble the inlet valve assembly as follows:
1. If the valve assembly has been removed from the compressor, position and clamp the assembly, with the outlet
flange side down, on sturdy blocking.
CAUTION
!
Removal of the cylinder cap bolts without using spring retainers will enable the cap to
rapidly release resulting in the injury of personnel and damage to equipment. Attach
suitable spring retainers before removing all of the cylinder cap bolts.
2. Remove the spring loaded cylinder cap as follows:
A. Remove two cylinder cap bolts located 180" apart, and install two studs in the threaded bolt holes.
B. Install two nuts on the studs, and position the, finger tight, against the cylinder cap.
C. Remove the remaining cylinder cap bolts.
D. Loosen the nuts on the studs uniformly until the spring compression is completely released, then remove the
studs.
3. Remove the cylinder cap and cylinder cap gasket. Discard the gasket.
4. Pull the piston and piston spring from the bore of the cylinder.
Technician Tip
If the piston is seized or stuck inside the cylinder, it will be necessary to remove the cylinder
from the inlet housing. This will enable application of force from the back side to move the pis-
ton out of the bore.
5. Remove the eight capscrews and lockwashers that retain the cylinder to the housing, then pull the cylinder and
cylinder gasket from the housing. Discard the cylinder gasket.
6. Remove the inlet valve assembly and the valve spring from inside the inlet valve housing.
6.3.3.3 Repair
Clean the components of the inlet valve assembly thoroughly. See Appendix A of this manual for general instruc-
tions and precautions regarding the cleaning of components.
Inspect the components of the inlet valve assembly as follows:
1. Inspect the housing and cylinder bores for nicks, burrs, scratches or cracks.
2. Inspect the piston and inlet valve for nicks, burrs, scratches or cracks. Also check for broken piston ring land
areas.
3. Inspect the piston rings for wear, cracks and loss of spring compression.
4. Inspect the springs for worn or broken coils and loss of compression force.
5. Inspect the cylinder cap for nicks, burrs, scratches and distortion.
6. Inspect the pipe and straight threads on all parts for cleanliness and damage.Replace all defective parts if sig-
nificant damage or wear is found. Dress down all burrs, nicks and scratches with a fine file or emery cloth. All
gaskets should be replaced.
6.3.3.4 Assembly
Refer to Figure 6-43 and assemble the components of the inlet valve assembly as follows:
1. Insert the shaft of the inlet valve into the small bore end of the cylinder, and position the cylinder flange-end up
on top of the inlet valve disc.
2. Install the valve spring into the counterbore of the inlet valve shaft.
3. Position the piston spring over the spring guide in the bottom of the cylinder.
4. Install the piston rings in the grooves of the piston. Position the ring gaps so that they are approximately 180
apart.
5. Lubricate the bore and OD of the piston and rings with compressor oil, then install the piston into the cylinder
with the valve spring guide entering first. Assure that the spring guide enters the valve spring.
Technician Tip
Use a piston ring compressor to insert the piston into the bore. Do not use sharp objects such
as screwdrivers to aid in compressing the piston rings. Do not use excessive force to insert the
piston rings into the cylinder bore. Compress each ring as it enters the lead-in taper at the top of
the cylinder.
6. Place a new flange gasket on the cylinder, and install the cylinder in the inlet valve housing. Torque the eight
capscrews and lockwashers evenly to uniformly compress the gasket.
7. Install the cylinder cap with a new gasket as follows:
A. Install two temporary studs, positioned 180 apart, in the cylinder cap bolt holes.
B. Install the cylinder cap and new gasket over the studs, and position them against the piston.
C. Install a nut on each stud and position them against the cylinder cap.
D. Tighten the nuts uniformly until the cap and gasket are in position against the cylinder flange, then install
four cylinder cap bolts finger tight.
E. Remove the two temporary studs and nuts and install the remaining cylinder cap bolts finger tight.
F. Torque the cylinder cap bolts uniformly to avoid distorting the cap and to uniformly compress the gasket.
8. Confirm that the valve spring will freely move the inlet valve disc to its seat in the housing when the inlet valve
is in normal operating position. It is important that the disc seats completely, because it is the only device to
prevent back-flow of oil from the compressor into the inlet filters.
Install the inlet valve assemblies as follows:
CAUTION
!
Incorrect lifting of the valve assembly can cause serious injury or property damage. Be
certain lifting rigging is secure and the hoist is of sufficient capacity before attempting
the lift.
1. Attach a suitable hoist to the inlet valve assembly, lift it from the work area, and position it for installation over
the inlet valve manifold.
2. Place a new gasket in the correct position on top of the inlet manifold, and slowly lower the valve assembly
onto the top of the gasket.
3. Secure the inlet valve assembly to the manifold with capscrews, lockwashers, and nuts. Torque the bolts
evenly with a crosswise pattern to uniformly compress the gasket.
4. Install the air inlet tube, and the other hose assemblies that attach to the air inlet valves, in accordance with
Subtopic 6.3.2.3.
6.3.4 T-Tank R55420F1
The T-Tank is a pressure vessel that serves two functions within the main air system. Its first function is to provide
reservoir space for oil that is circulated through the compressor. The second function is to contain the air-oil sepa-
rator which removes the oil mist that remains entrained in the air flow after passing through the reservoir section of
the T-Tank.
The T-Tank is mounted on a platform on the left side of the drill, outside the machinery house (Figure 6-44). It is
located directly behind the main power transformer. Two oil separators extend vertically from the horizontal lower
part of the T-Tank.
A flanged port located near the bottom of the T-Tank is used to connect piping for circulating oil from the T-Tank,
through the cooler and main oil filter, then into the compressor. The air-oil separators (Figure 6-45) each have two
filter elements that remove the remaining oil mist from the air stream. Oil that is stripped by the outer oil separator
element drains by gravity into the T-Tank. The oil that becomes trapped between the outer and the inner element,
Figure 6-44: T-Tank (on Left Hand Platform)
01
02
03
04
07
08
11 10
09
BD0501b01
05
06
05
LEGEND
01. Sight Tube
02. Fill Plug
03. Oil Separators
04. Main Air Pipe
05. Sling Lift Point
06. Union
07. Safety Relief Valve
08. Air Pilot Valve
09. Air/Oil Reservoir
11. Shutoff (Drain) Valve
and also at the center of the inner element, is forced by air pressure into oil pickup scavenger tubes and is circu-
lated directly back to the compressor.
An outlet in the separator cover is connected to the main air delivery and control piping. Other fittings on the T-Tank
include an oil fill port, a tank drain and thermocouple port, pilot air pressure port, oil level sight tube, and a tank
inspection port.
The T-Tank does not need to be removed from the drill for service of its components. The only components requir-
ing periodic maintenance and/or replacement are the oil level sight-tube and the two filter elements in each of the
oil separators. These components are not repairable and should be replaced if they show signs of failure. Proce-
dures for replacement of these components follow:
6.3.4.1 Replace Oil Separator Elements GH5010587, GH5010588
Refer to Figure 6-44 and replace the filter elements inside the oil separator as follows:
Figure 6-45: Air/Oil Separator
01
02
03
04
05
06
07
08
09
10
BD0529a01
LEGEND
01. Outer Separator
02. Inner Separator
03. Capscrew
04. Lockwasher
05. Gasket
06. Lines to Compressor
07. Separator Cover
08. Straight Fittings
09. Scavenger Tubes
10. Insert
WARNING
!
work.
CAUTION
!
High pressure hydraulic or air systems can spray with extreme force and noise causing
severe injury. Shut down system and slowly release pressure or vent circuits before
loosening fittings or connections. Wear appropriate face, ear, and body protective
devices while venting air or hydraulic systems.
2. Vent any residual air pressure from the T-Tank. The T-Tank will vent through the main air system muffler when
the main air compressor is not running and the controls are de-energized.
3. Thoroughly clean the air-oil separator flange and fittings to remove any dirt that could fall into the T-Tank when
the separator cover and other fittings are opened.
4. Tag and remove the hose assembly on top of the oil separator cover that connects to the scavenger tubes.
Technician Tip
It is not necessary to remove the fittings or interconnecting tubing from the oil separator cover.
5. Tag and remove the upstream pressure tap hose assembly on top of the oil separator cover.
6. Remove hose from the safety relief valve.
CAUTION
!
Lifting heavy components with inadequate hoisting apparatus can injure personnel and/
or damage equipment. Use suitable slings and hoisting equipment to stabilize and lift
heavy objects.
7. Attach suitable hoisting equipment to the main air pipe assembly, and carefully take up the slack.
8. Remove nuts, lockwashers, and capscrews that attach main air pipe flange to the oil separator cover, and lift
the main air pipe assembly from the T-Tank.
9. Remove and discard gasket.
10. Attach a suitable hoist to oil separator cover, remove capscrews and lockwashers from the separator cover,
then lift the separator cover and attached inner separator element from the T-Tank. Lift the cover straight up
when removing it from the T-Tank to avoid damaging the separator element.
11. Remove outer separator element from the T-Tank. Discard the element in a suitable container, and cover the T-
Tank opening to prevent entry of dirt.
12. Remove capscrews, lockwashers, retainer, and inner separator element from oil separator cover. Discard the
element in a suitable container.
13. Clean away any deposits from inside the T-Tank and from the mounting surfaces of oil separator cover.
14. Inspect scavenger tubes for signs of deterioration or plugging. Replace as necessary.
15. Inspect the insert (Item 10, Figure 6-45) to be sure it is positioned correctly. The cut-out at the bottom must
face the front of the drill away from the 6" inlet pipe.
CAUTION
!
Staples on the element gaskets eliminate static electricity, which could cause the oil to
flash, resulting in personal injury and/or property damage. Do not remove the staples
from the element gaskets.
16. Inspect the element gasket to ensure that the staples are in place.
17. Install new inner separator element to oil separator cover assembly with retainer, capscrews, and lockwashers.
Position inner scavenger tube so that it rests on the bottom plate of the inner element.Install a new outer sepa-
rator element into the top of the T-Tank. Align the holes in the element cover with those of the T-Tank flange.
CAUTION
!
heavy objects.
18. Attach suitable lifting equipment to separator cover assembly, and position on top of outer element flange on
the T-Tank. Be sure outer scavenger tube is correctly positioned at the bottom of the outer element. Position
the holes in the separator cover to align with the holes in the outer element flange.
19. Install oil separator cover to the T-Tank flange with capscrews and lockwashers. Torque the capscrews evenly
in a crisscross pattern to uniformly compress the outer element flange.
20. Attach suitable lifting equipment to air inlet nozzle, and position the flange above the mating flange on top of
separator cover assembly.
21. Install main air pipe to separator cover assembly with capscrews, lockwashers, nuts, and a new gasket. Do not
tighten the nuts at this time.
22. Align the opposite end of air pipe with manifold and couple with union. Tighten the union securely, then uni-
formly tighten the nuts at the flange end of the air inlet nozzle.
23. Install the hose assembly to the scavenger tube fitting on top of oil separator cover.
24. Install the upstream pressure tap hose assembly on top of oil separator cover.
25. Check the level of compressor oil in the T-Tank, and fill as necessary.
26. Ensure the T-Tank shut-off valve is open and there are no leaks. Refer to Figure 6-46.
27. Start the main air system and check the T-Tank for leaks.
6.3.4.2 Oil Level Sight Tube R25778D1
The oil level sight-tube is installed on the side of the T-Tank. Replace the sight-tube assembly as follows:
WARNING
!
work.
CAUTION
!
Figure 6-46: T-Tank Shut-Off (Drain) Valve Positions
01
03
02
LEGEND
01. T-Tank
02. Closed Position
03. Open Position
CAUTION
Be sure to thoroughly clean the areas around the tank drain cock and the oil level sight-
tube before draining down the T-Tank. Close clearances between running components in
the compressor will not survive abrasive dirt in the oil.
3. Drain the oil in the reservoir so that the level of the remaining oil is below the lowest part of the sight tube
assembly. Drain the oil into a suitable, clean container so that the oil can be salvaged and re-used.
4. Loosen the compression nuts on the top and bottom 90 degree tube fittings, then bend the plastic sight-tube
enough to remove the tube from the compression fittings.
5. Coat the male pipe threads on the fittings with pipe thread sealant before installation.
6. Position compression nuts and new ferrules on each end of the replacement sight tube, and insert the tube
ends into the 90 degree tube fittings. Use care when bending the tube for insertion that the tube does not
become creased.
7. Tighten the compression nuts to seal and retain the tube.
8. Fill the reservoir with compressor oil to the correct level for operation.
6.3.5 Circulation Pump R56963D1
The circulation pump is used to ensure a flow of oil through the main air compressor during start-up, as well as
when the compressor is running and the bit air flow is turned off. The pump system is connected in the compressor
oil circulation circuit. In addition to the low pressure pump and electric motor, the system includes a pressure relief
which is an integral part of the pump assembly.
The circulation pump is mounted on the left hand platform between the T-Tank and the machinery house wall.
6.3.5.1 Removal
Remove the pump from the oil circulation circuit as follows:
WARNING
!
tenance work on a machine without first disabling the operators controls. Lock out and
tag the operators control to prevent inadvertent machine start-up during maintenance
work.
1. Lock out and tag the operator controls to prevent inadvertent machine start-up during pump removal.
CAUTION
!
loosening fittings or connections. Wear appropriate face, ear and body protective
3. Close the shutoff valve, located in the oil discharge piping below the T-Tank.
4. Clean all dirt from the area around the pump and hoses.
5. Tag and disconnect the suction and pressure hoses from the circulation pump. Cap or plug the hose fittings
and pump ports to prevent the entry of contaminants.
6. Remove wires from the motor junction box.
7. Remove the four capscrews and lockwashers from the pump feet and use a suitable lifting device to remove
the pump.
8. Tag and remove the hose adapters and pipe fittings from the pump ports.
6.3.5.2 Cleaning, Inspection And Repair
Clean and inspect the oil circulation pump in accordance with the general cleaning and inspection procedures
described in Appendix A of this manual.
Inspect the pump for wear, housing cracks and leaks. If any leaks or cracks are found, replace the pump; it is not
field repairable.
Install the oil circulation pump as follows:
1. Coat the male pipe threads with pipe thread sealant and install the pipe fittings and hose adapters in the suc-
tion and pressure ports of the pump. Position the fittings for ease of connection to the hoses.
2. Install the pump assembly with four capscrews and lockwashers.
3. Connect the suction and pressure hoses to the pump fittings.
4. Connect wires.
5. Open the shut-off valve located in the oil discharge piping below the T-Tank.
6. Check the oil level in the T-Tank. Add oil as necessary.
7. Operate the system and check for leaks. Also check pump rotation (the pump must turn clockwise when
viewed from the motor fan). The circulation pump is non-adjustable.
6.3.6 Compressor Oil Cooler R56568D1
6.3.6.1 Removal
Remove the compressor oil cooler from the system as follows (refer to Figure 6-47):
WARNING
!
work.
1. Lock out and tag the operator controls to prevent inadvertent start-up of the hydraulic systems and air systems
during maintenance activities.
CAUTION
!
3. Turn the shut-off valve located at the bottom of the T-Tank to closed position
Figure 6-47: Compressor Oil Cooler
Technician Tip
.Detach the cable reel support bar and lower the reel to provide some working room.
CAUTION
!
sonnel and/or damage equipment. Use suitable slings and hoisting equipment to stabi-
4. Attach suitable hoisting equipment to the cooling air louver and take up the slack in the slings.
5. Tag and disconnect the hose assemblies from the hydraulic oil cooler assembly. Collect any fluid that leaks
from the hoses and fittings in a suitable container. Cap or plug the open end of the hose and the cooler ports to
prevent entry of dirt.
6. Loosen and remove the pipe cap on top of the compressor oil cooler assembly.
7. Loosen and remove the drain plug at the bottom of the compressor oil cooler, and drain all of the oil into a suit-
able container for disposal.
8. Tag and disconnect the hose assemblies from the compressor oil cooler assembly. Collect any fluid that leaks
from the hoses and fittings in a suitable container. Cap or plug the open end of the hose and the cooler ports to
prevent entry of dirt.
CAUTION
!
heavy objects.
9. Attach a suitable hoist to the cooler to provide support while the fasteners are removed.
10. Remove the capscrews, washers, and nuts which fasten the cooler to the shroud assembly, then lift the cooler
away from the shroud.
11. Disassemble the hose fittings from the cooler.
Clean and inspect the compressor oil cooler in accordance with the general cleaning and inspection procedures
described in Appendix A of this manual. Inspect the cooler for cracks, leaks, and/or damaged fins. The cooler
assembly is not field repairable, and therefore must be replaced with a new or reconditioned cooler if it is damaged
or leaking.
Install the compressor oil cooler as follows:
1. Apply pipe thread sealant to the pipe threads of the hose adapters, and install the adapters in the inlet and out-
let ports of the cooler. Tighten the adapters so the hose connection ends will couple easily with the hoses when
the cooler is installed.
CAUTION
!
or damage equipment. Use suitable rigging and hoisting equipment to stabilize and lift
heavy objects.
2. Attach a suitable hoist to the compressor oil cooler assembly, and lift the cooler to its mounting position. Leave
the hoist in place until the fasteners have been installed.
3. Install the compressor oil cooler to the cooler shroud with capscrews, washers, and nuts. Torque the nuts
securely.
4. Install the inlet and outlet oil hoses to the bottom of the cooler.
5. Be sure the drain plug at the bottom of the cooler is sealed and tightened.
CAUTION
!
heavy objects.
6. Attach suitable hoisting equipment to the cooling air louver and install the louver on the oil cooler shroud with
capscrews, lockwasher and nuts.
7. Add compressor oil to the T-Tank reservoir as necessary to replace the oil lost during cooler replacement.
8. Return the cable reel to its operating position (if it was lowered) and secure.
9. Confirm that the T-Tank shut-off valve is in the open position.
6.3.7 Thermostatic Mixing Valve R38039D2
The thermal mixing valve is used to control temperature of the compressor oil in the oil cooling system. The ele-
ments are so designed that a portion of the oil is flowing through the oil cooler at all times. On start-up with the unit
cold, the elements are open to the by-pass, allowing oil to pass directly from the T-Tank to the compressor during
warm-up. As the oil warms, the elements gradually close the bypass flow, causing more oil to flow through the
cooler. After the main air system is at normal operating temperature, the mixing valve maintains compressor dis-
charge temperature.
Figure 6-48: Themostatic Mixing Valve
LEGEND
01. O-ring
02. Capscrew
03. Lock Washer
04. Sleeve
05. Bolt-in Seat
06. Flange Gasket
07. Element
6.3.7.1 Removal
Refer to Figure 6-49 and remove the thermal mixing valve from the oil cooling circuit as follows):
WARNING
!
work.
Figure 6-49: Thermostatic Mixing Valve Piping
CAUTION
!
3. Match mark the three flanges that mate with the flanges on the thermal mixing valve for subsequent assembly.
4. Close the shut-off valve at the bottom of the T-Tank to prevent oil drainage from the tank while the system is
open.
5. Slowly loosen and remove the capscrews, lockwashers, and nuts from the mixing valve flanges. Separate the
flanges, then remove and discard the flange gaskets. Collect any oil leaking from the open flanges in a suitable
container for disposal.
6. Plug the open fittings to prevent entry of dirt.
7. Lift the thermal mixing valve out of the valve support.
6.3.7.2 Disassembly
Refer to Figure 6-50 and disassemble the thermostatic mixing valve as follows:
1. Remove the four capscrews that retain the housing cover to the valve housing, then remove the cover and hous-
ing gasket. Discard the used gasket.
Figure 6-50: Thermostatic Mixing Valve Components
2. Remove the two thermostatic elements with the element O-rings and O-ring sleeves.
6.3.7.3 Cleaning, Inspection, And Repair
Clean and inspect the compressor oil cooler in accordance with the general cleaning and inspection procedures
described in Appendix A of this manual. Check the elements for correct operation by heating them in oil. They
should be fully open at 10F above their rating.
None of the thermal mixing valve components are repairable. See the LinkOne electronic parts manual for compo-
nent identification. Provide the following new components for assembly:
Two thermostatic elements.
Two element O-rings.
Two O-ring sleeves.
One housing O-ring.
6.3.7.4 Assembly
Refer to Figure 6-50 and assemble the thermostatic mixing valve as follows:
1. Install the two sets of O-rings and O-ring sleeves on the two thermostatic elements.
2. Install the elements in the valve housing. Make sure that the elements are correctly seated.
3. Position the new housing O-ring on the cover flange, then install the housing cover with four capscrews.
Torque the capscrews evenly to obtain uniform compression of the gasket.
Install the thermostatic mixing valve in the cooler circuit as follows:
1. Position the thermal mixing valve in the valve support bracket. Be sure to match the flange locations with the
assembly match marks on the mating pipe flanges.
2. Install new flange gaskets, and install the three pipe flanges to the thermal mixing valve with capscrews, lock-
washers, and nuts. Torque the capscrews evenly to obtain uniform compression of the gaskets.
3. Open the shut-off valve at the bottom of the T-Tank.
4. Add oil to the T-Tank to make up for the oil lost during disassembly.
6.3.8 Compressor Oil Filter, R51071F1
The main compressor oil filter is located to the right of the main air compressor. It has several indicators to help
determine when the filter needs to be changed.
For element changes based on time, refer to Section 17, Preventive Maintenance.
Refer to Figure 6-52. Change the element in the main compressor oil filter when the filter indicator indicates
in the CHANGE FILTER area.
A pressure differential valve on the Main Air Control Panel allows monitoring of the condition of the filter ele-
ment. Change the filter if the pressure differential exceeds 8 psi.
The GUI will register a fault if the filter element needs to be changed.
Figure 6-51: Main Air Compressor Oil Filter
Figure 6-52: Main Compressor Oil Filter Indicator
LEGEND
01. Air Compressor Oil Filter

C
H
A
N
G
E
F
I
L
T
E
R

C
H
A
N
G
E
F
I
L
T
E
R
BD0558a01
Normal Operation Change Filter condition
The element should be changed when indicated by any of the above monitoring systems. To change the main com-
pressor oil filter element, refer to Figure 6-53 and proceed as follows:
WARNING
!
Inadvertent machine movement can cause injury or death. Do not perform maintenance
work on a machine without first disabling the operator controls. Lock out and tag the
operator controls to prevent inadvertent machine operation while performing manual
lubrication tasks.
Figure 6-53: Changing Main Compressor Oil Filter
LEGEND
01. Visual Indicator
02. Seal Kit
03. Bleed Valve
04. Nut Kit
05. Nut Retainer Kit
06. Electric Indicator
07. Sending Unit
08. Fill Plug and O-ring
09. Head O-ring
10. Baffle
11. Cup Seal
12. Bypass Valve
13. Bypass Indicator O-ring
14. Filter Element
15. Bypass Spring
16. Drain Plug
1. Lock out and tag out the operators controls to prevent inadvertent drill operation.
2. If the filter indicator is in the red CHANGE FILTER position or if it has been more than 160 hours of operation
since the last filter element change, change the element as follows:
CAUTION
!
Pressurized oil will spray with extreme force from the compressor main oil filter when
being loosened, and can cause severe injury. Slowly release air pressure or vent the T-
Tank before loosening the filter canister. Wear appropriate face, ear, and body protective
devices while opening the canister.
A. Vent any residual air from the T-tank.
B. Remove the drain plug and drain the oil into a pail.
CAUTION
Do not remove the filter element from the housing until all the oil has drained to prevent
unfiltered oil from contaminating the filtered compressor oil
C. Remove filter head by rotating handle counterclockwise until the head is free of housing. Carefully place the
filter head to the side to avoid damaging the sensor.
D. Hold baffle down and push down on indicator assembly to be sure it moves freely up and down within the
baffle.
E. Remove baffle and check the bore for nicks. Smooth the bore if necessary and replace seal if it is damaged.
F. Remove element from housing. Remove indicator assembly from the element using a screwdriver between
the indicator assembly and the element cap and carefully prying downward. Inspect O-ring and replace it
with a new, oiled O-ring if necessary.
G. Remove O-ring from head and replace it if necessary. Clean the O-ring area of the head, lubricate a new O-
ring with oil and reinstall the O-ring in the head.
H. Install indicator assembly into new element. Place the element into housing being sure the large diameter of
spring contacts the new element. Install baffle.
I. Place head on housing and turn handle clockwise until it is hand tight. Do not exceed 20 ft-lb (26 Nm).
J. If leakage appears around handle, remove snap ring and remove the handle from the head. Discard O-ring.
Coat a new O-ring with oil and reassemble the unit with the new O-ring.
To ensure unrestricted flow of oil to the main compressor, the oil filter assembly must be serviced at regular inter-
vals. To determine when the filter media needs replacing, an indicator has been built into the body of the main com-
pressor oil filter assembly. Change the filter before the indicator reads CHANGE FILTER.
The main compressor oil filter is flange mounted to the oil return port on the main compressor. Check this indicator
once each week or every 40 hours of operation.
The element must be replaced when the top of the indicator on the filter is in the red Change Filter half of the win-
dow (refer to Figure 6-52). The compressor must be running and the oil at operating temperature for the indicator
to read accurately. Check the indicator with a bright light to be certain of the indicator position. Some lubricants will
obscure the indicator.
If the filter indicator is in the red Change Filter zone, or if there are filter faults on the GUI, the filter element must
be replaced.
6.3.9 Subtractive Pilot Valve, 36Q577D1
6.3.9.1 Description
The subtractive pilot is a spring-loaded diaphragm pressure regulator, which is used to control operation of the
compressor inlet valve, after the compressor has achieved normal operating rpm (refer to Figure 6-54). The dia-
phragm cavity receives pressure from the oil separator. At the pilot setting, the diaphragm begins to unseat (open)
a poppet to admit pressure to the compressor inlet unloading valve piston. This pressure begins to stroke the pis-
ton that closes the inlet valve, thereby restricting the inlet and partially unloading the compressor.
As pressure in the oil separator rises, the subtractive pilot admits higher pressure to the unloader piston to further
restrict the inlet, until the inlet is fully closed at the subtractive pilot valve's highest setting.
6.3.9.2 Adjustment
In order to obtain full compressor capacity at the maximum operating pressure, the subtractive pilot valve (refer to
Figure 6-54) should be set to unload with the inlet valve fully closed at approximately 10 psig (0.7 bar) above the
maximum operating pressure. Adjustment is accomplished by loosening the pressure screw locknut, then turning
the screw in or out to achieve the desired pressure setting. The farther the pressure screw is turned clockwise, the
higher the set pressure will be. After the desired setting has been achieved, tighten the pressure screw locknut
securely.
Figure 6-54: Subtractive Pilot Valve
01
02
03
04
01
05
06
07
08
09
10
11
12
13
14
15
16
LEGEND
01. Pressure Adjustment Screw
02. Locknut
03. Spring Button
04. Pressure Spring
05. Damper
06. Diaphragm Stop
07. Diaphragm
08. Disc Seat
09. Vale Body
10. Ring Seat
11. Gasket
12. Gasket
13. Pressure Plate
14. Lock Washer
15. Pressure Plate Nut
16. Valve Cover
6.3.9.3 Removal
Remove the subtractive pilot valve from the system as follows:
CAUTION
!
Compressed air will exit from air line fittings with extreme force when being loosened,
and can cause severe injury. Slowly release air pressure or vent the T-Tank before loos-
ening any air line fittings. Wear appropriate face, ear, and body protective devices while
opening pressurized systems.
the main air compressor is not running and all controls are in the OFF position.
2. The subtractive pilot valve is located on the main air system control panel. To remove the valve from the sys-
tem, remove the inlet and outlet pipe fittings from the body of the valve.
6.3.9.4 Disassembly
Technician Tip
In determining whether to rebuild or replace the subtractive pilot valve, consider that a simple
repair error could result in significant system malfunctions. It may be more economical to dis-
card the faulty subtractive pilot valve and replace it with a new one.
Disassemble the subtractive pilot valve as follows (refer to Figure 6-54 for identification and location of compo-
nents):
1. Loosen the locknut and pressure screw to remove spring pressure from the diaphragm and valve cover.
2. Clamp the valve body in soft jaws in a vise, and unscrew the valve cover, and remove it from the valve body.
3. Remove the spring button, pressure spring, and damper from the assembly.
4. Lift the diaphragm stop out of the valve body.
5. Remove the pressure plate nut and lockwasher from the seat disc stem, then remove the pressure plate, dia-
phragm, diaphragm gasket, and the seat gasket from the seat disc.
6. Lift the seat ring out of the valve body.
6.3.9.5 Repair
None of the components from the subtractive pilot valve are repairable. Replace all defective parts. It is necessary
to replace some components in groups to ensure satisfactory repair. When replacing the diaphragm, also replace
both diaphragm and seat gaskets. When replacing the seat disc at seat ring, also replace the mating seat ring of
disc and the seat disc gasket.
6.3.9.6 Assembly
Assemble the subtractive pilot valve as follows (refer to Figure 6-54 for component identification and location):
1. Install the seat ring in the counterbore in the valve body.
2. Assemble the diaphragm assembly by installing the following components over the stem of the seat disc in this
order: seat gasket; diaphragm gasket, diaphragm, and pressure plate; then install and tighten the lock washer
and pressure plate nut.
3. Install the diaphragm assembly in the valve body so that the seat disc mates with the seat ring.
4. Install the diaphragm stop in the valve body with the flange seated on top of the diaphragm.
5. Insert the damper inside of the pressure spring, then install the pressure spring and damper on top of the dia-
phragm assembly.
6. Position the spring button on top of the pressure spring with the pilot diameter inside the top coil of the spring.
7. Make sure that the pressure screw is only minimally engaged in the valve cover, then screw the cover on to the
valve body and tighten securely.
Install the subtractive pilot valve in the main air system as follows:
1. Spread a thin film of pipe compound on the male pipe threads of the connecting fittings, and install them
securely into the body of the valve.
2. Check the adjoining fittings and clamps to confirm that they are connected securely.
3. Adjust the pressure setting of the subtractive pilot valve in accordance with the procedure described in Sub-
topic 6.3.9.2.
6.3.9.8 Pilot Pressure Gauge
The pilot pressure gauge registers pressure from the subtractive pilot to the compressor inlet unloader piston. The
gauge is installed in the air line between the subtractive pilot valve and the inlet valve assembly. The gauge pres-
sure reading varies with pressure in the T-Tank, from a range of 0 psi to 21 psi.
The pilot pressure gauge is not repairable and must be replaced if it fails.
NOTICE
The gauge is installed into a " pipe fitting. Wrap the male pipe threads with Teflon pipe thread
tape before installation into the pipe fitting.
6.3.10 Main Air Control Panel
Figure 6-55: Main Air Control Panel
CIPS MAPS
SUB PILOT
VALVE OPENS
AT 58 PSI
TANK FILTER
COMP. FILTER
COPS
BAPT
BACS
01
02
03
04
05
06 07
08
09
10 11 12
A
B
C
E
D
G
F
H
MAPT
BD0509a01
LEGEND
01. Bit Air Pressure Transducer
02. Check Valve*
03. Bit Air Control Solenoid*
04. Main Air Pressure Transducer
05. Electrical Panel
07. Main Air Pressure Switch
09. T-Tank Oil Separator Pressure
Differential Manual Switch
10. Scavenger Oil Filter
11. Compressor Oil Filter Differential
Manual Switch
(COPS)
PIPING LEGEND
A. From Bit Air
B. To Air Pilot Valve
C. From Compressor Filter (inlet side)
D. From Compressor Filter (outlet side)
E. From Separator (outlet side)
F. From Separator (inlet side)
G. From T Tank
H. To Compressor
* The check valve and the bit air control solenoid are for drills with pneumatic but-
terfly valves. They are not used on drills with electrically-operated butterfly valves.
The main air control panel is mounted inside the machinery house, at the left side of the main air compressor. This
panel contains many of the control components required for operation and control of the main air compressor. It
also supports the transducer for bit air pressure control. Figure 6-55 identifies the specific components mounted on
the panel.
The individual control components can be serviced without need to remove the entire panel from its location.
6.3.11 Bit Air Pressure Transducer (BAPT), 44Q1536
6.3.11.1 Removal
The bit air pressure transducer can be removed from the panel without disconnecting any other components.
Remove the pressure transducer as follows:
WARNING
!
work.
CAUTION
!
3. Tag and disconnect the signal wiring from pressure transducer.
4. Turn the pressure transducer in a counter-clockwise direction to remove it from the pipe fitting.
Clean and inspect the transducer in accordance with the general cleaning and inspection procedures described in
Appendix A of this manual. Check the transducer for correct operation by pressure testing on a test bench, if avail-
able. The pressure transducer is not field repairable. See the LinkOne electronic parts manual for component iden-
tification.
Install the pressure transducer on the panel as follows:
1. Apply pipe thread sealant to the male pipe threads, and install the transducer on the pipe fitting. Tighten
securely to prevent leakage and loosening by vibration.
2. Install the signal wiring on top of pressure transducer.
3. Operate the main air system to test the repair.
6.3.12 Compressor Oil Pressure Switch (COPS), 79Z5680
6.3.12.1 Removal And Disassembly
Remove and disassemble the low-oil pressure switch as follows:
WARNING
!
work.
CAUTION
!
3. Tag and disconnect the pressure tubing from the pressure switch assembly.
4. Tag and disconnect the signal wiring from the low-oil pressure switch.
5. Remove the mounting capscrews from the pressure switch, and remove the pressure switch assembly from
the panel.
6. Remove the elbow tube fitting from the pressure port of the switch.
6.3.12.2 Cleaning, Inspection, And Repair.
Clean and inspect the pressure switch in accordance with the general cleaning and inspection procedures
described in Appendix A of this manual. Check the switch for correct operation by pressure testing on a test bench,
if available. The pressure switch should be set to open at 8 psi (0.55 bar) and to close at 15 psi (1.0 bar). The pres-
sure switch is not field repairable. See the LinkOne electronic parts manual for component identification.
6.3.12.3 Assembly And Installation
Assemble and install the low-oil pressure switch assembly as follows:
1. Coat the male pipe threads of the tubing elbow fitting with pipe thread sealant, and install in the pressure
switch. Position the fitting as shown on Figure 6-55.
2. Position the pressure switch on the panel, and install with the mounting capscrews.
3. Connect the pressure tubing connector to the elbow fitting.
4. Install the signal wiring in the terminal box of the pressure switch.
6.3.13 Main Air Pressure Transducer (MAPT) 44Q1536
6.3.13.1 Removal
The main air pressure transducer can be removed from the panel without disconnecting any other components.
Remove the pressure transducer as follows:
WARNING
!
work.
CAUTION
!
3. Tag and disconnect the signal wiring from pressure transducer.
4. Turn the pressure transducer in a counter-clockwise direction to remove it from the pipe fitting.
Clean and inspect the transducer in accordance with the general cleaning and inspection procedures described in
Appendix A of this manual. Check the transducer for correct operation by pressure testing on a test bench, if avail-
able. The pressure transducer is not field repairable. See the LinkOne electronic parts manual for component iden-
tification.
Install the pressure transducer on the panel as follows:
1. Apply pipe thread sealant to the male pipe threads, and install the transducer on the pipe fitting. Tighten
securely to prevent leakage and loosening by vibration.
2. Install the signal wiring on top of pressure transducer.
6.3.14 Scavenger Oil Return Filter GH5000348
6.3.14.1 Removal
The scavenger oil return filter assembly can be serviced for normal maintenance without removing the entire unit
from the air panel. Remove the filter unit assembly for replacement as follows (refer to Figure 6-55):
WARNING
!
work.
CAUTION
!
3. Spin the filter counterclockwise until the filter clears the stud threads. Discard the filter.
Coat the gasket on a new filter with a thin coat of oil. Spin the filter onto the stud threads clockwise until the gasket
contacts the housing. Rotate the filter another turn.
6.3.15 Air Pilot Valve R56220D1
The function of the air pilot valve is to vent air pressure from the main air line and T-Tank when the bit air flow is
turned off. When pilot air pressure is removed from the pilot air valve, the air pilot valve opens to discharge air from
the main air line into the muffler. The air pilot valve is mounted to a pipe nipple in the discharge air line between the
safety valve and the muffler.
6.3.15.1 Removal
Remove the air pilot valve as follows:
WARNING
!
work.
CAUTION
!
3. Tag and disconnect the pilot air and main air pressure hoses from the air pilot valve, and remove the hose
adapters.
4. Remove the air pilot valve from the pipe nipple on which it is mounted.
Clean and inspect the air pilot valve in accordance with the general cleaning and inspection procedures described
in Appendix A of this manual. The valve unit is not field repairable. See the LinkOne electronic parts manual for
component identification.
Install the air pilot valve as follows:
1. Apply pipe thread sealant to the male pipe nipple, and install the air pilot valve on the nipple. If a directional
arrow is indicated on the valve body, the flow should be in the direction toward the muffler.
2. Install the pilot pressure and main air pressure hoses and adapters as previously tagged.
3. Start the main air system, and test the function of the air pilot valve.
6.3.16 Pressure Relief Valve R12262D4
The main air system pressure relief valve is factory adjusted to open if the pressure in the main air line exceeds
130 psi (9.0 bar). The valve is mounted in a coupling in the main air line near the T-Tank.
6.3.16.1 Removal
Remove the pressure relief valve as follows:
WARNING
!
work.
CAUTION
!
3. Tag and disconnect the pilot air valve discharge hose from the pressure relief valve discharge piping.
4. Loosen the two upper hose clamps, and disconnect the air discharge hose from the pressure relief valve dis-
charge pipe fittings.
5. Remove the pipe fittings, as a unit, from the discharge of the pressure relief valve.
6. Remove the pressure relief valve from the main air line.
Clean and inspect the pressure relief valve in accordance with the general cleaning and inspection procedures
described in Appendix A of this manual. This valve is not field repairable. See the LinkOne electronic parts manual
for component identification.
Install the pressure relief valve as follows:
1. Apply pipe thread sealant to the male pipe threads on the pressure relief valve, and install the valve on the
main air line. Align the valve discharge to match the position of the air discharge hose leading to the muffler.
2. Apply pipe thread sealant to the male pipe threads on the pipe fittings for the discharge port of the pressure
relief valve, and install the fittings.
3. Install the pressure relief valve discharge hose with two hose clamps.
4. Apply pipe thread sealant to the male pipe threads, and connect the pilot air valve discharge hose to the pres-
sure relief valve discharge piping.
5. Start the main air system, and check for air pressure leaks.
6.3.17 Butterfly Valve R51305D1
The butterfly valve is used to start and stop the flow of air to the drilling bit. It is a 4-inch flange-mounted valve,
located immediately downstream of the pressure relief valve in the main air line. The butterfly valve is operated by
an electric actuator, which controls the timing and the extent of opening and closing. There is also a manual over-
ride in the event the actuator were to become inoperable.
6.3.17.1 Removal
Remove the butterfly valve from the main air piping as follows:
Figure 6-56: Butterfly Valve Electric Actuator and Valve Assembly
BD0570a01
Electric Actuator
Air Valve Assembly
WARNING
!
work.
CAUTION
!
3. Tag and disconnect the electrical connections from the butterfly valve.
CAUTION
!
heavy objects.
4. Attach a suitable hoist to the butterfly valve, and remove all slack from the sling or cables.
5. Remove the capscrews, lockwashers, and nuts that hold the pipe flanges and valve body together, then
remove the butterfly valve and gaskets from the main air piping. Discard the used gaskets.
NOTICE
It may be necessary to spread the pipe flanges slightly to remove the valve assembly.
Clean and inspect the butterfly valve and the main air pipe flanges in accordance with the general cleaning and
inspection procedures described in Appendix A of this manual.
Repair is limited to the replacement of worn or damaged parts. Before repairing the valve for the first time, contact
your local P&H MinePro Services representative for tool kit R51305D4. Refer to Figure 6-57.

Install the butterfly valve assembly as follows:
Figure 6-57: Butterfly Valve Components
LEGEND
01. Hex Head Capscrew
02. Hex nut
03. Retainer Plate
04. Socket Head Capscrew
05. Liner
06. Seat
07. Inboard O-ring
08. Outboard O-ring
09. Top Gland
10. Spring
11. Spacer
12. Bearing
13. Stem Wedge Ring
14. Stem Compression Ring
15. Bottom Gland
CAUTION
!
heavy objects.
1. Attach a suitable hoist to the butterfly valve, and lift the valve into position between the main air line pipe
flanges.
2. Install two new gaskets between the valve body and the pipe flange faces, then install the mounting cap-
screws, lockwashers, and nuts through the pipe flanges. Torque the capscrews uniformly using a crisscross
tightening pattern.
3. Install the electrical wiring on the butterfly valve as tagged.
4. Start the main air system, check for air leaks, and test the operation of the butterfly valve.
6.3.18 Muffler 27Q762D1
The muffler is mounted on the left-hand catwalk, just behind the T-Tank. It is mounted vertically on a back brace.
The muffler is not field repairable. If it becomes unserviceable, it must be replaced.
6.3.19 Dump Valve GH5000369
This is a normally open, pressurize to close check valve. When pressure from the main air system acts on the
valve, the valve closes. When the pressure is removed, the valve opens to allow air to exhaust without going
through the drill string.
6.4 Troubleshooting
Table 6-3 identifies some potential compressor system problems and lists probable causes to be corrected:
Unit starts but then stops
after short run
High discharge air tempera-
ture
Check for low compressor oil level
Check for clogged oil cooler or oil filter
Check themostatic mixing valve for proper
operation
Remove dirt from oil cooler
Check ventilation of unit and/or oil cooler
Check that the optional inlet and exhaust cold
weather dampers are operating properly.
Oil Flow Switch malfunction Replace oil flow switch
Oil Pressure too low Determine cause and take corrective action
Excessive oil consumption
Oil carry-over through
discharge
Check for over filling of the T-Tank
Check for clogged, broken or loose oil return
lines
Check for ruptured separator element
Check for loose assembly
Check for incorrect oil, causing foam.
Oil leaks at fittings
and gaskets
Tighten fittings or replace gaskets
Compressor low on
delivery and pressure
Clogged air filter Clean or replace air filter
Restricted inlet valve Clean or replace air valve
Broken inlet valve spring Replace spring
Binding inlet valve piston Replace inlet valve piston
Turn valve and/or inlet valve
pilot adjustment and/or
malfunction
Adjust or replace turn valve and/or inlet pilot
valve
Compressor will not start on
low torque start-up mode
No compressor oil flow or
pressure detected
Check compressor oil flow switch (COFS)
Check for clogged oil filter or cooler
Check for inoperative oil circulation pump
Check for faulty compressor oil pressure switch
(COPS)
CIPS set too high Correct setting on CIPS
Compressor shuts down with
bit air flow turned on or off
No compressor oil flow
detected
Check compressor oil flow switch (COFS)
Check for inoperative oil circulation pump
Table 6-3: Troubleshooting Guide
BD120149 Mechanical Systems Manual Low Pressure Hydraulic System
Sec07LowPress.fm -7.1- Section 7, Version 00 - 03/06
Section 7
Low Pressure Hydraulic System
7.1 General
The low pressure hydraulic system consists of an electric-motor-driven pumping unit (refer to Figure 7-1), which
supplies hydraulic flow to valves on the low pressure hydraulic stand and the lube pump in the lubrication room.
The low pressure hydraulic valves (refer to Figure 7-2) direct flow to the boarding ladder and cab roof hatch cylin-
ders. Other valves present on the valve block are not connected and are considered spares.
Figure 7-1: Low Pressure Motor/Pump Assemblies
Figure 7-2: Low Pressure Hydraulic Valve Bank (Valve Bank 4)
LEGEND
01. Hoist Brake
motor and pump
02. Low Pressure
Hydraulics motor
and pump
Low Pressure Hydraulic System BD120149 Mechanical Systems Manual
Section 7, Version 00 - 03/06 -7.2- Sec07LowPress.fm
The pump-motor assembly is mounted inside the machinery house, forward and to the left of the main hydraulic
pumps. The hydraulic valves are mounted on a valve stand in the lubrication room on the front right area of the drill
frame.
Figure 7-3: Low Pressure Hydraulic Valve Stand
BD0723a01
02
01
03
04
LEGEND
01. Low Pressure Hydraulic Valve Stand
02. Low Pressure Hydraulic Valve Bank (Valve Bank 4)
03. Pilot Control Valve Bank (Valve Bank 5)
04. Hydraulic Tank
7.2.1 General
The pump and motor are mounted in a stand to the left of the main hydraulic system pumps. The pump and motor
share the stand with a pump and motor that are used for the hoist brake system (the hoist brake system is dis-
cussed at the back of this section). The following subsections will discuss each circuit of the low pressure hydraulic
system.
Figure 7-4: Low Pressure Hydraulic Circuit Overview
BD0519a01
6
7.2.2 Intake and Delivery
The low pressure hydraulic system motor becomes energized when the drill main motor starts. For diagnostic and
maintenance purposes, it also becomes energized when there is power on the drill and the DC SYSTEM switch
(Figure 7-6) on the operators console is switched to the ON position.
This system shares the same hydraulic reservoir as the main and auxiliary hydraulic systems. Hydraulic oil is
drawn from the tank through a the Handwell valve suction filter. The system features a pump-motor package with a
460V electric motor driving a positive displacement hydraulic pump. A check valve internal to the 5-station manifold
prevents back-flow of oil through the pump when the unit is not operating. An adjustable pressure relief valve,
Figure 7-5: Intake and Delivery
Figure 7-6: DC Systems Switch
BD0519a01
located immediately downstream of the check valve, establishes the maximum output pressure from the hydraulic
pump.
7.2.3 Cab Roof Hatch Circuit
The cab roof hatch circuit actuates a pair of single-acting hydraulic cylinders to open the roof hatch. Each cylinder
is equipped with a breather plug on the vented side of the piston to keep the inside (rod end) of the cylinders clean.
A solenoid-operated directional valve is used to control the pressurized oil flow for hatch opening, to hold the hatch
in its open position, and to allow the hatch to close by gravity. The configuration of the directional valve also
enables the roof hatch to be manually opened. A pressure relief valve located downstream of the directional valve
limits the force at which the roof hatch can be opened with hydraulic power. Set the pressure relief valve to 250 psi.
Figure 7-7: Cab Roof Hatch Circuit
BD0519d01
7.2.4 Boarding Ladder Circuit
The boarding ladder circuit actuates a single-acting hydraulic cylinder to raise the boarding ladder. The cylinder is
equipped with a breather plug on the vented side of the piston to keep the inside (rod end) of the cylinders clean. A
solenoid-operated directional valve is used to control the pressurized oil flow for raising the ladder, to hold the lad-
der in its raised position, and to allow the hatch to lower by gravity. The configuration of the directional valve also
enables the deck hatch to be manually lowered. A pressure relief valve located downstream of the directional valve
limits the force at which the ladder can be raised with hydraulic power. Set the pressure relief valve to 300 psi.
A limit switch senses when the ladder is fully raised. The drill cannot propel if the ladder is not fully raised.
Figure 7-8: Boarding Ladder Circuit
BD0519a01
7.2.5 Grease Pump Circuit
The grease pump is connected directly to the hydraulic pressure circuit with no intermediate control valves. An
internal grease pump supply solenoid (GPSS) energizes when the PLC initiates a lubrication cycle. With the GPSS
energized, oil flows through the grease pump supply valve, through a pressure reducing valve and to the grease
pump cycle solenoid (GPCS) valve. The GPCS energizes for one second, then de-energizes for one second, as
long as the GPSS is energized. This applies pressure alternately to the top and bottom of the pump piston, allow-
ing lubricant to be drawn from the reservoir and pushed out through the vent valve to the automatic lubrication sys-
tem components.
Figure 7-9: Grease Pump Circuit
BD0519a01
16
01
02 03
04 05
06
08
07
7.3 Low Pressure Hydraulic System Maintenance
7.3.1 Hydraulic Pump-Motor
Either of the hydraulic pump-motor packages can be removed and replaced using similar procedures, Replace a
hydraulic pump-motor assembly as follows:
WARNING
!
Inadvertent machine movement during service can cause serious injury, or death. Do not
perform maintenance work on a machine without first disabling the operator controls.
Lock out and tag the operator controls to prevent inadvertent machine startup during
maintenance work.
2. Tag and disconnect the wiring from the pump motor electrical junction box.
WARNING
!
Hot hydraulic oil can spray with extreme force and volume, causing injury or death. Use
3. Be sure that no pressure exists in any of the low pressure hydraulic system circuits.
Figure 7-10: Hydraulic Pump-Motor Package
CAUTION
Clean dirt from the pump-motor assembly and hydraulic hose fittings before loosening
any of the hydraulic components.
4. Turn the Handwell valve off (fully counterclockwise).
NOTICE
Failure to execute step 4 will enable oil to siphon from the hydraulic oil tank during removal of
the pump-motor assembly.
5. Tag and disconnect the pressure and suction hose assemblies and fittings from the pump. Cap and/or plug the
hose fittings and pump ports to prevent contamination of the hydraulic system.
6. Remove the capscrews and lockwashers from the pump-motor mounting feet, and remove the pump-motor
assembly from the low-pressure hydraulic system panel. The nuts are weld nuts and will remain attached
below the panel floor.
7. Clean dirt and oil from the pump mounting surface of the low pressure hydraulic panel. Follow the cleaning pro-
cedures in Appendix A.
8. Position the replacement pump-motor assembly on the low-pressure hydraulic panel, and install securely with
capscrews and lockwashers.
9. Attach SAE fittings. If SAE fittings are not used, coat the male pipe threads of the hose fittings with pipe thread
sealant, and install the fittings in the suction and pressure ports of the pump-motor assembly.
10. Install the suction and pressure hose assemblies.
11. Open the Handwell valve.
12. Connect the electrical wiring to the pump motor as tagged.
13. Jog the pump-motor until the system is fully primed, and bleed air from the low pressure hydraulic system, as
necessary.
7.3.2 Check Valve Cartridge
Check valves consist of a valve body that is drilled, tapped, and counterbored to accept a check valve cartridge,
the valve cartridge assembly, and the O-rings and back-up rings that seal the land areas of the valve cartridge.
Cartridge-type valve bodies need not be removed from the system to replace the cartridge assemblies.
Check valves should not be serviced, except for two conditions:
Valve Leakage. Remove the cartridge and replace the O-ring seals.
Valve Malfunction. Replace the cartridge as a unit.
Replace a cartridge-type check valve as follows:
WARNING
!
maintenance work.
WARNING
!
CAUTION
!
Clean dirt from the valve assembly and hydraulic hose fittings before loosening any of
3. Close the Handwell valve.
NOTICE
the check valve cartridge.
4. With a wrench, loosen and remove the check valve cartridge from the valve body. Be sure to use the wrench
flats provided for removal. Plug the hole in the valve body to prevent contamination of the hydraulic system.
5. Remove and discard the O-rings and back-up rings from the O-ring grooves on the outside diameter of the
valve cartridge.
6. Clean and inspect the valve assembly in accordance with the general procedures for cleaning and inspection
in Appendix A. The cartridge valves are not field repairable. Replace any faulty valve cartridges, and all O-rings
and back-up rings. Refer to the LinkOne electronic parts manual for cartridge and seal kit information.
7. Lightly lubricate the new O-rings and back-up rings for the cartridge valve, and install them in the grooves on
8. Carefully install the valve cartridge into its seat in the manifold. Avoid displacement or cutting of the O-ring
seals during installation. Torque the valve securely.
10. Jog the pump-motor until the system is fully primed. Bleed air from the low pressure hydraulic system, as nec-
essary.
7.3.3 Low Pressure Hydraulic System Valve Bank
7.3.3.1 Cab Roof Hatch Relief Valve
The cab roof hatch pressure relief valve is a cartridge-type valve assembly. Cartridge-type pressure relief valve
assemblies consist of a valve body that is drilled, tapped, and counterbored to accept a pressure relief valve car-
Figure 7-11: Low Pressure Hydraulic Valves
LEGEND
01. Pressure Relief Valve
02. Directional Control Valve
04. Flow Control Valve
05. Manifold
06. Test Port Connector
07. Check Valve
08. Pressure Reducing Valve
09. Flow Control Valve
10. Pilot Operated Check Valve
11. Directional Control Valve
tridge, the valve cartridge assembly, and the O-rings and back-up rings that seal the land areas of the valve car-
tridge. Cartridge-type valve bodies need not be removed from the system to replace the cartridge assemblies.
Replace the pressure relief valve cartridge as follows:
1. Lower the cab roof hatch to the closed position.
WARNING
!
maintenance work.
WARNING
!
fully loosening any connection or refitting.
4. Turn the Handwell valve off.
CAUTION
5. With a wrench, loosen and remove the pressure relief valve cartridge from the valve body. Be sure to use the
wrench flats provided for removal. Plug the hole in the valve body to prevent contamination of the hydraulic
system.
valve cartridge.
9. Carefully install the valve cartridge into its seat in the valve body. Avoid displacement or cutting of the O-ring
11. Operate the pump-motor and cab roof hatch circuit to fill the circuit with hydraulic oil. Bleed all trapped air from
the hatch operating cylinders.
7.3.3.2 Front Stairs Relief Valve
The front stairs pressure relief valve is a cartridge-type valve assembly. Cartridge-type pressure relief valve assem-
blies consist of a valve body that is drilled, tapped, and counterbored to accept a pressure relief valve cartridge, the
valve cartridge assembly, and the O-rings and back-up rings that seal the land areas of the valve cartridge. Car-
tridge-type valve bodies need not be removed from the system to replace the cartridge assemblies.
Replace the pressure relief valve cartridge as follows:
1. Lower the front stairs.
WARNING
!
maintenance work.
WARNING
!
fully loosening any connection or refitting.
CAUTION
5. With a wrench, loosen and remove the pressure relief valve cartridge from the valve body. Be sure to use the
system.
valve cartridge.
11. Operate the pump-motor and front stair operating circuit to fill the circuit with hydraulic oil. Bleed all trapped air
from the hatch operating cylinders.
7.3.3.3 Cab Roof Hatch Valve
The cab roof hatch directional control valve is a solenoid-operated, cartridge-type assembly. The valve assembly
consists of a valve body that is drilled, tapped, and counterbored to accept two directional valve cartridges, the
valve cartridge assemblies, and the O-rings and back-up rings that seal the land areas of the valve cartridges. Car-
tridge-type valve bodies do not need to be removed from the system to replace the cartridge assemblies. Replace
the directional valve cartridges as follows:
1. Lower the cab roof hatch to the closed position.
WARNING
!
maintenance work.
3. Tag and disconnect the electrical connectors from the valve solenoids.
4. Remove the solenoid retaining nut from the outer end of the solenoid, then remove the solenoid from the valve.
WARNING
!
NOTICE
Clean dirt from the valve assembly and hydraulic hose fittings before loosening any of the
7. With a wrench, loosen and remove the directional valve cartridge from the valve body. Be sure to use the
system.
valve cartridge.
12. Install the solenoid over the valve, and secure.
13. Connect the electrical connector to the solenoid as tagged.
15. Operate the pump-motor and cab roof hatch circuit to fill the circuit with hydraulic oil. Bleed all trapped air from
the hatch operating cylinders.
7.3.3.4 Front Stairs Valve
The front stairs directional control valve is a solenoid-operated, cartridge-type assembly. The valve assembly con-
sists of a valve body that is drilled, tapped, and counterbored to accept two directional valve cartridges, the valve
cartridge assemblies, and the O-rings and back-up rings that seal the land areas of the valve cartridges. Cartridge-
type valve bodies do not need to be removed from the system to replace the cartridge assemblies. Replace the
directional valve cartridges as follows:
1. Lower the front stairs.
WARNING
!
maintenance work.
3. Tag and disconnect the electrical connectors from the valve solenoids.
4. Remove the solenoid retaining nut from the outer end of the solenoid, then remove the solenoid from the valve.
WARNING
!
NOTICE
Clean dirt from the valve assembly and hydraulic hose fittings before loosening any of the
7. With a wrench, loosen and remove the directional valve cartridge from the valve body. Be sure to use the
system.
valve cartridge.
12. Install the solenoid over the valve, and secure.
13. Connect the electrical connector to the solenoid as tagged.
15. Operate the pump-motor and front stairs circuit to fill the circuit with hydraulic oil. Bleed all trapped air from the
hatch operating cylinders.
7.4 Hoist Brake Circuit
While the hoist brake circuit is considered a part of the low pressure hydraulic system, it uses a different pump than
the one used for the low pressure hydraulic valve stand in the lubrication room. The low pressure pump and motor
and the hoist brake pump and motor share the same low pressure hydraulic stand in the machinery house, but the
hoist brake circuit is a completely independent circuit.
The hoist brake circuit provides hydraulic pressure to release the brake on the carriage in the mast. It consists of a
solenoid-activated directional control valve with an integrated heater and check valve. The hoist brake valve sole-
noid is energized when the operator presses the BRAKE RELEASE button on the operators console.
There is no relief valve in the pump circuit. The pump is a pressure compensated pump that runs as long as the DC
System switch on the operators console is in the ON position. Because the flow is low, little heat is generated;
because the pump is always on, brake release is not delayed.
The associated pressure switch indicates to the PLC that there is sufficient hydraulic pressure present to cause the
release of the brake. Set the pressure switch to close at 900 psi.
Figure 7-12: Hoist Brake Circuit
BD120149 Mechanical Systems Manual Automatic Lubrication System
Sec08AutoLube.fm -8.1- Section 8, Version 00 - 03/06
Section 8
Automatic Lubrication System
8.1 General
The automatic lubrication system provides measured amounts of lubricant to specified lubrication points at prede-
termined intervals. The drill uses the Lincoln Automatic Lubrication System.
The lubrication tank, pumps and controls are located in a separate enclosure, called the lubrication room, on the
front right corner of the drill frame. Also in the lubrication room are the hydraulic tank, the hydraulic oil cooler, and
the low pressure hydraulic valve stand. The hydraulic grease pump is driven by the low pressure hydraulic pump in
the machinery house.
8.1.1 Automatic Lubrication System Components
8.1.1.1 Tank-mounted Components.
Figure 8-1: Automatic Lubrication System Componentsl
08
02 03 04
06 07
05
01
LEGEND
01. Grease Tank
02. Grease Pump Cycle Solenoid GPCS
03. Grease Pump Supply Solenoid GPSS
04. Pressure Gauge
05. Lubrication Pump
06. Vent Valve
07. Dipstick
08. Filler/Breather
Automatic Lubrication System BD120149 Mechanical Systems Manual
Section 8, Version 00 - 03/06 -8.2- Sec08AutoLube.fm
Refer to Figure 8-1. The grease tank (01) holds approximately 60 gallons of multipurpose grease (refer to Section
16, Lubrication for lubricant specifications). Lubricant level is checked using the dipstick (07) and filled through the
filler/Breather (07).
The lubrication pump (05) is driven by a low pressure motor/pump in the machinery house (the same pump that
supplies hydraulic fluid to the hoist brake. Refer to Section 7, Low Pressure Hydraulic System). Lubrication pump
operation is controlled by the grease pump supply solenoid (GPSS), which opens to provide hydraulic flow to the
pump when the PLC indicates that a lube cycle should begin. Intake and discharge are controlled by the grease
pump cycle solenoid (GPCS), which alternately causes the pump to move upward (to provide intake) for one sec-
ond and downward (to provide discharge) for one second for as long as GPSS is energized.
The vent valve (06) is normally open, providing a path for pressure in the system to return to tank. When a cycle
starts, pilot pressure from the GPSS closes the vent valve. When the cycle is complete and pilot pressure is
removed from the vent valve, system pressure causes the vent valve to open and pressure is vented back to tank.
8.1.2 Control Panel Components
Figure 8-2: Lubrication Control Panel
01 03 02 04 05 06
LEGEND
01. Grease Strainer
02. Gauge
03. Relief Valve
04. Grease Pressure Switch (GPS)
05. Upper Grease Solenoid (UGS)
06. Upper Grease Pressure Switch
(UGPS)
On the control panel (Figure 8-2), a strainer (01) filters contaminants from the grease before it goes to the injectors.
The gauge (02) provides visual indication of the pressure within the system. The system is protected by a 4000 psi
relief valve (03).
The grease pressure switch (GPS) (04) sends a signal to the PLC when the system reaches the pressure that indi-
cates that the cycle is finished.
The upper grease solenoid (UGS) (05) is normally closed. It opens when a lubrication cycle begins and the drill is
in one of the drilling modes (lower systems are greased in every cycle). The upper grease pressure switch (UGPS)
(06) sends a signal to the PLC when the system reaches the pressure that indicates that the upper has been lubri-
cated. The PLC will de-energize the UGS and the pump will continue to operate until the GPS closes.
The automatic lubrication system will be discussed in three sections:
Pump operation
Lube control
Lubrication points
Figure 8-3: Automatic Lubrication System Circuit
H
1
H
2
H
3
F
1
F
2
F
3
F
4
E
1
E
2
E
3
E
4
A
1
7
A
1
8
A
1
9
A
2
0
A
2
1
A
2
2
A
2
3
A
2
4
A
1
A
2
A
3
A
4
J
1
J
2
J
3
J
4
J
5
J
6
J
7
J
8
J
9
J
1
0
J
1
1
J
1
2
J
1
3
J
1
4
K
1
K
2
K
3
K
4
K
5
K
6
K
7
K
8
K
9
K
1
0
K
1
1
K
1
2
K
1
3
K
1
4
A
5
A
6
A
7
A
8
A
9
A
1
0
A
1
1
A
1
2
A
1
3
A
1
4
A
2
5
A
2
6
A
2
7
A
2
8
C
1
C
2
B
1
B
2
C
3
C
4
D
1
D
2
D
3
D
4
A
1
5
A
1
6
M
16:1
01
02
BD0666a01
03 04 05 06
07
09 08
10
11
10
12
13 14
16
15
17
18
19
20
21
LEGEND
01. Grease Tank
02. grease pump
03. Grease Pump Cycle Solenoid (GPCS)
04. Gauge
05. Reducing Valve
06. Grease Pump Supply Solenoid (GPSS)
07. Vent Valve
08. Auto Lube Motor and Pump
09. Hydraulic Tank
10. Grease Strainer
12. Gauge
14. Tow Lube Pressure Switch
16. Upper Grease Pressure Switch (UGPS)
17. Mast Grease (A)
18. Upper Machinery (B-D)
19. Upper Machinery (E-H)
20. Propel Machinery (J)
21. Propel Machinery (K)
8.2.1 Pump Operation
The automatic lubrication system turns on based on signals from timers in the PLC. Typically, the PLC will start an
automatic lubrication cycle every 60 minutes when the drill is in one of the drilling modes, and every five minutes
when it is in propel mode. The system can also be operated manually through the operators touch screen.
Hydraulic fluid used to power the Automatic Lubrication System is supplied by the low pressure hydraulic pump.
The pump is active whenever the DC Systems are functioning. When the cycle starts, the motor turns the pump.
The pump draws hydraulic fluid from the main hydraulic tank and sends it to the automatic lubrication system cir-
cuit.
8.2.1.1 Grease Pump Supply Solenoid (GPSS)
The GPSS is normally closed. Low pressure fluid is available at the GPSS whenever DC Systems are on.
The GPSS energizes when the lubrication cycle begins. This permits hydraulic fluid to flow to the reducing valve.
CAUTION
Incorrect pressure can cause equipment damage. The reducing valve is factory preset at
220 psi. Do not adjust the reducing valve.
The grease pump has a 16:1 ratio, which means that for every 1 psi of hydraulic oil pressure, the pump can
develop 16 psi of grease pressure. When the hydraulic oil pressure is 220 psi, the grease pressure could be as
high as 3520 psi (16 x 220 = 3520) before the pump stalls. If the reducing valve is set too low, some lubrication
points may not get lubricated; if it is set too high, it could cause damage to system components.
After the reducing valve, an portion of the oil is used to provide pilot pressure to the vent valve. When this pilot
pressure is present, the vent valve closes the grease return line to the grease tank.
Figure 8-4: Pump Operation Circuit Schematic
03
01
02
04 05
06
07 08
16 : 1
LEGEND
01. Grease Tank
02. Grease Pump
03. Grease Pump
Cycle Solenoid (GPCS)
04. Reducing Valve
05. Grease Pump
Supply Solenoid (GPSS)
06. Vent Valve
07. Auto Lube Motor and Pump
08. Hydraulic Tank
8.2.1.2 Grease Pump Cycle Solenoid (GPCS)
The Grease Pump Cycle Solenoid energizes and de-energizes. The intervals are adjustable up to one second by
settings used on the GUI lube screen.
When the solenoid is energized, hydraulic fluid flows to the rod end of the grease pump, causing the plunger to
draw lubricant from the lube tank. When the solenoid is de-energized, hydraulic fluid flows to the head end of the
grease pump, causing the plunger to press lubricant out to the auto lube system. Check valves on the inlet and out-
let of the pump plunger ensure that grease flows in the correct direction. The GPCS continues to function in the
same cycle as long as the GPSS is energized.
8.2.2 Lube Control
Lubricant supplied by the grease pump flows through a strainer. System pressure is limited by the relief valve and
indicated by the gauge.
NOTICE
The 4000 psi relief valve is not adjustable.
8.2.2.1 Grease Pressure Switch (GPS)
The Grease Pump Supply Solenoid (GPSS, item 5, Figure 8-4) energizes with every lubrication cycle. The GPS
monitors pressure in the lube lines and closes at 2500 psi, indicating that the lubrication cycle is complete. This
causes the PLC to de-energize GPSS.
If the GPS fails to close within three minutes, a lubrication system fault will occur; however, faults in the lubrication
system will not cause automatic shutdown of the drill.
Figure 8-5: Lube Control Circuit Schematic
09
12
13
14
11
10
LEGEND
09. Relief Valve
(UGPS)
13. To upper machinery lube points
14. To propel machinery lube points
8.2.2.2 Upper Grease System Operation
When the drill is in propel mode, only the propel machinery requires lubrication. Therefore, when the drill is in pro-
pel mode, the Upper Grease Solenoid (UGS) does not energize. Lubricant flows directly to the propel machinery
lubrication points.
When the drill is in one of the drill modes and the GPSS energizes, the UGS also energizes. This opens the line to
the upper machinery lubrication points.
As lubricant flows to the upper machinery lubrication points, pressure builds in the system. When pressure reaches
1500 psi, the Upper Grease Pressure Switch (UGPS) closes. This indicates to the PLC that the UGS energized as
required.
When the GPS senses 2500 psi, it closes, causing the GPSS to de-energize and the grease pump to stop pump-
ing. At the same time, the pilot pressure to the vent valve (Item 6, Figure 8-4) is relieved, allowing the vent valve to
open the return line back to the tank. The UGS remains open for two minutes after the GPSS de-energizes. The
pressure that has built up in the upper and lower machinery lubrication lines relieves back to the grease tank.
After the two minutes for depressurization, the UGS de-energizes and the cycle is complete.
8.2.3 Lubrication Points
Figure 8-6: Lubrication Injectors
Table 8-1provides information for lube points lubricated by the automatic lubrication system.
Injector Lube Point Component Location of
Injector Bank
A1 Air Swivel
Rotary and Hoist/
Pulldown Machinery
Rotary Carriage
A2 Main Bearing
A3 Idler Pinion
A4 Gear Rack
A5 Drive Pinion-Inner
A6 Drive Pinion-Inner
A7 Gear Rack
A8 Idler Pinion
A9 Backup Roller
Eccentric Lower RH
A10 Backup Roller
Eccentric Lower LH
A11 Backup Roller
Eccentric Upper RH
A12 Backup Roller
Eccentric Upper LH
A13 Upper Rack Arm RH
Pipe Racks Mast
A14 Upper Rack Arm RH
A15 Upper Rack Gate RH
A16 Upper Rack Arm LH
A17 Upper Rack Arm LH
A18 Upper Rack Gate LH
A19 Lower Rack Arm RH
A23 Lower Rack Arm LH
S24 Lower Rack Arm LH
A27 Deck Wrench
Deck Wrench Mast
A28 Deck Wrench
Table 8-1: Automatic Lubrication System Lube Points
B1 Pivot Shaft
Main Machinery Machinery Deck
B2 Pivot Shaft
C1-C4 Left Front Jack Left Front Jack
At jack, below deck
D1-D4 Right Front Jack Right Front Jack
E1-D4 Left Rear Jack Left Rear Jack
F1-F4 Right Rear Jack Right Rear Jack
H1 Crawler Equalizer Crawler Equalizer
Below deck H2 Right Crawler Axle Right Crawler Axle
H3 Left Crawler Axle Left Crawler Axle
J1 Front Lower Roller
Left Crawler Crawler, left side
J2 Rear Lower Roller
J3 - J9 Lower Rollers
J11 Idler
J10-J14 Upper Rollers
K1 Front Lower Roller
Right Crawler Crawler, right side
K2 Rear Lower Roller
K3 - K9 Lower Rollers
K11 Idler
K10-K14 Left Upper Rollers
Injector Lube Point Component Location of
Injector Bank
Table 8-1: Automatic Lubrication System Lube Points
8.3 Automatic Lubrication System Maintenance
8.3.1 Hydraulic Pump-Motor, 37Q117D2
The pump and motor package is part of the low pressure hydraulic circuit, located in the low pressure hydraulic
pump stand in the machinery house. Replace the hydraulic pump-motor assembly as follows:
WARNING
!
maintenance work.
2. Tag and disconnect the wiring from the pump motor electrical junction box.
WARNING
!
Hot hydraulic oil can spray with extreme force and volume, causing injury or death. Use
Figure 8-7: Hydraulic Pump-Motor Package
CAUTION
Clean dirt from the pump-motor assembly and hydraulic hose fittings before loosening
any of the hydraulic components.
NOTICE
the pump-motor assembly.
5. Tag and disconnect the pressure and suction hose assemblies and fittings from the pump. Cap and/or plug the
hose fittings and pump ports to prevent contamination of the hydraulic system.
6. Remove the capscrews and lockwashers from the pump-motor mounting feet, and remove the pump-motor
assembly from the low-pressure hydraulic system panel. The nuts are weld nuts and will remain attached
below the panel floor.
7. Clean dirt and oil from the pump mounting surface of the low pressure hydraulic panel. Follow the cleaning pro-
cedures in Appendix A.
8. Position the replacement pump-motor assembly on the low-pressure hydraulic panel, and install securely with
capscrews and lockwashers.
9. Coat the male pipe threads of the hose fittings with pipe thread sealant, and install the fittings in the suction
and pressure ports of the pump-motor assembly.
10. Install the suction and pressure hose assemblies.
11. Disconnect the hose assembly from above the suction filter and fill the suction line with hydraulic oil. Refer to
the Lubrication section for oil specifications.
12. Connect the hose assembly above suction filter, and tighten securely.
13. Connect the electrical wiring to the pump motor as tagged.
14. Jog the pump-motor until the system is fully primed, and bleed air from the low pressure hydraulic system, as
necessary.
8.3.2 Grease Pump 37U154D1
The grease pump is a Lincoln 16:1 hydraulic reciprocating-type unit. The pump consists of an intensifier cylinder
pump, two solenoids valves, and a pressure-reducing valve. The pressure setting is adjustable. Disassembly and
repair of this pump requires special tools and methods. If the pump malfunctions, replace it, and send the old unit
to a qualified repair facility.
8.3.2.1 Removal
CAUTION
!
High-pressure oil or grease can spray and penetrate skin or eyes causing severe injury.
Use extreme caution when working around operating lubrication system and wear
appropriate face and body protective devices. Shut down, lock out, and tag the machine
before performing inspection, service, and maintenance of the lubrication system.
Obtain medical aid immediately for lube spray into eyes or penetration into the skin. Be
sure that the hydraulic and air systems are not pressurized before loosening or remov-
ing any connections or parts for maintenance.
1. Shut down the machine, and lock out and tag the controls.
2. Turn off the main PLC.
Figure 8-8: Grease Pump
01
04
05
06
07
08
09 10
11
BD0517a01
02
03
LEGEND
01. Grease Inlet
02. Grease Tank
03. Cover Plate
04. Grease Outlet
05. Oil Return Port
06. Vent Valve Pilot Port
07. Oil Supply Port
08. Grease Pump Supply Solenoid
09. Reducing Valve
10. Pressure Gauge
11. Grease Pump Cycle Solenoid
3. Tag and disconnect the electrical wiring to the valve solenoids.
4. Tag and disconnect the hoses from the grease pump.
5. Disconnect the grease hose at the pump.
6. Remove the bolts from the cover plate and remove the pump.
7. Remove the capscrews and pump mounting fitting from the grease pump.
8.3.2.2 Cleaning, Inspection and Repair
Refer to Appendix A for general mechanical maintenance procedures, and to Appendix B for general hydraulic
component maintenance procedures. Repair of the grease pump is limited to the replacement of worn or damaged
parts.
CAUTION
!
appropriate face and body protective devices. Shut down, lock out, and tag the machine
before performing inspection, service, and maintenance of the lubrication system.
Obtain medical aid immediately for lube spray into eyes or penetration into the skin. Be
sure that the hydraulic and air systems are not pressurized before loosening or remov-
ing any connections or parts for maintenance.
1. Fasten the pump mounting fitting to the pump.
2. Mount the pump to the cover plate.
3. Insert the grease pump in the tank and attach the cover plate to the tank.
4. Connect the grease supply hose to the pump.
5. Connect the oil pressure supply to the grease pump.
6. Connect the grease return hose to the grease pump.
7. Connect the vent valve to the grease pump.
8. Turn on the main PLC.
9. Bleed the system. Refer to the topic. Bleeding Grease System.
8.3.2.4 Adjustment
The pressure reducing valve is set at 190 psi (13.1 bar). The valve is factory-set and normally should not be
changed.
8.3.3 Lubrication Control Panel R7686F1
8.3.3.1 Grease Strainer 46Z503
The grease strainer is mounted on the control panel. To clean or replace the grease strainer,
1. Shut down the lubrication system, and lock out and tag the controls.
2. Remove the filter plug and element, clean the element in nonflammable solvent, and replace the element and
plug.
3. If the strainer in the Lincoln system must be replaced. refer to Figure 8-9 and proceed as follows:
A. Disconnect the supply hose at the strainer.
B. Replace the strainer and connect the supply hose.
C. Disconnect the grease return hose at the vent valve,
Figure 8-9: Lubrication Control Panel
01 03 02 04 05 06
LEGEND
01. Grease Strainer
02. Gauge
03. Relief Valve
(UGPS)
D. Place a catch basin under the end of the hose to collect drained grease.
E. Turn on the lubrication system and initiate a lube cycle. Observe the discharge from the grease return hose
and continue to cycle the system until all air is purged from the grease line.
F. Connect the grease return hose to the vent valve.
8.3.3.2 Relief Valve 36Z879D68
CAUTION
!
appropriate face and body protective devices. Shut down the machine, and lock out and
tag the controls before performing inspection, service, and maintenance of the lubrica-
tion system. Obtain medical aid immediately for lube spray into eyes or penetration into
the skin. Be sure that the grease system is not pressurized before loosening or remov-
ing any connections or parts for maintenance. The pressure relief valve is set at 4000 psi
(276 bar) and is not adjustable.
The relief valve is not adjustable, and cannot be repaired by the user. To replace the valve, proceed as follows.
1. Use lockout-tagout procedures to shut down the drill.
2. Unscrew the valve from the manifold.
3. Install a new valve. Be sure that the connection is tight.
8.3.3.3 Pressure Switches 79Z4843
Pressure switches GPS and UGPS are SPDT snap-action type with automatic reset. The range is adjustable
between 235 and 3000 psi (16 to 205 bar) on decreasing pressure, and between 295 and 3400 psi (20.2 to 233
bar) on increasing pressure. The switches are connected normally open.
WARNING
!
Hazardous voltage can cause burns, injury, or even death. Disconnect, lock out, and tag
Removal
CAUTION
!
appropriate face and body protective devices. Shut down machine, and lock out and tag
the controls before performing inspection, service, and maintenance of the lubrication
system. Obtain medical aid immediately for lube spray into eyes or penetration into the
skin. Refer to Figure 7-7 or 7-8 and proceed as follows:
1. Disconnect, lock out, and tag the power source that feeds the system to prevent power from being applied
while service is being performed.
2. Disconnect and tag the wiring to the switch to be removed.
3. Unscrew the pressure switch from the fitting.
Repair
component maintenance procedures. Replace the pressure switch if faulty.
Installation
1. Install the pressure switch onto the fitting.
2. Connect the wiring to the switch.
3. Connect the power source after service is being performed.
4. Bleed the grease system. Refer to the topics, Bleeding Grease System.
Adjustment
To adjust the pressure switches the main PLC must be on. Refer to Figure 8-10 and proceed as follows:
1. Remove the pressure adjustment screw cover to gain access to the adjustment screw.
2. Turn the adjustment screw clockwise to lower the actuation pressure setting. Turn the adjustment screw counter-
clockwise to raise the actuation pressure setting. Pressure settings are as follows:
GSPS - 2500 psi (172.5 bar)
UGPS - 1500 psi (103.5 bar)
3. After adjustment, install the pressure adjustment screw cover.
8.3.3.4 Upper Grease Solenoid 36Z1412D2
The Upper Grease Solenoid valve is installed in the line to the upper machinery.
WARNING
!
hazardous voltage can cause burns, injury, or even death. Disconnect, lock out, and tag
the power source that feeds this device to prevent power from being applied while
Figure 8-10: Pressure Switch Adjustment
CAUTION
!
appropriate face and body protective devices. Shut down the machine, and lock out and
tag the controls before performing inspection, service and maintenance of the lubrica-
tion system. Obtain medical aid immediately for lube spray into eyes or penetration into
the skin.
Removal
2. Disconnect and tag wiring to the solenoid.
3. If the solenoid is not actuating the valve, remove the screws on top of the valve to detach the solenoid. Inspect
the valve for signs of malfunction. If the valve is damaged, replace the entire solenoid valve.
4. Check operation of the solenoid with a 125VAC power source, If faulty, replace the solenoid. Check operation
of the valve after installation.
5. If the entire valve must be removed, it will be necessary to remove the components from the panel to access
the valve.
A. Disconnect and tag wiring to the pressure switches. Remove the pressure switches.
B. Disconnect and tag the lube hoses.
C. Remove attaching hardware to unfasten the manifold, valve, and fittings.
Repair
component maintenance procedures. Repair of the solenoid valve is limited to the replacement of worn or dam-
aged parts.
Installation
1. Assemble the solenoid, manifold and fittings, and mount these parts on the panel.
2. Connect wiring to the solenoid.
3. Install pressure switches and connect wiring.
4. Connect lube hoses to the tee fittings.
5. Bleed the grease system. Refer to the topic, Bleeding Grease System.
8.3.4 Vent Valve 36Q525
The vent valve is mounted on top of the lubrication tank near the grease pump. It is a hydraulically piloted valve
that is normally open to vent the lube system. During lubrication the valve is closed to shut off grease flow to the
tank.
8.3.4.1 Removal
Refer to Figure 8-11 and proceed as follows:
Figure 8-11: Vent Valve
01
02
03
04
05 06
07
LEGEND
01. Vent Valve
02. Lubricant Inlet Port
03. Tank Return Port
04. Lubricant Outlet Port
05. From Grease Pump
06. To Injectors
07. To Lube Tank
CAUTION
!
appropriate face and body protective devices. Shut down the machine, and lock and tag
the controls before performing inspection, service, and maintenance of the lubrication
system. Obtain medical aid immediately for lube spray into eyes or penetration into the
skin.
1. Use lockout/tagout procedures to shut down the drill.
2. Tag and disconnect each of the hoses leading to vent valve.
3. Remove the vent valve from the tank bracket.
8.3.4.2 Disassembly
1. Loosen and remove the valve body from cylinder.
2. Unthread valve seat. Remove the seat and gasket from the valve body.
3. Remove packing assembly from cylinder.
4. Remove piston from the cylinder.
5. Remove V-seal from piston.
6. Remove needle from the packing assembly.
Figure 8-12: Vent Valve Assembly
LEGEND
01. Cylinder
02. Piston
03. V Seal
04. Needle
05. Packing Assembly
06. Valve Seat
07. Valve Seat Gasket
08. Valve Body
component maintenance procedures. Repair of the vent valve is limited to the replacement of worn or damaged
parts.
8.3.4.4 Assembly
1. Apply a light coating of oil to V-seal and install on piston as shown.
2. Apply a light coating of oil to the inside wall of cylinder.
3. Install piston in cylinder, rotating the piston so that the lip of V-seal will not invert.
4. Install needle in packing assembly, and place the packing assembly in the cylinder as shown.
5. Place gasket in valve body; then thread valve seat into the valve body.
6. Thread valve body into cylinder.
1. Mount the vent valve on the tank bracket.
2. Connect the hoses to the valve.
8.3.5 Lubrication Injectors 44Z1169D__
The lubrication injectors are pressure-operated and spring-reset. They are mounted on manifolds, located in
groups strategically positioned on the drill. The Lincoln SL-1 injector used on this drill delivers a measured volume
of lubricant to the lubrication point. The volume is adjustable from .008 - .080 in
3
(131 - 1310 mm
3
) (refer to Sub-
topic 8.3.5.2). The injectors have dual outlets, allowing them to be crossported to deliver increased amounts of
lubricant to the lube point.
The injectors operate within a pressure range between 1,850 and 3000 psi. (typical pressure switch setting is 2500
psi).
Maximum vent pressure (the pressure the system must get below to allow the injectors to reset after a cycle) is 300
psi.
As shown in Figure 8-13 for Position 1, when the lubrication cycle starts, pressure from lubricant entering the injec-
tor forces the slide valve to open and allows lubricant to enter the passage leading to the measuring chamber.
Figure 8-13: Injector Operation, Position 1
.
After the slide valve opens, lubricant is directed into the measuring chamber above the injector piston. The injector
piston is pushed down, forcing lubricant from the discharge chamber, through the outlet port to the lube point.
Figure 8-14: Injector Operation - Position 2
The injector piston completes its stroke by pushing the slide valve, blocking the lubricant supply through the pas-
sage to the measuring chamber. The injector piston remains in this position until all the injectors have finished the
first half of their cycle.
After all the injectors have cycled, pressure builds up until the pressure switch trips, de-energizing the solenoid
valve and stopping the lubrication pump. Excess lube pressure in the supply lines relieves through the vent valve
back to the tank.
Position 4 in Figure 8-16 shows the injector spring expanding after pressure has been vented from the supply lines.
The injector spring expands, pushing the slide valve to its original position, pushing lubricant from the measuring
chamber though the passage and valve port, and into the discharge chamber. The injector cycle is completed and
the injector is ready for the next cycle.
8.3.5.2 Adjustment
CAUTION
In addition to lubricating the various components in the lubrication system, the lubricant
supplied to the lube point flushes dirt and other impurities from the lube point (compo-
nent). Reducing the amount of lubricant to the lube point can result in excessive wear
and premature component failure. Contact your P&H MinePro Services representative
before changing (especially before reducing) the amount of lubricant being supplied to
the lube point.
1. Loosen output adjusting screw locknut.
2. Adjust the injector to deliver the desired amount of lubricant to the lube point. Turn the output adjustment screw
outward (anticlockwise) to increase the amount of lubricant to the lube point (maximum .08 in
3
or 131 mm
3
), or
turn the output adjustment screw inward (clockwise) to decrease the amount of lubricant delivered to the lube
point (minimum .008 in
3
or 1310 mm
3
).
3. Tighten the output adjusting screw locknut to lock the adjusting screw in place.
8.3.5.3 Removal
WARNING
!
Accidental shovel movement during service procedures can result in serious personal
injury or death. Always park on level ground, and use lockout and tagout procedures to
prevent accidental start-up and/or motion.
Figure 8-17: Injector Adjustment
1. Use lockout and tagout procedures to prevent accidental movement or startup.
2. Remove the feeder line from the injector being removed.
3. Loosen and remove the adapter bolt.
4. Remove the injector and gasket from the injector manifold. Discard the gasket.
Figure 8-18: SL-1 Injector Removal/Installation
8.3.5.4 Disassembly
1. Loosen locknut.
2. Loosen and remove adjusting nut with locknut.
3. Loosen and remove piston stop plug with packing and washer.
4. Remove packing and washer from piston stop plug. Discard the packing.
5. Remove injector piston assembly with o-ring. Remove the o-ring and discard.
6. Remove injector spring.
7. Remove spring seat through the top of the injector body.
8. Remove washer, packing, inlet disc packing and slide valve through the bottom of the injector.
8.3.5.5 Repair
Repair of SL-1 injector is limited to replacing worn or defective parts. Whenever an SL-1 injector is disassembled,
all gaskets, o-rings, and packings should be replaced.
8.3.5.6 Assembly
Refer to Figure 8-19 and assemble the injector as follows:
1. Install spring seat in injector body with the flat side of the seated flat against the bottom of the cylinder in the
injector body.
Figure 8-19: Injector Components
LEGEND
01. Adjusting Nut
02. Locking Nut
03. Piston Stop Plug
04. Gasket
05. Packing
06. O-ring
07. Fitting Assembly
08. Slide Valve
09. Washer
10. Adapter Gasket
11. Adapter Bolt
12. Gasket
13. Manifold
14. Packing
15. Inlet Disc
16. Packing
17. Spring Seat
18. Injector Spring
19. Injector Piston
20. Injector Body
21. Washer
2. Place injector spring into the cylinder bore in the injector body.
3. Lubricate a new o-ring with a light coating of grease and install in the groove of injector.
4. Place piston assembly with installed o-ring into the cylinder bore of the injector body. Make sure that the
tapered portion on the piston assembly is pointed toward the top of the injector body
5. Place washer and new packing into the bore at the bottom of piston stop plug.
6. Place piston stop plug over injector piston onto the injector body. Torque to 25-30 ft-lbs (33.9-40.7 Nm).
7. Install the lock nut onto the adjusting nut. Install the adjusting nut over the injector into the threaded bore in pis-
ton stop plug.
8. Install new packing into the bore inside the bottom of the injector body.
9. Place slide valve into the bore of packing.
10. Place inlet disc in the bore at the bottom of the injector.
11. Place new packing in the bore at the bottom of the injector.
Refer to Figure 8-18 and install the injector as follows:
1. Place the injector at the top of the manifold.
2. Install new gasket on the adapter bolt.
3. Install adapter bolt through the bottom of the manifold and thread into the bottom of the injector. Tighten the
adapter bolt to 45-50 ft-lbs (61-68 Nm).
4. Install the feeder line into the injector body.
5. Bleed the air from the injector and feeder line, refer to Bleeding Air from Feeder Lines.
6. Start up the drill using lockout and tagout procedures.
8.3.5.8 Bleeding The System
During component replacement procedures, or as a means of resolving a lubrication fault, it may become neces-
sary to remove air from the supply or feeder lines. Air can be introduced into the lubrication system for several rea-
sons:
Because lubricant levels in the reservoir become too low before refilling.
Because the lubrication pump is improperly primed.
During component replacement.
It is necessary to bleed air from the system to prevent lack of proper lubrication from causing damage to drill
components and to keep the lubrication fault alarm from sounding.
The following procedures are provided for bleeding air from the automatic lubrication system.
WARNING
!
Inadvertent movement of the drill during the following procedures can result in injury or
death. Be sure that an operator is stationed at the controls to prevent inadvertent opera-
tion of any drill components.
Bleeding Air From Supply Lines (System)
CAUTION
!
appropriate face and body protective devices. Obtain medical aid immediately for lube
spray into eyes or penetration into the skin.
1. Set all brakes.
2. Start the machine. Station the operator at the controls to prevent inadvertent operations of the drill.
3. Be sure that the grease pump is primed and free of air. If necessary, adjust the lube cycle time and interval at
the GUI to slow grease pump operation.
4. Start a manual lubrication cycle using the GUI. It will be necessary to start a manual lubrication cycle several
times to complete the bleeding process.
5. Bleed each supply line in the lubrication system to be bled starting with the shortest section and working up to
the longest section. Bleed each section as follows:
A. If there are fittings that could trap air, as shown in Figure 8-20, start with the fitting closest to the grease
pump; remove each plug in order and run the grease pump until lubricant flow is free of air or foreign matter.
Then install and tighten the plug, and move on to the next fitting.
Figure 8-20: Bleeding Air at Fitting
B. Remove the plug(s) at the end of the section. It will be located on the injector manifold as shown in Figure 8-
21.
C. Operate the lubrication pump until lubricant flow is free of air or foreign matter. Use a drain pan to collect the
lubricant discharged during the bleeding process.
D. Replace the plug.
6. Bleed air from each section in the lubrication system until all sections of the lubricant supply lines are bled.
7. After all air is removed from the grease system, manually cycle the lubrication system via the GUI Lube screen
and check all injectors for proper operation.
Bleeding Air from Supply Lines After Component Replacement
When installing new or repaired lubrication components such as the injectors, air is introduced into the grease sys-
tem supply lines. This air will cause a fault warning alarm to sound, or, if undetected, could cause excessive wear
and premature component failure.
When bleeding air from the supply lines after installation of a component, it is only necessary to bleed air from the
section of supply line into which the component was installed.
To bleed air from the supply lines after installation of a component, proceed as follows:
1. Start the drill. Station the operator at the controls to prevent anyone from operating the drill while performing
bleeding procedures.
2. If necessary, adjust the lube cycle time and interval at the GUI to slow grease pump operation.
3. If an injector, or set of injectors, was installed, remove the plug(s) at the injector (Figure 8-21). If a pressure
switch was installed, or if a hose or pipe was replaced, loosen the next fitting in that section of the supply line.
Collect the lubricant discharged during the bleeding process in a drain pan.
A. Start a manual lubrication cycle using the GUI. It will be necessary to start a manual lubrication cycle several
times to complete the bleeding process.
Figure 8-21: Bleeding Air at Manifold
B. Close the air flow control valve. Record the number of turns required to close the valve.
C. Open the flow control valve enough so that the grease pump runs slowly.
4. Operate the grease pump until lubricant flow is free of air or foreign matter.
5. Replace the plug and tighten the fitting.
6. After all air is removed from the system, manually cycle the lubrication system via the GUI Lube screen and
check the injector(s) for proper operation.
Bleeding Air from Feeder Lines
To bleed air from feeder lines, refer to Figure 8-22 and proceed as follows:
1. Disconnect the feeder line at the lube point.
2. Remove the cap from the filler fitting on the injector.
3. Using a grease gun containing the same type of grease being used in the lubrication system, attach the grease
gun nozzle and pump grease through the feeder line until clean grease, free of dirt and contaminants, exits the
feeder line.
4. Remove the grease gun, replace the cap on the filler fitting, and connect the feeder line at the lube point.
8.3.5.9 System Start-up After Repair
When returning the drill to service after repairs, make the following checks:
1. Check the lubrication intervals on the GUI Lube screen. Adjust if necessary.
2. Manually cycle the grease system and check the following for proper operation:
Figure 8-22: Bleeding Air from Feeder Lines
A. Observe the pressure gauge, pressure switches and the Upper Grease Solenoid to verify proper operation and
adjustment. Adjust as required.
B. Observe injectors for proper operation. Check injector indicators for complete motion. SL-1 injector indicators
will lower when the injector discharges lubricant. The indicator will remain in the lowered state until the pump turns
off, and will then raise when the injector is reset.
8.4 Troubleshooting
Grease pump does not run Circuit breaker off or PLC off Turn on circuit breaker or PLC
Low or no drive oil pressure Identify and correct problem in low
pressure hydraulic system.
Faulty grease pump Repair or replace grease pump
Grease pump does not
build pressure
Leak at hoses or connections Check condition of hoses and tight-
ness of connections. Replace faulty
hoses. Tighten all connections.
Pockets of air in system Bleed lube lines
Obstructed pump inlet Clean pump inlet and check valves
as required. Drain and clean tank
interior to remove debris as
required.
Grease pump reducing valve set
too low
Adjust reducing valve setting to
220 psi (15.2 bar).
Faulty vent valve Repair or replace valve.
Faulty pump Repair or replace grease pump.
Grease pump runs erratically Erratic drive oil pressure Identify and correct problem in low
pressure hydraulic system.
Faulty pump solenoid Repair or replace solenoid
Faulty pump cylinder Repair or replace cylinder
Faulty reducing valve Repair or replace reducing valve
Grease pump operates but cycle
does not complete
Incorrect pressure switch setting Set pressure switch to 2500 psi.
Faulty pressure switch Repair or replace pressure switch.
Grease pump reducing valve set
too low
Adjust reducing valve setting to
220 psi (15.2 bar).
Faulty vent valve Clean, repair or replace valve.
Lack of grease at lube point Leaking lines Inspect hose from lube point to
injector for loose connections or
ruptured hose. Correct deficiencies.
Blocked line Check injector stem for movement
during lube cycle. If unit is not
working, disconnect supply hose
and flush at the fitting with a
grease gun to clear line. Connect
supply hose.
Faulty injector Repair or replace faulty injector.
Lack of grease at injector manifolds Clogged or ruptured
supply hose(s)
Disconnect supply hose and flush
using a grease gun to clear the
line. Replace faulty hose and con-
nect hose after service.
Blocked manifold Remove injectors or measuring
valves. Disconnect supply hose and
flush manifold using a grease gun
to clear. Install injectors or valves
and connect hose after service.
Inadequate grease at lube points No grease supply Check grease tank and replenish as
required.
Incorrect viscosity Check grease weight. Grease may
be too heavy for operating environ-
ment.
Leaking lines Inspect applicable lines for leak-
age. Correct deficiencies.
Faulty grease pump Repair or replace grease pump.
BD120149 Mechanical Systems Manual Propel System
Sec09Propel.fm -9.1- Section 9, Version 00 - 03/06
Section 9
Propel System
9.1 General
The drill is propelled by left and right hand crawler tracks mounted on crawler side frames. The crawler assemblies
are identical to each other except that they are configured as left- and right-hand units.
Each crawler track is driven by a reversible hydrostatic drive system. Pressurized hydraulic oil is supplied to each
hydraulic motor by individual pumps in the main hydraulic system. The direction of crawler travel is reversed by
reversing the direction of fluid flow through the motors. This is accomplished when the operator moves the propel
control levers on the operator console.
Propel speed is controlled by modulating the volumetric rate of hydraulic fluid passed through the motors. Each
propel drive transmission is flange-mounted at the front end of the crawler frame. The transmission consists of a
three stage planetary gear reducer with an integrated spring-set, hydraulically released, disc brake. The propel
motor is flange-mounted to the input shaft end of the transmission, as an integral part of the transmission unit.
Each transmission has a manually operated mechanical coupling (only used with the optional towing package,
which is included with this drill).
Figure 9-1: Propel Drive Components
LEGEND
01. Drive Tumbler
02. Transmission
03. Track
Propel System BD120149 Mechanical Systems Manual
Section 9, Version 00 - 03/06 -9.2- Sec09Propel.fm
The propel brakes are automatically released when hydraulic pressure is applied to the propel motors. When
hydraulic pressure is removed or lost, the brakes automatically apply, thus preventing uncontrolled machine travel.
The crawler transmissions multiply the torque received from the hydraulic motors and produce output torque to
rotate the drive tumblers, which are bolted to the transmission hub. The drive tumblers engage and drive the
crawler tracks. The crawler side frames are connected to the main frame at the rear of the machine by a rigidly
mounted main axle. A compensating equalizer axle at the front of the crawlers is designed to maintain the machine
in a stable condition while traversing uneven terrain.
NOTICE
Power for the propel system is provided by the main hydraulic system. Because of its complex-
ity, the main hydraulic system is covered as a separate section in this manual. Refer to Section
4, Main Hydraulic System..
9.2.1 Propel Motor 41U100D2
The propel transmissions are driven by variable-displacement, plug-in type, axial piston hydraulic motors of bent
axis design. The propel motor is an integral component of the propel transmission assembly, but it can be removed
independently.
When the operator places the drill in PROPEL mode, the PLC allows the joystick to control the propel pump ser-
vos. As the joystick is moved, hydraulic pressure is ported to the propel motor, and the propel motor causes the
propel transmission to turn.
The propel brakes are an integral part of the propel transmission. When the operators BRAKE RELEASE button is
in the RELEASE position and when the joystick is moved off its neutral position, oil is ported from the main pumps
Figure 9-2: Propel Motor
to special brake ports in the motor (not the same pressure lines as those that drive the motor) to cause the brakes
to release. When the joystick is in the neutral position, the brakes are not released.
The piston displacement is hydraulically actuated, and can be controlled by the drill operator. When the operator
places the DRILL SPEED switch to LOW speed setting, the motors maximum displacement provides high torque,
low speed propelling. When the switch is in the HIGH speed setting, the motors minimum displacement provides
low torque, high speed propelling.
The high speed/low torque setting provides for a specific minimum motor displacement. The motors swash plate is
in its destroked configuration. The amount the swash plate can move in the destroked direction is limited by a phys-
ical stop that can be adjusted by turning the stop in or out, adjusting the degree to which the plate can be
destroked.
The low speed/high torque setting provides for a specific maximum motor displacement. The motors swash plate
is in its fully stroked configuration. The amount the swash plate can move in the stroked direction is limited by a
physical stop that can be adjusted by turning the stop in or out, adjusting the degree to which the plate can be
stroked.
9.2.2 Propel Transmission 53R176D2
The propel transmission (refer to Figure 9-3) is a three-stage planetary gear reducer with an integral hydraulically-
released, multiple-disc brake. The transmission and motor can be removed or installed as a unit, without need for
disassembly or subassembly of its components.
The drive tumbler, R54640D2, meshes with lugs on the crawler track shoes, causing them to move. The crawler
track shoes are supported by rollers at the top of the crawler frames and provide a continuous track on which the
drill propels.
Figure 9-3: Propel Transmission
9.2.3 Crawler Assembly R6575F3
There are two crawler assemblies, one on either side of the drill. They are connected to the drills main frame by
means of two axles:
9.2.3.1 Equalizer Axle R11405F1
The equalizer axle is mounted to the forward end of the main frame by a large pin and clevis at the center bottom
of the frame. It attaches to the two crawler frames by means of pins. This arrangement permits some flexibility side-
to-side as the drill propels over uneven terrain.
9.2.3.2 Main (Pivot) Axle R41245D1
The main axle, also called the pivot axle, is mounted to the underside of the main frame by two split collars. To
attach the crawler frames, the axle extends through an unbushed bore at the rear of each crawler frame. The con-
nection is secured by a retainer plate bolted into the end of the shaft. This arrangement permits some flexibility
front-to-back as the drill propels over uneven terrain.
Figure 9-4: Crawler Assembly
BD177b01
01
02
03
04
05
05
08
09
06
07
LEGEND
01. Propel Transmission
02. Equalizer Axle
03. Propel Motor
04. Idler Roller
05. Crawler Frame
06. Main (Pivot) Axle
07. Crawler Track
08. Lower Rollers
09. Upper Rollers (not visible under
crawler track)
9.2.3.3 Crawler Frames R6570D3/D4
The crawler frames support and distribute the weight of the drill to the ground. In addition to the propel transmis-
sion assembly and the two axles, the crawler frames contain three upper rollers, ten lower rollers, and an idler
roller.
9.2.3.4 Upper and Lower Rollers 13P627F1
On each crawler frame, thirteen rollers support the track as it moves around the crawler frame. Three upper rollers
support the weight of the track as it moves across the top of the crawler frame. Ten lower rollers support and dis-
tribute the weight of the drill to the crawler track.
Figure 9-5: Crawler Frame
Figure 9-6: Upper Roller
9.2.3.5 Idler Roller 13N385D1F1
At the rear of each crawler frame, an idler roller is used to maintain alignment of the track shoes as they move
around the crawler frame. The idler roller is mounted in sliding bearing blocks, which enable it to move fore and aft
in the crawler frames. This provides a means of adjusting track tension.
9.2.3.6 Crawler Track R3122F2
The crawler track provides a surface on which the drill propels. It consists of a series of shoes pinned together to
form a continuous track. The shoes are 36" wide. The original set includes 58 shoes, 1/3 of which are cleated.
Figure 9-7: Idler Roller
9.3 Propel System Maintenance
9.3.1 Propel Motor 41U100D2
The propel transmissions are driven by variable-displacement, plug-in type, axial piston hydraulic motors of bent
axis design.
The piston displacement control is hydraulically actuated, and can be positioned by the drill operator to either the
maximum displacement for high-torque/low-speed propelling, or to the minimum displacement for low-torque/high-
speed propelling. The minimum and maximum displacement adjustments are factory set.
The motor is an integral part of the propel transmission. However, it can be removed from the transmission for
replacement without having to remove the transmission from the crawler frame.
9.3.1.1 Removal
To remove either propel motor proceed as follows:
1. Position the machine on level ground. Block the machine to prevent movement in either direction.
Figure 9-8: Propel Motor and Transmission
01
02
BD0053c01
LEGEND
01. Motor
02. Transmission
WARNING
!
work.
3. Clean all dirt away from the hydraulic motor and hose assemblies.
WARNING
!
sure circuits.
5. Close the Handwell valves.
6. Tag and remove the hydraulic hoses from the motor. Cap or plug all hose fittings and motor ports.
CAUTION
!
Lifting heavy components with inadequate hoisting apparatus can cause the load to
drop, resulting in personal injury and/or damage to equipment. Use suitable slings and
hoisting equipment to stabilize and lift heavy objects.
7. Attach a suitable hoist to the motor to prevent an overhung load on the shaft when the mounting bolts are loos-
ened.
8. Mark the mounting position of the motor on the transmission so that the hose connection ports will be correctly
located when the motor is reinstalled. Identify the motor, if more than one is being removed, to assure that it is
remounted on the same transmission.
9. Remove the capscrews and lockwashers from the mounting flange of the motor, and pull it away from its
mounting. Use care to prevent binding of the shaft or damage to the spline teeth when withdrawing the motor.
10. Remove and discard O-ring from the pilot diameter on the motor.
Clean and inspect the propel motor and motor mounting area in accordance with the general cleaning and inspec-
tion procedures described in Appendix A of this manual. Inspect the drive splines for wear or tooth damage.
Inspect the hydraulic hoses and fittings for damage or signs of leaking. The motor shaft seal can be replaced, but
the propel motors are not field repairable, and must be replaced if they become worn or damaged. Replace O-ring
whenever the motor is removed from the transmission. Refer to the LinkOne electronic parts manual for compo-
nent identification.
Install the hydraulic motor on the propel transmission as follows:
1. Lubricate O-ring with oil, and install on the hydraulic motor pilot diameter.
2. Grease the motor output shaft spline with lithium grease.
CAUTION
!
Assembling heavy components with inadequate hoisting apparatus can injure personnel
and/or damage equipment. Use suitable slings and hoisting equipment to stabilize and
lift heavy objects.
3. Using a suitable lifting device, lift the hydraulic motor and insert the shaft into the bore of the transmission input
shaft. Note the identification markings to ensure correct location of the motor. The motor case drain fitting
should be positioned at the top. Be careful to avoid side loading and/or binding of the shaft as the motor is
moved into position against the transmission.
4. Fasten the motor to the transmission with socket head capscrews, M30X180, DIN 10.9.
5. Fill the motor case with clean oil, then install the hydraulic hose assemblies in accordance with the identifica-
tion tags placed during motor removal.
6. Open the Handwell valves.
7. Start the hydraulic pumps, and bleed air from the control and high-pressure circuits.
9.3.1.4 Adjustment
Technician Tip
Propel motors are preset and should only need adjustment in rare instances. Consider that the
motors receive their flow from the main pumps, and the main pump minimum and maximum
displacement settings affect the propel speed as much as the motor displacement. Before
adjusting any motor settings, be certain that all pump settings are as specified and that the
other components of the propel system are working properly.
The propel motor features variable displacement, and provides either high speed and low torque, or low speed and
high torque. This feature is activated by a switch on the operators console.
The motors are adjusted at the factory for both high speed and low speed, and in most instances do not require re-
adjustment once the drill is in production. In the event that the drill does not propel evenly, however, the capability
to adjust the high speed and low speed settings is provided. Confirm that the pumps are properly adjusted prior to
adjusting the propel motors.
Refer to Figure 9-9 and adjust the propel motor settings as follows:
NOTICE
The motor displacement adjustments are not capable of modulating the servo settings to inter-
mediate positions. Their function is limited to establishing the maximum and minimum setpoints
for motor piston displacement. At the maximum displacement position, the motor has the lowest
output speed and highest torque capability. At minimum displacement, the motor has the high-
est speed and lowest torque capability.
1. Start the main drive, and raise the drill with the jacks until the crawler tracks are completely clear of the ground.
CAUTION
!
Operation of the propel system with the drill partially supported on the jacks can cause
injury to personnel and damage to the equipment. Check visually to be certain that the
crawler tracks are raised completely off the ground before operating the propel drive.
2. Place the PROPEL MODE - MAINTENANCE switch, located on the operator console, in the MAINTENANCE
position to enable operation of the propel drive while the drill is supported on the jacks.
Figure 9-9: Propel Motor Adjustments
01
02
BD0523a01
LEGEND
01. Maximum Displacement Adjustment
02. Minimum Displacement Adjustment
3. Remove the motor displacement caps.
NOTICE
Motor displacement caps are part of the sealing system designed to prevent oil from leaking
around the adjusting screw. Always re-install the cap after adjustments have been made.
4. Adjust the maximum displacement stops on each propel motor to obtain drive tumbler speed of 4.0 rpm at
maximum pump output. Turn the adjusting screw inward (clockwise) to increase tumbler speed.
5. Adjust the minimum displacement stops to obtain drive tumbler speed of 8.0 rpm at maximum pump output.
Turn the adjusting screw outward (counterclockwise) to increase tumbler speed.
Lower the drill from the jacks, and test the propel mode for straightness of tracking.
+
Figure 9-10: Motor Displacement Cap
Figure 9-11: Propel Transmission Assembly
9.3.2 Propel Transmission 53R176D2
The transmission and motor can be removed or installed as a unit, without need for disassembly or subassembly of
its components.
9.3.2.1 Removal
Refer to Figure 9-11 and remove the propel transmission from the crawler frame assembly as follows:
1. Position the drill on firm even ground, and rotate the crawler drive so that the transmission oil drain plug is at
the six o'clock position.
2. Raise the drill with the jacks to relieve the weight from drive tumbler, and place blocking under the machine
frame for support.
WARNING
!
work.
4. Separate two track links (08), and remove the crawler track from the top of the drive tumbler (Refer To Sub-
topic 9.3.5.1).
LEGEND
01. Bolt
02. Cap
03. Spacer
04. Bolt
05. Shift Ring
06. Locking Nut
07. Bearing
08. Snap Ring
09. Bolt
10. O-ring
11. Snap Ring
12. Locating Ring
13. First Stage Planetary
14. Snap Ring
15. Sun Gear
16. O-ring
17. Thrust Washer
18. Face Seal
19. Roller Bearing
20. Shaft Nut
21. Snap RIng
22. Ball Bearing
23. Retaining Collar
24. Locating Ring
25. Third Stage Planetary
26. Second Stage Planetary
27. Sun Gear Shaft
28. Snap Ring
29. Not Used
30. Plug
31. Snap Ring
32. Snap Ring
33. Shifter Shaft
34. Input Shaft
35. Coupler
36. Back-Up Plate
37. Brake Disk Kit
38. Inner Disk
39. Outer Disk
40. Brake Seal Kit
41. Back-Up Ring
42. O-ring
43. O-ring
44. Back-Up Ring
45. Piston
46. Back-Up Plate
47. Snap Ring
48. Gearshift Hub
49. Snap Ring
50. Hex Head Bolt
51. Locating Ring
52. Input Sleeve
53. Not used
54. Not used
55. Hex Head Bolt
56. Hydraulic Motor
57. O-ring
5. Clean all dirt away from the hydraulic motor and hose assemblies.
WARNING
!
sure circuits.
7. Turn Handwell valves off.
8. Tag and remove the hydraulic hoses from the motor. Cap or plug all hose fittings and motor ports.
9. Tag and remove the hydraulic hose assembly from the brake pressure supply fitting on the transmission. Cap
or plug the hose fitting and brake hydraulic supply port.
10. Remove thirty capscrews from drive tumbler.
CAUTION
!
11. Attach suitable lifting equipment to drive tumbler, and remove it from transmission.
12. Remove the transmission lubricant fill and drain plugs, and drain the oil into a suitable disposal container.
Install the plugs again, when all of the lubricant has been drained.
CAUTION
!
hoisting equipment to stabilize and lift heavy objects. The transmission and motor
assembly weighs approximately 2800 lbs (1270 kg).
13. Support propel transmission with adequate lifting/moving equipment. Be sure it is positioned straight and level
in relation to the crawler frame bore.
14. Remove thirty capscrews that fasten transmission to crawler frame.
15. Slide transmission out of the pilot bore in the crawler frame, being careful to move straight out to prevent cock-
ing of the spindle in the frame bore. Protect the motor from contacting the frame as it is being withdrawn
through the frame.
16. Transport the transmission to a suitable, clean work area for disassembly.
9.3.2.2 Disassembly
Disassemble the propel transmission as follows:
1. Place the transmission on blocks with the hydraulic motor located at the top.
2. Remove the hydraulic motor from the input end of the transmission, as described under the Subtopic 9.3.1.1,
Steps 6 through 8, inclusive.
3. Remove bolt, retaining plate and coupler.
4. Remove hydraulic hose adapter and ring seal from the spindle.
5. Attach a spring cage fixture and protective buffer (Figure 9-13) to the spindle, and apply enough axial force
against coupler to enable removal of snap ring.
6. Back out the adjustment screw slowly to allow concentric compression springs to completely relax while they
push back-up plate and coupler away from piston.
7. Remove the spring cage fixture from the spindle, then pull coupler and back-up plate out of the spindle coun-
terbore.
8. Remove compression springs from the spring pockets in piston. Discard the springs.
Figure 9-13: Spring Cage Fixture
01
02
03
04
BD0524a01
LEGEND
01. Spring Cage Fixture
02. Buffer
03. Adjusting Screw
04. 20MM Screw
9. Place a large, clean, protective rag into the counterbore of the spindle, then apply very-low-pressure com-
pressed air through the brake hydraulic pressure supply port. Increase the air pressure slowly until piston is
forced out of the bore and onto the rag. Remove the piston and rag from the spindle.
10. Remove and discard the O-ring and back-up ring from piston. Notice the relative positions of the O-ring and
back-up ring for reassembly.
11. Remove snap ring from the inside end of shifter shaft, then remove coupler from the shifter shaft.
12. Remove and discard the O-ring and back-up ring from the spindle bore. Notice the relative positions of the O-
ring and back-up ring for reassembly.
13. Remove and discard the eleven inner and five outer brake disks.
14. Remove brake back-up plate from the assembly.
15. Remove snap ring from the counterbore of the spindle.
16. Remove snap ring from bearing carrier.
CAUTION
!
hoisting equipment to stabilize and lift heavy objects
17. Attach suitable hoisting equipment, and reposition the transmission assembly so that the motor-mounting face
of the spindle is down, and well supported on wooden blocking.
18. Remove bolts from spacer, then remove spacer and cap from the end cover.
19. Remove the twenty-four bolts, and remove the end cover.
Figure 9-14: Brake Disk Arrangement
01
02
03
BD0525a01
LEGEND
01. Piston
02. Outer disk (5 pieces)
03. Inner disk (11 pieces)
CAUTION
!
hoisting equipment to stabilize and lift heavy objects
20. Place lifting eyes in the threaded screw holes in the end cover, support the cover with adequate lifting/moving
equipment, then lift the end cover and entire shifter shaft assembly away from the transmission.
CAUTION
To avoid damage to the shifter shaft, be sure to lift the end cover straight up to enable
the shifter shaft to be withdrawn without binding.
21. Loosen the thrust washer from the pilot diameter in the end cover, then remove the thrust washer from shifter
shaft.
22. Remove snap ring from shift ring.
23. Remove bolts from shift ring, then remove the shift ring, with shifter shaft and ball bearing intact, from the end
cover.
24. Remove snap ring from shift ring, and remove shifter shaft and ball bearing from shift ring.
25. Remove and discard O-ring from shift ring bore.
26. Remove locking nut, then press the ball bearing from the shifter shaft.
27. Carefully lift the third stage planetary out of the ring gear, and away from input shaft.
28. Loosen ring gear A from the pilot diameter in ring gear B, and remove ring gear A from the assembly.
29. Remove and discard the two O-rings from ring gear A.
30. Remove input shaft and thrust washer. Be careful to prevent the thrust washer from dropping off the end of the
input shaft.
31. Remove thrust washer from input shaft.
32. Lift sun gear shaft, including snap ring, out of the assembly. Then, remove snap ring from the sun gear shaft.
33. Carefully lift the second planetary stage gear assembly out of ring gear B.
34. Lift sun gear shaft out of engagement with the first stage planetary.
35. Remove locating ring from bearing carrier.
36. Carefully lift the first stage planetary, bearing carrier, ball bearing, and coupler as a unit out of ring gear B.
37. Remove coupler and ball bearing from bearing carrier by removing snap ring.
38. Remove ball bearing from coupler by removing snap ring.
39. Remove the crimping on the eight locations of shaft nut, then loosen and remove the shaft nut from the spindle.
CAUTION
!
40. Attach a suitable lifting device to ring gear B, and lift the ring gear away from the spindle. The cups and one
cone of the two tapered roller bearings, and one half of face seal, will remain with the ring gear.
41. Remove tapered roller bearing cone from inside ring gear B.
42. Remove the other tapered roller bearing cone from the hub of the spindle.
43. If bearings are going to be replaced, remove the two bearing cups from ring gear B.
44. Remove each half of face seal from ring gear B and the spindle.
Clean and inspect the propel transmission components in accordance with the general cleaning and inspection
procedures described in Appendix A of this manual. None of the components are repairable, and, therefore must
be replaced if worn or damaged. If a component in any one of the three planetary gear assemblies needs replace-
ment, that entire planetary unit must be replaced. It is recommended that all O-rings be replaced whenever the
transmission is disassembled for repair. Refer to the LinkOne electronic parts manual for component identification.
9.3.2.4 Assembly
Refer to Figure 9-11 and assemble the propel transmission as follows:
1. Position the spindle with the motor mounting side down on clean wooden blocking.
2. Install the two cups from tapered roller bearings (19) in the bearing seats of ring gear (B). Be certain that the
cups remain seated firmly against the shoulder in the counterbore.
NOTICE
Dry ice may be used to freeze the cups, so they may be installed. If the cups are pressed into
the housing, extreme care should be taken so they are not damaged.
3. Install one half of face seal (18) on the spindle.
4. Install one cone of tapered roller bearing (19) on the spindle.
5. Pack the half of face seal (18) and bearing cone (19) with an excess of clean grease.
6. Install the other half of face seal (18) in ring gear (B).
CAUTION
!
7. Attach suitable hoisting equipment to ring gear (B), and position the ring gear on the spindle so bearing (19)
and face seal (18) halves are correctly mated.
8. Pack bearing (19) seat area with an excess of clean grease.
9. Install remaining tapered bearing cone (19) with shaft nut (20). Tighten the nut finger tight. Be sure that the
bearing cone seats correctly in the cup.
10. Measure the axial position of ring gear (B) relative to the spindle, then torque shaft nut (20) until the bearing is
preloaded 0.3mm (0.012"). Crimp the torque nut flange in eight equally spaced locations.
NOTICE
Ring gear (B) may be rotated in only one direction during preloading of the tapered roller bear-
ings.
11. Install ball bearing (22) on coupler (39), and retain it with snap ring (11).
12. Install coupler (35) and mounted bearing (22) in the bore of bearing carrier (23), and fasten with snap ring (21).
NOTICE
The bearing retainer should already be assembled as a factory-installed component of the third
stage planetary (25).
13. Install the third stage planetary (25) in ring gear (B). Mesh the planetary gear/ring gear teeth and the planetary
gear carrier/spindle splines with care to avoid causing nicks and burrs. Lubricate the teeth with gearcase oil
before assembly.
CAUTION
!
14. Attach a suitable hoisting apparatus to ring gear assembly (B), and position the unit on its side.
15. Install snap ring (31) on bearing carrier (23). Access can be gained through the input shaft opening in the spin-
dle.
16. Reposition the transmission assembly so the unit is resting securely on wooden blocking with the motor mount-
ing face of the spindle down.
17. Install locating ring (24) in pilot counterbore of bearing carrier (23).
18. Install sun gear shaft (27) in the third stage planetary (25). Be sure the relieved face of the sun gear is inserted
first, and that it seats against locating ring (24).
19. Install the second stage planetary (26) into ring gear (B) and over the end of sun gear shaft (27). Retain the
planetary gear assembly with snap ring (28).
20. Install the sun gear (15) in the second stage planetary (27). Be sure that the counterbored end of the gear is
positioned at the top after installation.
21. Slide thrust washer (15) over end of the input shaft (34), then insert the splined-end of the input shaft through
the center of the sun gear shafts, and mesh the splines with those in coupler (35). The thrust washer bottom
face should be seated on the bottom of the counterbore in sun gear (15).
22. Lubricate two O-rings (16) with oil, and install them in O-ring grooves of ring gear (A).
23. Line up the through-bolt holes in ring gear (A) with the tapped holes in ring gear (B), then insert ring gear (A)
pilot diameter into the counterbore of ring gear (B). Be sure that the matching faces of the two ring gears are
tight together, when installed. Do not install the mounting bolts at this time.
24. Carefully install the first stage planetary (13) in ring gear (A) and over input shaft (34).
25. Install ball bearing (07) on shifter shaft (33), and retain the bearing securely with lock nut (06).
NOTICE
Apply Loctite compound to the threads of the lock nut before assembling to the shifter shaft.
26. Install shifter shaft (33) and mounted bearing (07) into the counterbore of shift ring (05), and fasten in place
with snap ring (08).
27. Lubricate and install O-ring (10) in the bore of the end cover.
28. Assemble shift ring (05) with mounted shifter shaft to the end cover, and fasten with bolts (04). Torque the bolts
to 38 ft lbs (51 N.m).
NOTICE
Apply molybdenum-based protectant/sealant to sealing surfaces and threads. AVOID contact
with sealant and O-ring (10). Assemble the parts only after sealant has cured (dried).
29. Install snap ring (11) on shift ring (05).
30. Slide thrust washer (12) over shift shaft (33) and position in the pilot counterbore of the end cover.
CAUTION
!
31. Attach suitable hoisting equipment to the end cover assembly and lift it into position above the ring gear. Lower
the end cover so that the shift shaft feeds through the center of input shaft (34), and the cover closes com-
pletely over the pilot diameter of ring gear (A). Install twenty-four bolts (09) and torque in a crisscross pattern
evenly, and uniformly to 85 N.m (63 ft-lbs).
NOTICE
Input shaft (34) should have 0.039-0.079" (1-2 mm) end play after the end cover is installed.
32. Apply molybdenum-based protectant/sealant to the sealing surfaces of the cap (02) and spacer (03), and to the
threads of bolts (01). Allow to dry before assembling to the end cover. Torque the bolts to 38 ft-lbs (51 N.m).
CAUTION
!
33. Attach suitable hoisting apparatus to the propel transmission and position it so that the end cover is on the bot-
tom and the input shaft side is exposed on top for assembly.
34. Install snap ring (32) in the brake disk area of the spindle.
35. Install back-up plate (36) against snap ring (32).
36. Install inner and outer brake disks (38 and 39), and be sure that they are correctly engaged with the spindle
and coupler (35). Refer to Figure 9-14 for the arrangement of the inner and outer brake disks.
37. Lubricate back-up ring (41) and O-ring (42) with gear oil, and install in the spindle. The back-up ring must be
installed before the O-ring.
38. Install coupler (48) on shifter shaft (33), and retain it with snap ring (49). Lubricate splines with gear oil before
inserting coupler (48) into coupler (35).
39. Lubricate back-up ring (44) and O-ring (43) with gear oil, and install on the outside diameter of piston (45). The
back-up ring must be installed before the O-ring.
40. Install piston (45) in the counterbore of the spindle, and push it in as far as it will go against the brake disks.
Lubricate the counterbore with gear oil before installing the piston.
41. Position back-up plate (46) subassembly in the counterbore of the spindle until it contacts the brake springs.
42. Attach the spring cage fixture and protective buffer to the spindle, and apply enough axial force against coupler
(48) to enable compression of the brake springs. Press the shaft in only to the point where back-up plate (46)
seats firmly against the bottom of the counterbore in the spindle. Over-tightening can cause damage.
43. Install snap ring (47) in the spindle to retain back-up plate (46).
44. Remove the spring cage fixture from the spindle.
45. Install seal ring (29) and adapter (30) in the brake hydraulic pressure port, and tighten securely.
46. Install coupler (52) on the motor spindle with retaining plate (51) and bolt (50).
47. Install the hydraulic motor on the propel transmission as described above under Subtopic 9.3.1.3, Step 1
through Step 4.
48. Open Handwell valves.
Figure 9-15: Crawler Frame Assembly
LEGEND
01. Roller Shaft Tube
02. Cotter Pin
03. Roller Shaft Pin
04. Lower Roller Shaft
05. Upper Roller Shaft
06. Thrust Washer
07. Roller Assembly
08. Bushing
09. Link Assembly
10. Roller Shaft tube
11. Capscrew
12. Washer
13. Shoe Guide
14. Shim Shoe Guide
15. Screw
16. Transmission
17. Drive Tumbler
18. Capscrew
19. Crawler Frame
20. Upper Shim Pin
21. Lower Shim Pin
22. Idler Shim
23. Idler Shim
24. Cotter Pin
25. Idler Bearing
26. Idler Shaft Pin
27. Idler Thrust Washer
28. Idler Roller Assembly
29. Idler Bushing
30. Idler Shaft
Refer to Figure 9-15 and install the propel transmission on the crawler frame as follows:
CAUTION
!
hoisting equipment to stabilize and lift heavy objects. The transmission and motor
assembly weigh approximately 2800 lbs (1270 kg).
1. Attach suitable hoisting apparatus to propel transmission (15) and position it so that the hydraulic motor end is
aligned with the pilot bore in crawler frame (18). Be sure that the lube drain plug is located at the six o'clock
position, then insert the transmission into the frame.
2. Align the screw holes in the transmission with those in the frame, then install the thirty capscrews (14). Torque
the capscrews to 1526-1873 ft-lbs (2070-2540 N.m).
CAUTION
!
3. Attach suitable lifting equipment to drive tumbler (16), and install it on transmission (15) with thirty capscrews
(17). Torque the capscrews to 1526-1873 ft-lbs (2070-2540 N.m).
4. Install crawler track (08) on drive tumbler (16). Refer to Subtopic 9.3.5.3 for installation procedures.
5. Install the hydraulic pressure hose assembly for the brake to the fitting on the transmission spindle.
6. Install the high-pressure and control pressure hoses to the motor.
7. Remove the transmission lubrication fill/level plug and fill the transmission with approximately 9.5 gallons (36
liters) of gear oil (refer to Subtopic 16.3.5). Check and replace the fill plug seal if damaged, then install the plug
securely.
9.3.3 Idler Roller 13N385D1F1
The idler roller keeps the crawler track aligned. The idler roller is mounted in sliding bearing blocks, which enable it
to move fore and aft in the crawler frames. This provides a means of adjusting track tension.
9.3.3.1 Removal
Remove the idler roller assembly as follows:
1. Position the machine on level ground.
WARNING
!
work.
3. Separate the crawler track as described under Subtopic 9.3.5.1 and remove it from the idler roller.
4. Remove two cotter pins (02) from each upper shim pin (20) on the inside and outside frame locations, then
remove both upper shim pins from the crawler frame.
5. Note the locations of shims (22 and 23) ahead of and behind inner and outer idler bearings (25), then remove
all shims (refer to Subtopic 9.3.5.4 for shim removal procedure).
6. Remove the lubrication hose assembly from idler shaft (30).
7. Remove cotter pins (24) from each idler shaft pin (26), and remove the idler shaft pins from two idler bearings
(25).
CAUTION
!
8. Attach suitable lifting equipment to the idler roller, and lift the weight of the idler from idler shaft (30).
9. Remove two idler bearings (25) and idler thrust washers (27) from each end of idler shaft (30).
10. Remove idler shaft (30) from idler roller (28), then lift the idler away from the crawler frame.
Clean and inspect the idler roller components in accordance with the general cleaning and inspection procedures
described in Appendix A of this manual. None of the components are repairable, therefore, replace any that are
damaged or worn. Refer to the LinkOne electronic parts manual for component identification.
Refer to Figure 9-15 and install the idler roller assembly as follows:
CAUTION
!
1. Using suitable lifting equipment, position idler roller (28) in the pocket of crawler frame (19).
2. Lubricate idler shaft (30) with oil and install it in the bore of idler roller (28). Position the shaft so that the grease
hole is horizontal, and is pointed toward the tumbler end of the crawler.
3. Install thrust washer (27) on idler shaft 30) at each side of the idler roller.
4. Install idler bearing (25) on each end of idler shaft (30), and fasten it with idler shaft pin (26) and two cotter pins
(24).
5. Install shims (22 and 23) in the same positions on each side of inner and outer idler bearings (25) as before
removal.
6. Lock the shims in place with upper shim pins (20) and two cotter pins (03).
7. Install the lubrication hose assembly to idler shaft (30).
8. Refer to Subtopic 9.3.5.3 and reassemble the crawler track.
9. Adjust the crawler track tension as described under Subtopic 9.3.5.4.
9.3.4 Upper and Lower Rollers 13P627F1
On each crawler frame, thirteen rollers support the track as it moves around the crawler frame. Three upper rollers
support the weight of the track as it moves across the top of the crawler frame. Ten lower rollers support and dis-
tribute the weight of the drill to the crawler track.
Each roller is supported by a shaft mounted in a bushing along the side frame. The rollers are lubricated by the
auto-lube system.
9.3.4.1 Removal
Figure 9-16: Upper and Lower Rollers
03
02
01
06
04
05
07
BD0526a01
LEGEND
01. Crawler Track Link
02. Upper Roller Shaft
03. Upper Roller
04. Lower Roller
05. Lower Roller Shaft
06. Roller Shaft Pin
07. Cotter Pin
To remove the upper or lower rollers, proceed as follows:
1. Position the machine on level ground.
WARNING
!
Inadequate blocking of a raised drill can enable the machine to drop causing severe
injury, death, and/or equipment damage. Do not perform maintenance work under the
drill until it is securely blocked.
2. Raise the machine and position secure blocking beneath the frame.
WARNING
!
work.
4. Separate the crawler track as described under Subtopic 9.3.5.1. Remove the lubrication hose assembly from
the roller shaft.
5. Remove the cotter pins from the roller shaft pin.
6. Remove the roller shaft pin from lower or upper roller shaft.
7. Place blocking below the roller to prevent the roller from dropping when the roller shaft is removed.
8. Remove the lower or upper roller shaft from the roller, then remove the roller and thrust washers from the
frame.
Clean and inspect the track support roller components in accordance with the general cleaning and inspection pro-
cedures described in Appendix A of this manual. None of the components are repairable; therefore, replace any
that are damaged or worn. Refer to the LinkOne electronic parts manual for component identification.
Install the roller as follows:
9. Block the support roller with shim thrust washers in position within the crawler frame.
10. Lubricate the roller shaft with grease, and install the shaft through the frame supports and roller.
11. Install roller shaft pin in the roller shaft, and fasten it with two cotter pins.
12. Install the grease lubrication hose to roller shaft.
13. Manually operate the lubrication system and bleed the lines to the crawlers as required. Refer to Section 8,
Automatic Lubrication System..
9.3.5 Crawler Track Assembly
The crawler track assembly consists of a series of individual links (shoes), which are connected with link pins to
form the continuous track upon which the drill is propelled. The links are available in various widths and configura-
tions to accommodate differing soil conditions. The links on this drill are 36 wide; 2/3 of the links are cleated.
9.3.5.1 Track Link Removal
Remove track links as follows:
1. Propel the drill so the link to be removed is located behind the idler roller, and as near to ground level as possi-
ble, but with sufficient clearance to drive out the link pins.
2. Place temporary blocking between the under-side of the track links and the top of the crawler frame to support
the track when the link pins are removed.
WARNING
!
work.
Figure 9-17: Crawler Links
LEGEND
01. Track Link
02. Cleated Link
03. Link Pin
04. Pin Retainer
05. Nut
NOTE: Nut is tack welded to pin
retainer. Nut must be tight prior
to welding. Torque nut to 75 ft
lbs (102 Nm) and tack weld.
4. Remove the link pin retaining capscrew and hex nut from the track link (refer to Figure 9-17). The hex nut is
tack welded to the capscrew to prevent it from vibrating loose during operation. Cut off the weld, or break the
capscrew to remove it from the track link.
5. Remove the link pins at the place where the track is to be separated using one of the following two methods:
WARNING
!
The weight of a falling track can cause serious injury or death. Do not stand in the path
of a crawler track when the link pin is being removed.
Slide Hammer Method
CAUTION
!
Sparks or flying metal chips can injure eyes or face. Wear eye and face protection when
using hammers.
A. Obtain a rod with one end threaded for a nut.
B. Grind a 3/4" (19mm) x 45 degree chamfer on the other end of the rod.
C. Weld the ground end to the link pin (refer to Figure 9-18). Use sufficient weld to prevent the rod separating
from the pin.
D. Slide the slap hammer onto the rod, and install the hex nut on the rod end.
E. Remove the rod by slapping the hammer against the rod nut (refer to Figure 9-19).
Figure 9-18: Slide Hammer Method
Drive Rod Method
A. Obtain a smooth threaded rod of sufficient length and strength, with a mating hex nut on one end. The
threaded rod must be less than 1.5 inches (38 mm) diameter to fit into the bore of the track link.
B. Thread the hex nut on the striking end of the threaded rod.
C. Insert the rod into the bore of the track link, and drive the link pin out. The rod will need to be bent slightly at
the pin end to clear the link.
CAUTION
!
D. Attach suitable lifting equipment to stabilize the link being removed, then disassemble the remaining link
pins that fasten the link to the track. Link weight is approximately 450 Ibs (200 kg).
E. Remove the uncoupled link from the crawler track.
Clean and inspect the idler roller components in accordance with the general cleaning and inspection procedures
described in Appendix A of this manual. Repair of the crawler track is limited to replacement of defective link pins
and welding of the damaged track links.
Repair a damaged link as follows:
Figure 9-19: Drive Rod Method
WARNING
!
work.
1. Lock out and tag the operator controls to prevent inadvertent machine start-up during maintenance activities, if
the track link is being repaired while mounted to the drill.
2. Check suspected cracks with liquid dye penetrant or Magnaflux.
3. Clean the area to be welded. Remove all surface grease, oil, etc.
4. Grind or air-gouge the crack completely.
5. Pre-heat the weld zone to 600-700F (315-370C) and maintain this temperature during welding, checking with
a temperature indicating crayon.
6. Weld the track link with 10018-M electrodes. Pre-heat the electrodes in an oven at 350F (175C). Remove
only two electrodes from the oven at a time for use.
7. Slowly cool the track link after welding by wrapping the weld area with an insulating blanket.
9.3.5.3 Track Link Installation
Refer to Figure 9-17 and install track links as follows:
WARNING
!
tenance work on a machine without first disabling the operator - controls. Lock out and
work.
CAUTION
!
2. Using a lifting device of sufficient capacity, align the open track ends. Use a drift pin to help align the link pin
bores.
3. Install the link pins in the bores in the track links. There should be a slip-fit between the pin and the bore.
4. Install the link pin retaining capscrew and hex nut. Tighten the nut to 75 ft-lbs (102 Nm) maximum.
5. Tack weld the hex nuts to the capscrews to prevent loosening.
6. Repeat Step 2 through Step 5 to install addition track links and pins.
9.3.5.4 Track Tension Adjustment
Adjustment of crawler track tension is accomplished by adding or removing shims to the track adjustment mecha-
nism. A manually-operated hydraulic pump and two hydraulic rams with the required connecting hoses are fur-
nished with the machine, and are used to assist with track adjustment. To adjust track tension, proceed as follows:
1. Position the machine on level ground, then use the drill jacks to raise the drill enough to lift the crawler tracks
clear of the ground.
WARNING
!
work.
3. Remove two cotter pins from each upper shim pin on the inside and outside frame locations, then remove both
upper shim pins from the crawler frame.
4. Remove loose shims from behind inner and outer idler roller bearings (24).
5. Install one ram on the inboard side of the crawler frame between the ram support bracket on the crawler frame
and the idler bearing. Position the other cylinder similarly on the outboard side of the frame.
6. Connect the hydraulic hand pump to the two rams.
Figure 9-20: Track Tension Adjustment
TC0706
7. Operate the hand pump to pressurize the rams. This action moves the idler bearings to the rear, and removes
slack from the crawler track. Continue operating the pump until the crawler track sag is approximately 12" - 14"
(300mm - 350 mm), as measured at the track midpoint, between the top of the crawler link and the underside
of the crawler frame. Refer to Figure 9-21
8. Add shims as required on the ram side of the idler bearings to maintain the new position and ensure that the
track sag will remain as set. Use the shims which were removed from behind the idler bearings to fill the
required gap. The number and sizes of shims used should be identical at both idler bearing locations.
NOTICE
Shims are furnished in two thicknesses, 0.5 and 0.75 inch (12.7 and 19 mm).
9. Relieve the pressure on the rams, then remove them from the crawler frame brackets.
10. Lower the machine to the ground.
Figure 9-21: Track Tension Measurement
BD0530b01
C
BD120149 Mechanical Systems Manual Levelling System
Sec10Level.fm -10.1- Section 10, Version 00 - 03/06
Section 10
Levelling System
10.1 General
This section provides descriptive and maintenance information for the leveling jacks and jack hydraulic cylinders.
NOTICE
During maintenance procedures, apply standard torque to fasteners, unless otherwise speci-
fied. Refer to Appendix A for general mechanical maintenance procedures, and to Appendix B
for general hydraulic component maintenance procedures. It is advisable to replace all seals
and O-rings whenever hydraulic components are disassembled. Refer to the Parts Manual for
identification of components and service kits.
The four leveling jacks, attached to the corners of the main frame, are hydraulically actuated units that establish
and maintain a level and stable position for the drill during drilling operations. Hydraulic pressure is supplied from
the auxiliary hydraulic system. Refer to Section 3, Auxiliary Hydraulic System..
Operation of the jacks is controlled from the operator cab. The rear jacks (nearest the mast) are independently
adjustable. The front jacks cylinders are connected in parallel so that they raise or lower as a self-equalizing pair.
The jacks can also be placed in the automatic mode, which automatically raises the drill deck to the lowest level
elevation for good drill stability.
Levelling System BD120149 Mechanical Systems Manual
Section 10, Version 00 - 03/06 -10.2- Sec10Level.fm
10.2.1 Rear Jacks 100J6691F5 and 100J6691F6
Each of the two rear jacks consists of a hydraulic cylinder, spud, and shoe with housing and mounting hardware.
The rod end of the cylinders is pinned to the jack cap on top of the jack housing. The cylinder barrel is pinned to the
spud; the spud, in turn, is pinned to the shoe. The operator controls each jack independently by separate switches
on the operators console. Hydraulic pressure is applied to the cylinder piston through internal passages in the rod,
causing the spud and shoe to extend or retract.
Figure 10-1: Rear Jack (left shown, right similar)
LEGEND
01. Jack Cap
02. Lockwasher
03. Capscrew
04. Housing
05. Upper Cylinder Pin
06. Cotter Pin
07. Washer
09. Pipe Plug
10. Lower Cylinder Pin
11. Jack Spud
10.2.2 Front Jacks 100J6692F3 and 100J6693F3
Each of the two front jacks consists of a hydraulic cylinder, spud, and shoe with housing and mounting hardware.
The rod end of the cylinders is pinned to the jack cap on top of the jack housing. The cylinder barrel is pinned to the
spud; the spud, in turn, is pinned to the shoe. The operator actuates both jacks simultaneously through a single
switch on the operators console. Hydraulic pressure is applied to both cylinder pistons through internal passages
in the rods, causing the spuds and shoes to extend or retract.
10.2.3 Leveling Jack Shoes R56352D1, R56353D1
On the lower end of each front and rear jack is the jack shoe. Jack shoes provide a wide area of support, distribut-
ing the drills weight over a relatively large surface area. Jack shoes are 127 cm (50") in diameter and weigh
approximately 730 kg (1610 lbs).
Figure 10-2: Front Jack (left shown, right similar)
Figure 10-3: Jack shoe
10.3 System Maintenance
10.3.1 Leveling Jack Shoes R56352D1, R56353D1
10.3.1.1 Removal
1. Lower the drill so that the shoes rest on the ground, but without weight bearing on the shoes.
WARNING
!
Inadvertent operation of the blasthole drill during maintenance could cause severe
injury and/or death. Lock out and tag out the drill operating controls to prevent opera-
tion.
2. Lock out and tag out the drill operating controls to prevent inadvertent start-up or movement of the drill during
maintenance activities.
3. Remove the cotter pin and lockwasher that attaches the retainer pin to the to the spud.
4. Drive out the retainer pin.
WARNING
!
Some blasthole drill components are extremely heavy. Dropping or mishandling of
these parts can cause severe injury or death, and damage to the equipment. Always sup-
port heavy components using a suitable hoist or other means for removal, disassembly,
assembly and installation. Provide appropriate support for any components that are not
supported by the machinery during maintenance. Jack shoes weigh approximately
730 kg (1610 lbs).
5. Remove the shoe.
10.3.1.2 Repair
Clean and inspect the jack components in accordance with the general cleaning and inspection procedures pro-
vided in Appendix A of this manual. Repair consists of the replacement of all worn or damaged components. Refer
to the LinkOne electronic parts manual for component identification.
1. Position the shoe under the spud and align the mounting holes.
2. Push or drive in the retainer pin.
3. Install the cotter pins to attach the retainer pin to the to the spud.
10.3.2 Jack Hydraulic Cylinders R4102D2
Removal of all jack cylinders and spuds is similar. To remove the front cylinders or spuds, the mast must be raised
and locked in position and the back braces disconnected at the jack caps. Refer to Section 11, Mast. for instruc-
tions.
10.3.2.1 Removal
It is advisable to service one jack at a time, as follows:
1. Lower the drill so that the shoes rest on the ground, but without weight bearing on the shoes.
2. If necessary, raise the mast and lock it in position.
3. Disconnect the applicable back brace from the jack cap and secure the brace. Refer to Section 11, Mast. for
instructions.
Figure 10-4: Hydraulic Cylinder Components (typical)
LEGEND
01. Ingression Ring
02. Wear Ring
03. Backup Ring
04. Seal
05. O-ring
06. Ingression Ring
07. O-ring
08. Backup Ring
09. Wear Ring
10. Seal
11. Backup Ring
12. Wiper
NOTE: Numbered items
are part of a seal kit.
WARNING
!
injury and/or death. Lock out and tag out the drill operating controls to prevent acciden-
tal operation.
4. Lock out and tag out the drill operating controls to prevent inadvertent start-up or movement of the drill during
5. Remove the cotter pins that attach the retainer pin to the spud. Drive out the retainer pin.
6. Close the Handwell valve.
WARNING
!
Hot hydraulic oil under pressure can spray and burn with extreme force and volume,
causing injury or death. Use lockout and tagout procedures to guard against inadvertent
hydraulic system or machine start-up during service or maintenance. Allow the hydrau-
lic system to cool prior to any maintenance or repair. Slowly release pressure or vent cir-
cuits before disconnecting hydraulic lines. Wear appropriate face and body protective
devices while carefully loosening any connection or fitting.
7. Install a pressure gauge into the test port on the regeneration valve. Check pressure on both the head end and
the rod end of the cylinder. If any pressure remains, take action to remove the pressure before beginning any
disassembly.
8. Tag and disconnect the hydraulic hoses to the jack cylinder. Allow oil to drain into a catch basin. Cap and/or
plug all hoses and fittings to prevent contamination of the hydraulic system.
9. Remove the mounting hardware that attaches the jack cap.
WARNING
!
Some blasthole drill components are extremely heavy. Dropping or mishandling of these
parts can cause severe injury or death, and damage to the equipment. Always support
heavy components using a suitable hoist or other means for removal, disassembly,
assembly and installation. Provide appropriate support for any components that are not
supported by the machinery during maintenance.
10. Support and lift the jack cap with a suitable hoist to withdraw the cap, cylinder, and spud as a unit.
11. Remove the cotter pins, flat washers, and upper cylinder pin. Remove the jack cap.
12. Remove the pipe plugs and drive out the lower cylinder pin. Remove the spud.
10.3.2.2 Disassembly
1. Use a spanner wrench to remove retainer (03) from barrel (10).
2. Remove rod (01) and related components from the barrel.
3. Remove parts from the rod and barrel to access the seals and other parts of the service kit.
10.3.2.3 Repair
Clean and inspect the cylinder components in accordance with the general cleaning and inspection procedures
provided in Appendix B of this manual. Repair consists of the replacement of all service kit components. If other
parts are worn or damaged, the entire cylinder must be replaced. See the LinkOne electronic parts manual for
component identification.
10.3.2.4 Assembly
1. Lubricate service kit parts and other sliding parts with clean hydraulic oil before installation.
2. Install and assemble parts in the reverse order of removal.
3. When installing the piston, pre-set nylon plug (08) in place using a grade 8 hex head capscrew to 150 ft-lbs
(203 Nm). Then remove the capscrew, install setscrew (09), and tighten the setscrew to 75 ft-lbs (102 Nm).
Refer to Figure 10-1 or 10-2 and proceed as follows:
1. Align the cylinder and spud. Drive in the lower cylinder pin and install he pipe plugs.
2. Align the cylinder and jack cap. Be sure that the cylinder ports are aligned correctly to mate with the hydraulic
hose assemblies. Install the upper cylinder pin, flat washers, and cotter pins.
3. Support and position jack cap, cylinder, and spud with a suitable hoist. Lower the unit into the housing.
4. Install the mounting hardware to attach the jack cap.
5. Align the shoe and spud. Push in the retainer pin. Install the capscrew and lockwasher to attach the retainer pin
to the spud.
6. Install the hydraulic hose assemblies in accordance with their identification tags.
7. If necessary, connect the applicable back brace to the jack cap and secure. Refer to Section 11, Mast. for
instructions.
8. Bleed the hydraulic circuits. Refer to Section 10, Levelling System..
10.4 Troubleshooting
10.4.1 Basic Operational Test for Auto Level System
P&H Mining Equipment provides detailed procedures to be use when setting up the Auto Level System in the Auto
Level Setup Procedure, ELEC 3724. It is expected that once the drill is commissioned, there will be little or no need
(unless major components of the system need to be replaced) to engage in the extensive setup procedures
defined in ELEC 3724.
During Preventive Maintenance Inspection periods, this procedure provides a quick way to check the Auto Level
System without executing the meticulous and time-consuming process required by the Auto Level Setup Proce-
dure. If unexpected results are noted, contact your local MinePro Services representative to obtain a copy of the
Auto Level Setup Procedure, ELEC 3724.
WARNING
!
It is essential that any repairs be completed to the jack circuit prior to initiating the Auto
Level Basic Operational Test.
The pages that follow provide a checklist for the Basic Operational Test. It is also recommended that a copy of the
current auxiliary hydraulic schematic (R57349. Contact P&H MinePro Services for latest change mark) be available
during this test.
MECHANICAL CHECKED
1.0) Make sure Jack Spuds are well greased to prevent binding. _______OK
1.1) Check Hydraulic Oil tank for proper amount of oil. _______OK
1.2) Operate system components to warm oil to at least 70F (21C) before test-
ing.
_______OK
1.2) Manually Level Drill ensuring all jacks are taking load _______OK
1.3) Visually check all four Leveling Jack cylinders and their components for leaks or
cylinder drift.
Note: Repairs to the Leveling Jack circuit should be made if cylinder drift exceeds
inch (13mm) per hour before continuing on with this procedure.
_______OK
HYDRAULIC CHECKED
2.0) Verify Jack System Pressure (2900 PSI on VB1, 2850 PSI on VB3 [maxi-
mum]).
To Test: Retract all four Jack Cylinders to the full retract position. Next, select and
press one of the Jack Leveling rocker switches in the retract position (dead heading
the pump) while observe the Hydraulic Pressure Meter (HPM) on the cab console.
To Adjust [see 10-5]: Install a 0 - 5000 psi Pressure Gauge into the Relief/Unload
Oil Diverter Valve test port. Set controls at neutral and manually depress the valve
plunger on Valve Bank 1. Adjust to a maximum of 2900 psi.
Leave the pressure gauge installed and depress the valve plunger on Valve Bank 3.
Adjust to 2850 psi. Remove gauge.
Note: To prevent hunting between the two relief valves, differential should always be
at least 50 psid.
_______OK
2.1) Verify Right Rear Leveling Jack Counterbalance Valve Pressure
To Test: Manually Extend the Right Rear Leveling Jack Cylinder from the full retracted
position. As the jack is moving freely downward and before the jack touches the
ground, observe the Hydraulic Pressure Meter (HPM) on the cab console. Jack pressure
should range from 650-800* psi.
Note: During the Auto Leveling mode the instant the Jack pressure exceeds that of
the Jack Pressure Switch setting, the switch will close signaling the PLC to stop that
particular Jack operation.
_______OK
*If pressure exceeds 800 psi, contact your local P&H MinePro Services representative.
2.2) Verify Left Rear Leveling Jack Counterbalance Valve Pressure
To test: Manually Extend the Left Rear Leveling Jack Cylinder from the full-retracted
position. As the Jack is moving freely downward and before the Jack touches the
Note: During the Auto Leveling mode the instant the Jack pressure exceeds that of
_______OK
3.0) Verify Front Leveling Jack Counterbalance Valve Pressure
To test: Manually Extend the Front Leveling Jack Cylinders from the full-retracted
position. As the jacks are moving freely downward and before the jacks touch the
Note: During the Auto Leveling mode, the instant the Jack pressure exceeds that of
_______OK
HYDRAULIC CHECKED
Figure 10-5: Verify Jack System Pressure
Valve Bank 3
Install 0 - 5000 psi gauge
at Test Port
Manual Override*
System Adjustment
Test Port
Valve Bank 1
* Use a small Allen wrench
or screwdriver to manually
press in and hold the plunger.
ELECTRICAL CHECKED
4.0) Ensure GUI Auto Level screen is in working order. _______OK
4.1) Verify Jack Pressure Switches operation
To confirm operation: Manually extend the front & rear Leveling Jack Cylinders one
at a time from their full-retracted position. When the jack pad makes contact with the
ground and just begins to lift the drill, the pressure switch for that jack will mechani-
cally close the electric contacts, turning ON the input signal to the PLC. Next, manu-
ally retract the jack cylinder. As soon as the jack pad retracts from the ground, the
pressure switch contacts will mechanically open turning OFF the input signal.
Jack Input Signal PS Setting
a. Right Rear I:07/15 950 psi 50 psi
b. Left Rear I:07/16 950 psi 50 psi
c. Front I:07/14 950 psi 50 psi
d. Front Over-pressure I:07/13 950 psi 50 psi
Note: Pressure Switches produce a feedback signal to the PLC for the Auto Level
sequence. To ensure consistent Auto Leveling function and performance, pressure
switches must be working properly. Repairs and or adjustments must be made before
continuing on with this procedure. Refer to 10-6.
_______OK
_______OK
_______OK
_______OK
4.2) Verify level sensors operation (located inside the PLC cabinet on 120125 &
future)
To test (Refer to 10-7): Manually tilt each sensor and observe the GUI screen or
PLC input card I:30. Shims can be placed under the Sensor to simulate drill angle of
tilt.
a. Tilt LS3 towards the front of drill = I:30/5 ON @
b. Tilt LS3 towards the rear of drill = I:30/4 ON @
c. Tilt LS2 towards the right of drill = I:30/3 ON @
d. Tilt LS2 towards the left of drill = I:30/2 ON @
e. Tilt LS1 any direction = I:30/1 OFF @ 6
Note: There is a slight time delay on the sensor outputs as observed on the GUI or
the PLC card. The LED indicators on the bottom of the sensors are real-time corre-
sponding to the PLC inputs. Refer to Figure 2.
_______OK
_______OK
_______OK
_______OK
_______OK
Figure 10-6: Auto Level Pressure Switch Adjustment
0
500
2500
2000
1500
1000 Set to
900 psi
Minimum
Pressure Adjusting
Screw and Locknut
Pressure
Setting
Indicator
Figure 10-7: Auto Level Tilt Sensors (LS1, 2, & 3)
LS3
Front & Rear
LS2
Right & Left
LS1
Over-tilt
Tilt Sensor (Typ.)
Press sensor down,
place shims under
locknut to simulate
drill angle
Degrees
0.5
1.0
2.0
3.0
4.0
5.0
6.0
Shims
(approx.)
.014"
.027"
.054"
.082"
.109"
.136"
.163"
NOTE: Rough Setting.
May need to be fine-tuned
after setup by
adjusting locknut(s).
Sensor Panel
Time Delay
Adjustment
X - Y
LED
MANUAL AND AUTO LEVELING CHECKED
5.0) Verify Machine is Level (refer to Figure 10-8 on page 15)
Position a 3 foot (1m) level along main frame I-beam = bubble centered
Position a 3 foot (1m) level along the rear axle = bubble centered
Note: Manually adjust individual Jacks until machine is level. Refer to Figure 3.
_______OK
_______OK
5.1) Verify Clinometer Gauges inside operators cab are set at zero once machine is
level. Adjust if necessary.
_______OK
5.2) When the Machine is Level, the 'MACHINE LEVEL' lamp on the operator's con-
sole should illuminate.
_______OK
5.3) Verify That All Four (4) Jacks Indicate Ground Pressure on GUI Auto Level Screen
Note: It is essential that repairs be completed to the jack circuit to ensure the Auto
Level testing is accurately measured.
_______OK
5.4) Press the Auto Level Switch to LOWER.
a. The front Jacks should retract lowering the front of the machine until the load is
off of the front jacks.
b. Both rear jacks should retract and maintain L-R level while lowering the rear of
the machine until the load is off of the rear jacks.
c. When all jacks are fully retracted, the auto level system will turn off.
_______OK
_______OK
_______OK
5.5) Press the Auto Level Switch to Raise.
a. The front and rear jacks will begin to extend.
b. When all four (4) Jacks just make contact with the ground, the rear will equalize
side-to-side.
c. If the machine is level side-to-side, all jacks will extend simultaneously.
d. When the machine is level side-to-side and the front is low, the front will continue
to rise until the machine is level front-to-back.
e. Once the machine is level for 6 seconds, the system will not react to a change
f. If the machine is out-of-level for longer than 4 seconds and there is no move-
ment, the MACHINE LEVEL light will blink. See note.
Note: If pump pressure and or pump flow is low, jack(s) may stall during Auto Level.
As a result, the 4-second timer will cause a fault. Check pump operation, pressures,
etc.
_______OK
_______OK
_______OK
_______OK
_______OK
_______OK
5.6) After the previous tests are complete, the system should be checked at different
positions to simulate different operating conditions.
a. With the machine level, turn the auto level system off and retract one jack to
force the machine out of level.
b. Turn the Auto Level system on again to RAISE. Monitor system for proper level-
ing
c. During Auto Level raise operation, side to side and front to back movement
should be smooth and steady.
d. If, during the Auto Level process the drill ratchets from one Jack to the other, it's
possible that the Level Sensor(s) time delay adjustment interval is too short.
Refer to Step 5.1.
e. Repeat Auto Leveling Raise & Lowering after adjustments if necessary.
_______OK
_______OK
_______OK
_______OK
_______OK
5.7) Basic Operational Test Completed _______OK
Figure 10-8: Check Machine Level
TEST VERIFICATION
Model/Serial Number ______________ / _________________________________
Customer ________________________ Machine Hours _______________
Checked By: ______________________ Date: ______________________
Checked By: ______________________ Date: ______________________
Checked By: ______________________ Date: ______________________
Comments:
Use a 3-foot (1 meter) carpenter's box level
along the main frame and the rear axle
for front-to-back and side-to-side conditions.
It time permits, using surveying equipment
would provide more accurate results.
Main Frame Rear Axle
10.4.2 Troubleshooting Chart
Problems with the leveling system will almost always be caused by hydraulic system malfunction or electrical con-
trol circuit malfunction. the troubleshooting chart from Section 3, Auxiliary Hydraulic System. is included here for
convenience.
System fails to build
pressure
Control valve does not shift cor-
rectly
Replace the Relief/unload/oil diverter valve
System oil level is low Replenish tank supply
External leak in system
Tighten components and bleed air from sys-
tem
dirty filters Replace the filters
clogged inlet line Clean the inlet line
clogged tank breather Clean or replace the breather
fluid is too cold Heat the fluid
main drive motor is not operating Repair or replace the main drive motor
pump drive coupling failed Repair or replace the coupling
relief or unloading valve set too low Adjust the valve to the correct setting
pump is damaged Repair or replace the pump
Excessive hydraulic
pump noise
air in the fluid
Excessive system heat
air in the fluid
contaminated fluid Change filters and replace the fluid
Drill pipe racks operate
too slow or too fast
ment or faulty
dle valve
Leveling jacks and winch
move slowly
ment or faulty
dle valve
The unloading relief valve is faulty
Adjust the unloading relief valve to operate
at 1100 psig (75.9 bar). If unable to adjust,
repair or replace valve
Breakout Wrench moves
too fast or too slow
faulty flow control valves Adjust or replace the flow control valves
Table 10-1: Auxiliary Hydraulic System Troubleshooting
BD120149 Mechanical Systems Manual Mast
Sec11Mast.fm -11.1- Section 11, Version 00 - 03/06
Section 11
Mast
The mast supports the drilling components including the rotary machinery, pulldown/hoisting mechanism and
brakes, guide rollers, pipe handling components, and some of the bit air components. The mast is mounted on
hinge pins to allow the mast to be raised to the vertical position from the stored horizontal position and back. The
hinge pins are located at the top of the mast support frame uprights. Raising and lowering of the mast is accom-
plished by two operator-controlled hydraulic cylinders that are connected to the mast and the main frame. The
mast is locked in the vertical drilling position by the two operator-controlled, hydraulically-actuated anchor pins.
The mast is also supported in the drilling position by two articulated back braces that are pinned to the mast and
Figure 11-1: 120A Mast (Typ.)
Mast BD120149 Mechanical Systems Manual
Section 11, Version 00 - 03/06 -11.2- Sec11Mast.fm
the front jack caps. Hydraulically-actuated locking collars slide over the back brace joints to secure the extended
braces. When the mast is lowered, the locking collars are retracted and the back braces automatically fold. Each
back brace has an adjusting screw to allow adjustment of fixed length.
11.1.1 Mast Weldment R53818D1
The mast is 20.1 meters (66 feet) in length, and is made of structural steel welded in a lattice arrangement to pro-
vide strength and light weight. The four legs of the mast are tied together at the top by a crown block; the crown
block also supports the auxiliary winch sheaves. The winch acts as a support structure for the rotary carriage,
which contains the rotary motion motor and transmission as well as the pulldown motor and transmission. The
rotary machinery is covered in Section 12, Rotary Machinery..
The rearward part of the mast is provided with racking on both sides. This racking meshes with drive pinions on the
carriage to permit the pulldown and hoist systems to move up and down the mast. The pulldown machinery is cov-
ered in Section 12, Rotary Machinery..
11.1.2 Ladder 29J333F3
A ladder is mounted to the right side of the mast to permit inspection of the upper structure. The ladder is equipped
with safety hoops and the Saf-T-Climb system.
Figure 11-2: Saf-T-Climb
Figure 1. Pawl in unlocked position as worker climbs. The mechanism allows
hands-free climbing.
Figure 2. Pawl automatically slides into locked position during fall. When
descending, the pawl must be manually released at each catch point.
Always use the correct harness when using the Saf-T-Climb system.
11.1.3 Back Braces 100J6487F3
Two articulated structures are pinned to the mast and to the front jack caps. When the mast is hoisted to its vertical
position, the back braces extend to form a support for the mast. Hydraulically-actuated locking collars slide over
the articulated joints to secure the extended braces. When the mast is lowered, the locking collars are retracted
and the back braces automatically fold. Each back brace has an adjusting screw to allow adjustment of fixed
length.
11.1.4 Mast Lock Pins GH1302T14
The mast is locked in the vertical drilling position by the two pins, one on either side. These operator-controlled,
hydraulically-actuated anchor pins are mounted under the drilling deck.
Figure 11-3: Back Braces (Typical)
Figure 11-4: Mast Lock Pin
11.1.5 Mast Hoist Cylinders R6268D1
.The mast is raised and lowered by two large-bore, long stroke hydraulic cylinders. The cylinder rod end is
mounted with a clevis and pin joint to the mast. The cylinder head end is clevis and pin mounted to brackets on the
drill main deck.
11.2 Mast Maintenance
11.2.1 Mast Weldment R53818D1
It should seldom, if ever, be necessary to remove the entire mast assembly, except in the event of severe damage
to structural parts. Most service and replacements of components can be performed in the field. During mainte-
nance procedures, apply standard torque to fasteners, unless otherwise specified. Refer to Appendix A for general
mechanical maintenance procedures, and to Appendix B for general hydraulic component maintenance proce-
dures
11.2.2 Auxiliary Winch 23U52D1
11.2.2.1 General
The winch is mounted inside the machinery house, between the mast hoist cylinders.
11.2.2.2 Removal
1. Remove the clamps, hook and thimble from the end of the winch wire rope.
2. Tie one end of a 30 meter (200 foot) nylon, poly, or hemp line to the free end of the wire rope. Fasten the other
end of the line to the mast frame at a convenient point. This line will be used to pull the winch wire rope back
through the sheaves when the winch is reinstalled.
3. Operate the winch to rewind the wire rope onto the drum, allowing the line to pass over the guide sheave and
down to the drill deck. Fasten the wire rope to the drum to prevent unspooling, then untie the line, and fasten
the end to the mast frame at a convenient point.
4. Lock out and tag the drill operator controls to prevent inadvertent startup during maintenance procedures.
WARNING
!
Hot hydraulic oil under pressure can spray and burn with extreme force and volume
hydraulic system or machine startup during service or maintenance. Allow the hydraulic
system to cool prior to any maintenance or repair. Slowly release pressure or vent cir-
5. Tag and disconnect the hydraulic hoses and fittings from the winch motor and brake housing. Cap and/or plug
all hoses and motor ports to prevent undesired drainage and contamination of the hydraulic system. Refer to
Appendix B for information on the hydraulic connections.
WARNING
!
parts can cause severe personal injury or death, and damage to the equipment. Always
support heavy components using a suitable hoist or other means for removal, disassem-
bly, assembly and installation. Provide appropriate support for any components which
are not supported by the machinery during any maintenance.
6. Remove the capscrews and lockwashers that attach the winch to the deck. Remove the auxiliary winch.
7. Note the direction that the wire rope is wound on the winch drum. Remove the wire rope from the winch drum if
necessary.
If components of the winch require repair, refer to the following component repair instructions as necessary:
Subtopic 11.2.3
Subtopic 11.2.4
Subtopic 11.2.5
Subtopic 11.2.6
WARNING
!
1. Position the winch on the deck. Check the mounting surface for unevenness. Be sure that all four mounting
pads contact the mounting surface. If not, one pad should be shimmed to compensate. Install three mounting
capscrews and lockwashers. Measure the space underneath the fourth pad with a feeler gauge and install
shim stock of corresponding thickness with the capscrew and lockwasher. Apply new lockwire to the capscrew
heads.
2. Install the hydraulic hoses and fittings in accordance with the identification tags previously attached.
3. Be sure that the planetary is filled with lubricant. Refer to the lubrication section.
4. Start the drill and operate the winch to bleed air from the hydraulic circuit. Check for flow through the return line
when the winch is run in reverse to make sure that oil is being circulated through the brake. If not, investigate
the hydraulic circuit for the cause of malfunction and correct the problem.
5. Pull the wire rope through the sheave on the upper mast by using the temporary reeving line. Secure the free
end of the wire rope to the mast to prevent it from being pulled too far through the sheaves. Leave enough
length of wire rope to enable attachment to the winch drum.
WARNING
!
Inadvertent operation of the blasthole drill during maintenance on the machine could
cause severe bodily injury and/or death. Lockout and tagout the drill operating controls
to prevent accidental operation.
7. Remove the temporary reeving line. Install the hook (04) and thimble (03) with clamps (02) on the free end of
the wire rope.
CAUTION
!
Use the slot for clockwise rotation. Do not use the slot for counterclockwise rotation.
The slots are marked. If the wire rope is wound onto the drum for counterclockwise rota-
tion, the winch will not have any braking. This could result in uncontrolled lowering of a
load, resulting in personal injury and property damage. Be sure that the wire rope is
installed into the slot for clockwise forward rotation (clockwise when looking at the
motor end of the winch).
8. Detach the other end of the wire rope. Wrap the wire rope around the drum anchor and pull the anchor firmly
into the slot in the winch drum.
9. Operate the winch to wind the wire rope onto the winch drum. The wire rope will wind around the drum in the
proper direction.
NOTICE
The drum should always have at least four wraps around the drum to be sure that the rope does
not come off the drum
11.2.3 Winch Motor Repair
Motor repair requires removal of the motor from the winch motor adapter. If the motor does not need repair, do not
remove it from the adapter.
1. 1. Remove capscrews (03) and lockwashers (04).
NOTICE
When prying off parts, take care not to damage the machined surfaces of parts. This particularly
true of the cover and housing. Surface damage will cause motor leakage or other malfunction.
2. Remove end cover (09) with bearings (10), seal (16) and thrust plate (01). Pry the cover if necessary. The
thrust plate may remain in the housing (12). Leave the dowel pins (11) in the housing.
3. If the thrust plate came off with the cover, pry it off the bearings (10). Remove and discard pocket seals (13).
4. Remove gear set (14) and thrust plate, if necessary, from the housing.
Figure 11-5: Auxiliary Winch
LEGEND
01. Thrust Plate
02. Body Seal
04. Lockwasher
05. Motor Assembly
06. CCW Rotation Port
07. Pipe Plug
08. CW Rotation Port
09. End Cover
10. Needle Bearing
11. Dowel Pin
12. Gear Housing
13. Pocket Seal
14. Gear Set
15. Motor Adapter
16. Ring Seal (Consists of Items 06
through 18)
17. Pipe Plug
18. O-ring
20. Lockwasher
21. Pipe Plug
5. Carefully pry off the housing from the adapter (15). Use care to avoid damage to the splined shaft and gear
bore. The thrust plate may remain in the housing. Leave the dowel pins (11) in place.
6. If the thrust plate remained in the adapter, pry it off the bearings (10). Remove and discard pocket seals (13).
7. Remove bearings (10). Remove and discard ring seals (16) and body seals (02).
Clean and inspect parts as specified inAppendix A. Replace all worn and/or damaged parts. Replace all seals
using the motor seal kit. The seal kit includes two strips of rubber. The pocket seals must be cut to length from the
strips with a sharp knife to fit the openings in the thrust plates.
11.2.3.3 Assembly and Installation
1. Apply grease liberally to all seals.
2. Install new ring seals (16) in end cover (09) and adapter (15), followed by the bearings (10).
3. Install six new pocket seals (16) in each thrust plate (01). Press one thrust plate with seals onto the bearings
and adapter.
4. Install a new body seal (02) into one side of housing (12). Position the housing over dowel pins (11) in the
adapter and press into place. Tap the housing with a soft faced hammer if necessary.
5. Install gear set (14) into the housing. The longer gear goes on top with the internal spline toward the adapter.
6. Install a new body seal (02) into the other side of the housing. Press the second thrust plate with seals onto the
housing with the pocket seals facing away from the gears
7. Position the assembled end cover over the dowel pins and press into place. Tap the end cover with a soft faced
hammer if necessary.
8. Install capscrews (03) and lockwashers (04). Tighten the capscrews evenly to 270 Nm (200 ft-lbs) torque.
11.2.4 Winch Brake Repair
Figure 11-6: Auxiliary Winch Brake Components
LEGEND
01. Thrust Washer
02. Support Washer
03. Sprag Clutch
04. Divider Plate
05. Piston
06. O-ring
07. O-ring
08. O-ring
09. O-ring
10. Circlip
11. Circlip
12. Clutch Aligner
13. Brake Spring
14. Brake Hub
15. Clutch Aligner
16. Brake Housing
17. Plug (Oil Return)
18. Friction Plate
19. Brake Spacer
20. Circlip
21. Base
22. Thrust Bearing
23. Oil Seal
24. Needle Bearing
25. Drive Shaft
26. Drum
27. Connecting Shaft
28. Sun Gear
NOTICE
If the motor does not require repair, do not remove it from the adapter.
11.2.4.1 Removal and Disassembly
Refer to Figure 11-6 and proceed as follows
CAUTION
!
The brake springs (13, Figure 11-6) are under considerable tension against the motor
adapter. They can release unexpectedly with great force and cause severe personal
injury. Unscrew capscrews one turn at a time in sequence until the spring pressure is
relieved. Then remove capscrews (19) and lockwashers (20) to detach the winch motor
and adapter.
1. Remove and discard O-rings (08 and 09). O-ring (09) is located on the brake housing flange.
2. Remove brake springs (13).
3. Pull drive shaft (25) from brake housing (16) with the brake hub assembly.
4. Remove circlip (11) from the drive shaft. Remove washers (02), brake hub (14), and clutch aligners (12 and
15). Note the position of the sprag clutches (03) and remove them.
5. Pull piston (05) from the brake housing.
6. Remove and discard O-rings (06 and 07).
7. Remove friction plates (18) and divider plates (04).
8. Remove brake spacer ((19).
9. Remove thrust bearing (22) and thrust washers (01).
10. Remove and discard oil seal (23).
11. Do not remove brake housing (16) unless repair of the drum is required. Refer to Winch Drum Repair.
Clean and inspect parts as specified in Appendix A. Replace all seals and O-rings using the winch seal kit. Replace
all scored, worn and/or damaged parts.
1. If the outside diameter of the piston is scratched. polish it with fine emery cloth. Wash the piston thoroughly
after polishing.
2. Inspect the bore of the brake hub and outside of the drive shaft where both places contact the sprag clutches.
If these areas are indented or otherwise damaged, replace the shaft and/or hub.
1. Apply grease liberally to new seals and O-rings.
2. Install sprag clutches (03) in the bore of the brake hub (14). The clutches must be positioned so that the motor
end of the drive shaft (25) will turn freely in the clockwise direction and lock in the counterclockwise direction.
3. Install washers (02) and clutch aligners (12 and 15) on each side of brake hub (14). Slide the hub assembly
onto the drive shaft. Install circlip (11).
4. Install a new oil seal (23) in the bore of the connecting shaft (27).
5. Slide thrust bearing (22) with a thrust washer (01) on each side onto the large end of the drive shaft against cir-
clip (20). Insert the end of this assembly through the connecting shaft (25) so that the splines engage the sun
gear (28). Take care not to damage the oil seal (23) or needle bearing (24) during installation.
6. Install brake spacer (19) and one divider plate (04). Then starting with a friction plate (18), alternately install a
friction plate and a divider plate until all plates are in place. The brake disc stack must finish with a divider
plate.
7. Install O-rings (06 and 07).
8. Install brake piston (05) in the brake housing(l6) so that the spring holes facing outward.
9. Install sixteen brake springs (13) into the piston. There are 18 holes for the springs. The two empty holes
should be opposite each other.
10. Apply grease to O-rings (08 and 09) and install. O-ring (09) should be placed over the transfer hole for the
automatic release pressure on the motor adapter flange.
11. Slide the winch motor and adapter over the drive shaft so the splines engage and the pressure transfer holes
and brake spring holes are aligned.Install capscrews (19) and lockwashers (20) to attach the winch motor and
adapter. Tighten the capscrews evenly one turn at a time in a cross sequence until the adapter is fully in place.
11.2.5 Winch Planetary Repair
Figure 11-7: Auxiliary Winch Planetary Components
LEGEND
01. Breather
02. Thrust Washer
03. Planet Gear
04. Needle Bearing
05. Circlip
06. Circlip
07. Ball Bearing
08. Oil Seal
09. Cable Anchor
10. Clrclip
11. Pipe Plug
12. Circlip
13. Sun Gear
14. Cable Drum
16. Base
17. Lockwasher
18. Planetary Housing
19. Planet Hub
20. O-ring
21. Retaining Rings
22. Pipe Plug
23. Planet Hub Stopper
24. Sun Gear Stopper
25. End Cover
26. Planet Pin
27. Circlip
1. Remove pipe plug (21) and drain the oil from the planetary and drum interior. Tip the unit at an angle to drain all
oil from the drum.
2. Remove capscrews (15) and lockwashers (17) to detach base (16) from the planetary and drum.
3. Remove internal retaining ring (22) and end cover (25) with O-ring (20). Discard the O-ring.
4. Remove stoppers (23 and 24).
5. Withdraw planet hub assembly from housing (18).
6. To remove planet gears (03), remove circlips (05) and press pins (26) from hub (19). Slide out the planet gears
with needle bearings (04) and thrust washers (02).
7. Withdraw sun gear (I 3) from drum (1 4).
8. Remove circlip (10). Insert two pry bars between the flange of drum (14) and housing (18) and carefully pry the
drum from bearing (07).
9. Remove circlip (06) and bearing (07). disassemble the position the (08) in the (I8). Re- move and discard the oil
seal.
1. Inspect stoppers for excessive wear. Minimum thickness of the stoppers is 114 inch (6.4 mm). Replace exces-
sively worn or damaged stoppers.
2. Inspect thrust washers for excessive wear. Replace excessively worn or damaged washers.
1. Install a new oil seal (08) in housing (18).
2. Install circlip (06) and bearing (07) in the housing.
3. Align drum (14) with bearing (07). Apply pressure to the bearing inner race to press the drum and bearing into
place. Install circlip (10).
4. Install sun gear (13) in drum (14).
5. Slide planet gear (03) with needle bearing (04) and thrust washers (02) into hub (19). Align the bores and push
pin (26) into o place. Install circlips (05 and 27).
6. Repeat preceding step 5 for the other planet gears.
7. Install planet hub assembly into housing (18).
8. Install stoppers (23 and 24).
9. Coat the O-ring (20) with grease and install in the groove in end cover (25).
10. Install end cover (25) with O-ring (20) and secure with internal retaining ring (22).
NOTICE
If the winch drum was disassembled, do not proceed further until the drum components have
been installed. Refer to Subtopic 11.2.6.
11. Install capscrews (15) and lockwashers (17) to attach base (16) to the planetary and drum.
12. Fill the winch with oil. Refer to Subtopic 16.3.3.
13. Install pipe plug (21).
11.2.6 Winch Drum Repair
NOTICE
The brake and planetary components must be removed before the drum can be disassembled.
Refer to Subtopic 11.2.4 and Subtopic 11.2.5.
LEGEND
Figure 11-8: Auxiliary Winch Drum Components
LEGEND
01. Needle Bearing
02. Retaining Ring
03. Clrclip (3)
04. Internal Gear Stopper (3)
05. Needle Bearing (3)
06. Thrust Washer (6)
07. Circlip (3)
08. Planet Pin (3)
09. Planet Gear (3)
10. Sun Gear Stopper
11. Sun Gear
12. Planet Hub
13. Internal Gear
14. Connecting Shaft
15. Ball Bearing
16. Drive Shaft
17. Ball Bearing
18. O-ring
19. Oil Seal
20. Brake Drum
21. Base
22. Brake Housing
1. Insert two pry bars between the flange of drum (20) and housing (22) and carefully pry the housing from bear-
ings (15 and 17). The connecting shaft (14) will come off with the housing.
2. Pull connecting shaft (14) from brake housing (22). Remove and discard O-ring (18).
3. Remove needle bearing (01) and retaining ring (02) from the connecting shaft.
4. Withdraw sun gear (11) from the planet assembly in the drum.
5. Remove and discard oil seal (19).
6. Using a standard puller, remove bearings (15 and 17).
7. Remove the planet assembly with internal gear (13) from the drum.
8. To remove planet gears (09), remove circlips (03) and press pins (08) from hub (12). Slide out the planet gear
with needle bearing (05) and thrust washers (06).
9. Remove stoppers (04 and 10)
1. Inspect sun gear stopper for excessive wear. Minimum thickness of the sun gear stopper is 114 inch (6.4 mm).
Replace an excessively worn or damaged stopper.
2. Inspect internal gear stoppers and thrust washers for excessive wear. Replace excessively worn or damaged
washers and/or stoppers.
11.2.7 Assembly and Installation
The planetary components should be assembled before the drum components. Refer to Subtopic 11.2.5. Refer to
Figure 11-8 and proceed as follows:
1. Slide planet gear (09) with needle bearing (09) and thrust washers (09) into hub (12). Align the bores and push
pin (08) into o place. Install circlips (03 and 07).
2. Repeat preceding step 2 for the other planet gears.
3. Install stoppers (04 and 10).
4. Install planet assembly in internal gear (13) and install sun gear (1 1) in the planet assembly. Place the unit in
the drum so the splines on the planetary sun gear mesh with the planet hub (12).
5. Install bearings (15 and 17).
6. Install new oil seal (19).
7. Install needle bearing (01) in connecting shaft (14). Install retaining ring (02)
8. Apply grease to O-ring (18) and install on connecting shaft (14). Install connecting shaft (14) in brake housing
(22).
9. Insert the assembled brake housing into bearings (15 and 17) so that the connecting shaft (14) engages inter-
nal gear (13). Press into place. If necessary, use a soft faced hammer to tap the brake housing.
10. Install capscrews (15, Figure 10-4) and lockwashers (17) to attach base (16) to the planetary and drum.
11. Assemble and install the brake components. Refer to topic, Winch Brake Repair
12. Fill the winch with oil. Refer to Subtopic 16.3.3.
13. Install pipe plug.
11.2.8 Auxiliary Winch Sheaves
The two removable sheaves for the auxiliary winch wire rope are installed at the ends of a support on top of the
mast crown block. The support and one sheave are extended beyond the rear side of the mast so that the wire
rope drops just behind the drilling centerline.
Figure 11-9: Auxiliary Winch Sheaves
11.2.8.1 Removal
NOTICE
Lower the mast to its horizontal position to gain access to the mast crown block and sheaves.
WARNING
!
cause severe bodily injury and/or death. Lock out and tag out the drill operating controls
1. Lock out and tag out the drill operating controls to prevent inadvertent startup or movement of the drill during
2. To remove the sheaves, remove the cotter pins from the lock pins.
3. Support the sheave parts, then remove the capscrews and lockwashers, and withdraw the lock pins.
4. Remove and disassemble the bearings, retainers, and sheaves.
CAUTION
To remove the sheaves without first removing the wire rope, place steel rods under the
wire rope and clamp them in position on the sheave support. This will hold the wire rope
in place, and away from the sheaves, so that they can be removed. Do not clamp the wire
rope in a working section; this can cause rope damage, crushing, or kinking.
Clean and inspect the sheave components in accordance with the general cleaning and inspection procedures
described in Appendix A of this manual. Sheave repair consists of the replacement of all worn or damaged compo-
nents. See the LinkOne electronic parts manual for component identification.
1. Install the bearings and retainers in the sheaves.
2. Support the sheave parts and position them in the crown block support.
3. Insert the lock pins through the support holes and sheave assemblies.
4. Install the capscrews, lockwashers, and cotter pins to secure the assembly.
5. Back Braces 100J6487F3
11.2.8.4 Adjustment
CAUTION
The back braces must be adjusted when the crawlers are on the ground on a smooth
level surface. If back brace adjustment is made when the drill is elevated on jacks, or if
the back brace adjustment in not correct, unnecessary loading will be placed on the
back braces, mast and front jack assemblies that could result in early fatigue cracking
and/or structural failure.
Figure 11-10: Back Brace (exploded view)
NOTICE
This procedure assumes the mast has been correctly adjusted to be vertical when the mast
anchor pins are engaged and the drill is correctly leveled.
1. Raise the mast to the vertical position. Ensure that the mast anchor pins are engaged and that the back brace
locks are extended.
2. Place drill on a smooth level surface with the crawlers on the ground and the leveling jacks fully raised.
3. Retract the mast anchor pins and note if mast anchor pin bores on mast move relative to the anchor pin bores
on the main frame. No misalignment between the bores should be noted when the crawlers are on the ground.
If misalignment is noted with crawlers on the ground, the back brace length needs to be adjusted until there is
very little misalignment between the mast anchor in bores on the mast and main frame when the anchor pins
are removed.
4. Back brace length adjustment is accomplished by turning the threaded adjusting nuts/rods on the ends of the
back brace legs. Refer to Figure 11-11.
Figure 11-11: Back Brace Adjustment
01
02
03
04
05
BD0983a01
LEGEND
01. Adjusting Rod
02. Lower Brace
03. Locknuts
04. Clevis
05. Top of Front Leveling Jack
CAUTION
Minimum of 102mm (4") of thread engagement
is required on both ends of the extension rod.
5. After length adjustment, the back brace appearance will be a slight bow downward due to gravity with the
crawlers on the ground and the mast anchor pins engaged. When the machine is raised on jacks, the main
frame deflects in a direction that will reduce tension on the back brace members, resulting in a slack condition
when the machine is on jacks and drilling. This slack condition will produce slightly more sag in the back
braces when the drill is on jacks as compared to when the drill is on the ground.
NOTICE
It is critical to adjust both back braces to have equal loading on each side. This can be verified
by ensuring that each back brace has approximately the same amount of sag, verified by line
of sight viewing along the axis of each back brace leg.
6. After adjustments have been made, lower the mast, propel for about one machine length, raise the mast,
engage the mast anchor pins and then retract the mast anchor pins. Check the mast anchor pin displacement
with the machine still on the ground. If the bores displace more than 0.06" from each other, repeat the adjust-
ment procedure.
7. Engage the mast anchor pins and raise machine on leveling jacks to the point that both crawler belts are off the
ground and the machine is level.
8. Retract the mast anchor pins and note if the mast anchor pin bores move relative to the anchor pin bores on
the main frame. Note that adjusting back brace length to result in little anchor pin bore displacement when the
drill is on the ground will result in some anchor pin bore displacement when the drill is sitting on the jacks.
Slight bore misalignment (less than 3mm or 1/8") when the pins are removed is acceptable.
9. With mast anchor pins disengaged, lower the mast to the mast rests, then raise the mast to the vertical posi-
tion.
10. Engage the mast anchor pins to verify that the anchor pins can be readily inserted. If the mast pins are difficult
to engage, slight modifications may have to be made to remove some of the anchor pin bore misalignment with
the drill on jacks.
NOTICE
Any adjustments must result in approximately the same amount of sag on each back brace,
verified by line of sight viewing along the axis of each back brace leg. Also, any adjustment
must still result in the minimum amount of anchor pin bore misalignment when the drill is on the
ground.
After final adjustments are made, it is recommended to lock the back brace adjustment. This can be done by weld-
ing a small plate across the back brace and the adjusting block, being careful not to weld to the adjustment
threads.
11.2.8.5 Removal
CAUTION
The mast must be locked in the vertical upright position to service the back brace
assemblies. Back braces should be serviced one at a time.
To remove one back brace assembly, refer to Figure 11-10 and proceed as follows:
WARNING
!
bodily injury and/ or death. Lockout and tagout the drill operating controls to prevent
accidental operation.
1. Lock out and tag the drill operating controls to prevent inadvertent startup or movement of the drill during main-
tenance activities.
2. Securely fasten locking collar (03) and cylinders (02) in the extended (locked) position with rope, or other
means, to prevent retraction of the cylinders when the hydraulic hoses are disconnected.
WARNING
!
3. Tag and disconnect the hydraulic hoses and fittings to the back brace cylinders. Cap and/or plug all hoses and
fittings to prevent contamination of the hydraulic system. Refer to Appendix B for information on hydraulic con-
nections.
WARNING
!
4. Support the upper and lower braces with a suitable hoist and sling.
5. Remove four pins (5) and drive out clevis pins (6) to unfasten the brace assembly. Remove the brace assembly
and place it in an appropriate location for disassembly.
1. Remove lockwire (l8), capscrews (19), lockwashers (20) and hex nuts 21).
2. Remove six cotter pin (16), flat washers (15) and collar pins (17). Remove band (01) and cylinders (03).
3. Note the position of the extension rod engagement before disassembly. Unscrew lower clevis (08), nuts (9 and
11) and extension rod (10). Use the special spanner wrench tool 5002096 to loosen the nuts.
4. Remove roll pins (12), hinge pins (13) and link (14) 5. Separate braces (04 and 07) and collar (03).
Clean and inspect the back brace components in accordance with the general cleaning and inspection procedures
described in Appendix A of this manual. Repair consists of the replacement of all worn or damaged components.
Refer to the Parts Manual for component identification.
11.2.8.8 Assembly
1. Place collar (03) onto the upper brace (04). Connect link (14) to upper brace (04) and lower brace (07) with
pins (13) and roll pins (12).
2. Apply anti-seize compound to the threads of the lower clevis (08), nuts (9 and 11) and extension rod (10).
Screw these parts into the into lower brace (07). Use special tool, backbrace spanner (PN 5002096) to install
the nuts.
3. Attach the base ends of the hydraulic cylinders (03) to the brackets on the upper brace (04) with cotter pins
(16), flat washers (15) and collar pins (17).
NOTICE
Be sure that the cylinder ports are aligned correctly to mate with the hydraulic hose assemblies.
4. Position and install band (01) onto the lower base ends of cylinders (03). Secure the band with two capscrews
(19), lockwashers (20) and hex nuts (21). Apply lockwire (18).
5. Attach the rod ends of the hydraulic cylinders to the brackets on the collar (06) with cotter pins (16), flat wash-
ers (15) and collar pins (17).
1. Position the upper and lower braces in a straight line, then slide locking collar (03) into locking position over the
middle joint.
2. Securely fasten locking collar (03) and cylinders (02) in the extended (locked) position with rope, or other
means, to prevent unlocking the back braces.
WARNING
!
cause severe bodily injury and/or death. Lockout and tagout the drill operating controls
3. 3. Lock out and tag the drill operating controls to prevent inadvertent startup or movement of the drill during
WARNING
!
bly, assembly and installation. Provide appropriate support for any components that are
not supported by the machinery during any maintenance.
4. Using a suitable hoist and sling, lift up the back brace assembly and position it so that the upper and lower
ends are aligned with the mounting caps.
NOTICE
If the back brace cannot be connected because the brace is too short or too long, adjust the
extension rod as required. Refer to Subtopic 11.2.9.5.
5. Insert pin (06) and install pins (05) to attach the brace to the front jack caps.
CAUTION
!
There must be a minimum of 4 inches (100 mm) of adjusting screw threads engaged with
both the clevis and upper brace. Less thread engagement could result in brace failure.
6. Align the upper brace end with the mast cap. If the cap and clevis cannot be aligned, loosen nuts (9 and 11)
and adjust the rod (10) to permit alignment. Measure and record the distance between the clevis and lower
brace. This distance will be used in checking and adjusting the other back brace if serviced.
7. Check the length adjustment for the back brace on the other side. Adjust as required.
8. Connect the hydraulic hose assemblies in accordance with their identification tags.
9. Bleed the back brace hydraulic circuits.
11.2.9 Back Brace Locking Collar Cylinder R7187D1
11.2.9.1 Removal
The back brace locking collar cylinder is removed as part of the back brace removal procedure. Refer to Subtopic
11.2.8.5.
Move the cylinder to a clean work area for disassembly.
1. Extend piston rod to make clearance for spanner wrench.
2. Clamp the cylinder body in a vise and loosen the cylinder head with a spanner wrench.
Figure 11-12: Back Brace Locking Collar Cylinder
3. Unscrew the cylinder head until the threads become disengaged from the cylinder body, then remove the pis-
ton/piston rod and cylinder head assembly from the cylinder body.
4. Remove the locknut from the piston rod. Then separate the piston, wipers (01), seal assembly (02), O-ring
(03), backup ring (04), washer, and cylinder head assembly from the piston. Discard all seal parts.
5. Remove and discard O-rings (05 and 09), backup ring (06), rod seal (07), and rod wiper (08) from the cylinder
head. Note the orientation of these components for assembly.
Clean and inspect all cylinder components in accordance with the general cleaning and inspection procedures
described in Appendix A of this manual. After cleaning and inspection, cover all parts with a light film of oil and pro-
tect the parts from dirt and moisture. Cylinder repair consists of the replacement of wipers, seals, and all worn or
damaged components. See the LinkOne electronic parts manual for component identification.
11.2.9.4 Assembly
1. Lubricate and install O-rings (05 and 09), backup ring (06), rod seal (07), and rod wiper (08) on the cylinder
head.
2. Install the cylinder head assembly on the piston rod.
3. Lubricate and install piston, wipers (01), seal assembly (02), O-ring (03), and backup ring (04) on the piston.
4. Install the washer and piston assembly on the piston rod with the locknut and torque securely.
5. Lubricate the bore of the cylinder body (with hydraulic oil, and insert the piston/cylinder head assembly). Take
care to avoid cutting or pinching the seals and O-rings during insertion.
6. Thread the cylinder head into the bore of the cylinder body, and torque securely with a spanner wrench.
7. Retract the piston rod and install port plugs to prevent contamination of the hydraulic system with dirt.
Cylinder is installed as a part of installing the back braces. Refer to Subtopic 11.2.8.8
11.2.10 Mast Lock Pin 19T6502D3 And Cylinder R51992D2
The mast lock cylinders may removed from the drill with the mast either raised or lowered. The lock pins may be
removed and replaced with the mast vertical but only one at a time. The mast must be locked in the vertical posi-
tion with the back braces before starting the removal procedure.
11.2.10.1 Removal
1. Check to be sure that the mast back brace locking collars are in locked position and the other lock pin is
engaged.
Figure 11-13: Mast Lock Pin Cylinder Installation
WARNING
!
2. Lock out and tag out the drill operator controls to prevent inadvertent startup during maintenance procedures.
WARNING
!
3. Tag and disconnect the hydraulic hoses and fittings from the mast lock cylinders. Cap and/or plug all hoses
and cylinder ports to prevent contamination of the hydraulic system. Refer to Appendix B, General Hydraulic
System Maintenance, for information on hydraulic connections. Plug the cylinder ports tightly to keep the cylin-
der rod from extending or retracting during transport off the drill.
WARNING
!
Some blasthole drill components are extremely heavy. Dropping or mishandling of these parts
can cause severe personal injury or death, and damage to the equipment. Always support heavy
components using a suitable hoist or other means for removal, disassembly, assembly and
installation. Provide appropriate support for any components which are not supported by the
machinery during any maintenance.
4. Remove the cotter pins and push the end bar and cylinder pins from the ends of the cylinder(s)
5. If a locking pin is to be replaced, drive it out and replace immediately to maintain the locked condition.
1. Extend piston rod to provide clearance for a spanner wrench.
2. Clamp the cylinder body in a vise and loosen the cylinder head with a spanner wrench.
3. Unscrew the cylinder head until the threads become disengaged from the cylinder body, then remove the pis-
ton/piston rod, bearing retainer and cylinder head assemblies from the cylinder body.
4. Remove the locknut from the piston rod. Then remove the U-cup retainers, O-rings (07), and U-cups (06) and
piston bearing. Note the orientation of these components for assembly. Discard all seal parts.
5. Remove the bearing/seal retainer and cylinder head assembly from the piston rod.
6. Remove O-ring (05), backup ring (04), rod bearings, and packing set (03) from the bearing/seal retainer. Dis-
card all seal parts.
7. Remove O-ring (02) and rod wiper (01) from the cylinder head.
Clean and inspect all cylinder components in accordance with the general cleaning and inspection procedures
described in Appendix A of this manual. After cleaning and inspection, all parts must be covered with a light film of
oil and protected from dirt and moisture. Cylinder repair consists of the replacement of wipers, seals, and all worn
or damaged components. See the LinkOne electronic parts manual for component identification.
11.2.10.4 Assembly
Refer to Figure 10- 11 and proceed as follows:
1. Lubricate and install O-ring (02) and rod wiper (01) on the cylinder head.
2. Lubricate and install packing set (03) and rod bearings in the bearing/seal retainer.
3. Lubricate and install O-ring (05) and backup ring (04) on the bearing retainer.
4. Install the cylinder head and bearing/seal retainer assemblies on the piston rod.
5. Lubricate and install the U-cup retainers, O-rings (07), piston bearing and U-cups (06) on the piston rod. Be
sure that the orientation of these parts is correct.
6. Install the locknut on the piston rod and torque securely.
7. Lubricate the bore of cylinder body with hydraulic oil, and insert the piston cylinder head assembly. Take care
to avoid cutting or pinching the seals and O-rings during insertion.
8. Thread the cylinder head into the bore of the cylinder body, and torque securely with a spanner wrench.
9. Retract the piston rod, and install port plugs to prevent contamination of the hydraulic system with dirt.
Figure 11-14: Mast Lock Cylinder
WARNING
!
WARNING
!
2. Position the cylinders in the guide plates and lock pins.
3. Install the cylinder and end bar pins and the cotter pins to secure the ends of the cylinder(s).
4. Install the hydraulic hose assemblies to the cylinder ports in accord with the identification tags.
5. Operate the mast lock cylinders until full hydraulic pressure is achieved. This will ensure that the air has been
purged from the system.
6. Check operation of the mast lock indicating lamps.
7. If the lock pins are in position and the lamps are illuminated, continue with operation or shutdown as desired.
11.2.11 Mast Raise/Lower Cylinder R6268D1
The mast is raised and lowered by two large-bore, long-stroke hydraulic cylinders. The cylinder rod end is mounted
with a clevis-and-pin joint to the mast. The cylinder head end is clevis-and-pin-mounted to brackets on the drill
main deck.
11.2.11.1 Removal
The mast raise/lower hydraulic cylinders must be removed from the drill to service the seals and rod wipers. The
mast must be locked in the vertical position with the back braces, also in locked position, before starting the
removal procedure. To remove the cylinders, Refer to Figure 11-15 and proceed as follows:
1. Check to be sure that the mast locking pins and the back brace locking collars are in locked position.
WARNING
!
WARNING
!
3. Tag and disconnect the hydraulic hoses and fittings from the mast raise/lower cylinders. Cap and/or plug all
hoses and cylinder ports to prevent contamination of the hydraulic system. Refer to Appendix B, General
Hydraulic System Maintenance, for information on the hydraulic connections. Plug the cylinder ports tightly to
keep the cylinder rod from extending or retracting during transport off the drill.
Figure 11-15: Mast Raise/Lower Cylinder Installation
WARNING
!
bly, assembly, and installation. Provide appropriate support for any components which
4. Support the rod end (top) of the cylinder with a suitable hoist.
5. Remove the two capscrews, lockwashers, and retainer bar from each end of the pin that fastens the rod end of
the cylinder to the mast, then drive out the pin.
6. Remove the pin from the head end clevis and mounting bracket, and lift the cylinder free of the bracket.
7. Move the cylinder to a clean work area for disassembly.
1. Disconnect and remove tube (04). Remove adapters (03 and 05):
2. Remove screws (02) and counterbalance valve (01).
3. Extend piston rod to make clearance for spanner wrench.
CAUTION
Do not clamp on the body diameter. Damage to the cylinder could result.
4. Secure the fixed end of the cylinder in a suitable vise or fixture.
5. Using a spanner wrench, unscrew retainer (03) from barrel (12). Pull the entire piston rod assembly from the
body.
6. Remove bearings (07) and seal (08) from the piston. Unscrew the piston from the piston rod. Remove O-ring
(16) from the piston rod and discard.
7. Remove O-ring (10) and backup ring (1 1) from the cylinder head. Discard all seal parts.
8. Slide the cylinder head and retainer with rod bearing (09), seal (12), O-rings (13 and 14) and wiper (15) from
the piston rod. Remove and discard all seal parts.
Clean and inspect the cylinder as described in Appendix A. Repair of the mast cylinder is limited to replacement of
the rod wipers, O-rings, bearings and seals. Refer to the LinkOne electronic parts manual for component identifica-
tion.
Figure 11-16: Mast Raise/Lower Cylinder
11.2.11.4 Assembly
1. Lubricate and install O-ring (14) on the retainer. Slide assembled retainer onto the piston rod.
2. Lubricate and install rod bearing (09), seal (12), O-rings (13 and 14) and wiper (15) in the cylinder head. Slide
the assembled cylinder on the piston rod.
3. Lubricate and install O-ring (10) and backup ring (1 1) on the cylinder head.
4. Lubricate and install O-ring (16) on the piston rod. Screw the piston onto the piston rod.
5. Lubricate and install bearings (07) and seal (08) on the piston.
6. Lubricate the bore of cylinder body with hydraulic oil, and insert the piston/cylinder head assembly. Take care
to avoid cutting or pinching the seals and O-rings during insertion.
7. Thread the retainer into the bore of the cylinder body and torque securely with a spanner wrench.
8. Attach counterbalance valve (01) to he cylinder with screws (02).
9. Retract the piston rod and install port plugs to prevent contamination of the hydraulic system with dirt.
10. Install adapters (03 and 05). Connect tube (04).
WARNING
!
WARNING
!
bly, assembly, and installation. Provide appropriate support for any components which
2. Support the rod end (top) of the cylinder with a suitable hoist, and lift the cylinder into mounting position on the
drill deck.
3. Install the head end clevis to the mounting bracket on the drill deck, while supporting the cylinder directly above
the bracket. Do not apply side force with the hoist to avoid damaging the cylinder or mounting bracket.
4. While continuing to support the top end of the cylinder with the hoist, swing the top of the cylinder toward the
mast. Adjust the extension of the cylinder until the rod mounting hole is aligned with the mounting bracket on
the mast.
5. Insert the pin through the mast bracket and cylinder, and lock the pin in position with the pin retainer bars, cap-
screws, and lockwashers.
6. Remove the hoist from the top of the cylinder.
7. Install the hydraulic hose assemblies to the cylinder ports in accordance with the identification tags.
8. Before lowering the mast, operate the mast raise/lower cylinder several times, holding the valve in the raise
and lower positions until full hydraulic pressure is achieved. This will ensure that the air has been purged
from the system.
11.2.12 Mast Bottom Plate R11834D2
S
Figure 11-17: Mast Bottom Plate
LEGEND
01. Retainer
02. Lock Washer
03. Hex Head Cap Screw
04. Grease Fitting
05. Mast Hinge Pin
08. Flex Lock Nut
09. Boss Drillers Platform
10. Pin
11. Retainer
12. Lock Washer
14. Bottom Assembly Plate
15. Door Installation
16. Door Panel
17. Upper Plate Hinge
18. Cotter Pin
19. Drilled Pin
21. Lower Arm Hinge
22. Lower Block Hinge
23. Hardened Washer
24. Nut
25. Jam Nut
26. Cotter Pin
27. Drilled Pin
29. Rod End
The mast bottom plate is pinned and bolted to the bottom of the lower mast. A drill bushing is welded to the deck
plate in line with the drilling centerline. The bushing is fitted with a dust deflector which is secured with four remov-
able T-bolts and a deflector ring.
Clean and inspect components as described in Appendix A. Refer to the LinkOne electronic parts manual for com-
ponent identification.
Remove components selectively for repair or replacement. The location and method of attachment is shown in Fig-
ure 10-14.
WARNING
!
cause severe bodily injury and/or death. Lockout and tagout the blasthole drill operating
controls to prevent accidental operation.
11.2.12.1 Deflector Ring
Refer to Figure 11-17. To remove loosen hex nuts (7), lockwashers (8) and flat washers (9) from the four T-bolts
(6) to free the deflector ring (5) from underneath the drill deck plate. Remove dust deflector (3 1). Install in the parts
in the reverse order of removal.
WARNING
!
parts can cause severe personal injury or death and damage to the equipment. Always
support heavy components using suitable hoist or other means for removal, disassem-
bly, assembly and installation. Provide appropriate support for any units which are not
supported by the equipment machinery during any maintenance.
11.2.12.2 Adjustable Platform
1. Support access cover (10) with a suitable hoist. Remove two straight cover pins (12) and hardware, and
remove the access cover.
2. Support adjustable work platform (18) with a suitable hoist. Drive two roll pins (14) from each of four platform
brace pins (15), withdraw the brace pins, and remove the two braces. Lower platform (1 8).
3. Drive eight roll pins (16) from four platform hinge pins (17), withdraw the brace pins, and remove the platform
(18). 4. Install in the parts in the reverse order of removal
11.2.12.3 Mast Hinge Pins
The mast must be lowered to the horizontal position before replacing pivot pins. Support the lower end of the mast
with a suitable crane. Replacement parts should be available so that repair can be effected as soon as possible
after hinge pin removal.
Refer to Figure 11-17.Remove two capscrews (03) and lockwashers (02) to free the retainers (01). Push out the
hinge pins (04). Remove the lube fittings (30) from the hinge pins Install in the parts in the reverse order of
removal. Lubricate the hinge pins as specified in Subtopic 16.6.1.1.
11.2.12.4 Bailing Air Components
Figure 11-18: Mast
LEGEND
01. Union
02. Hose Clamp
03. Upper Air Hose
04. Upper Hose Trough
06. Locknut
07. Nut
09. Tray Bracket
10. Bracket
11. Tray Bracket
12. Bracket
13. Lower Hose Trough
14. Lower Air Hose
15. Standpipe
16. Bracket
17. Bracket
18.
Sheave
19. Bearing
21. Lockwasher
22. Retainer
23. Shaft
24. Cotter Pin
25. Trademark Plate
The location the bailing air components is shown on Figure 11-18. The hoses are attached to the air pipes with
unions and hose clamps. Remove and install to as required to replace any parts that are deteriorated or otherwise
damaged.
11.2.12.5 Upper Mast Repair
Under most conditions, the mast need not be removed from the drill either to service the components it supports or
to repair its structure. Contact your local P&H MinePro Services representative regarding mast structural repairs
and/or physical removal from the drill.
Figure 11-1 provides generic guidelines to aid in troubleshooting problems of the mast and related components.
Problem Probable Cause Remedy
Winch does not run at rated speed Winch sheaves are not turning
freely
Inspect winch sheaves for obstruc-
tion, binding or damage. Remove
any obstruction, lubricate bearings,
or replace damaged parts. Leak at
brake piston
Relief valve set too low Relief valve should be set to 2200
psi (152 bar). Refer to Section 3,
Auxiliary Hydraulic System..
Binding winch drum Check mounting of winch. Winch
must be level. Refer to installation
instructions.
Winch motor malfunction Repair winch motor.
Winch will not reverse Leak at brake piston lnspect O-rings at brake piston.
Replace O-rings.
Defective seal at brake release
channel
Check for leakage between motor
adapter and brake housing which
indicates O-ring failure. Replace O-
rings.
Plugged brake release passage Remove winch motor and adapter.
Clean brake release passage.
Insufficient hydraulic pressure. Check pressure. Brake releases at
approximately 600 psi (41 bar).
Refer to Section 3, Auxiliary
Hydraulic System..
Table 11-1: Mast Troubleshooting
Oil leakage at winch breather and/
or at brake housing and drum
Damaged seal between drum inte-
rior and brake housing
Replace oil seal. Seal failure may
be caused by excessive pressure
doe to incorrect hydraulic oil or a
restriction in the return line to the
tank. Check for deficiencies and
correct.
Oil leakage at winch motor flange
and adapter
Loose motor mounting Tighten mounting screws
Faulty O-rings between adapter
and motor flange
Replace O-rings
Winch brake will not hold Wire rope is attached to wrong
cable
anchor slot
Check wire rope installation. Cor-
rect deficiency.
Excessive back pressure causes
brake to release
Check for obstruction in the return
line to tank. Correct deficiency.
Damaged brake plates lnspect brakes. Replace damaged
brake plates. Check oil for contami-
nation which will cause failure.
Replace oil in system if contami-
nated.
Hydraulic control malfunction Hydraulic control malfunction
Winch brake vibrates
when lowering a load
Entrained air in hydraulic oil Check for foam in oil. Check sys-
tem for
leaks.lnvestigate cause. Correct
deficiency.
Winch brake running hot due to
insufficient
oil flow
lnvestigate cause. Correct defi-
ciency.
Return line oil flow should be
approximately
3.5 gpm (13 Ipm) when the
winch is reversed.
Damaged over-running clutch Inspect clutch sprags. Repair
clutch.
Damaged brake plates Inspect brakes. Replace damaged
brake plates. Check oil for contami-
nation which will cause failure.
Replace oil in system if contami-
nated.
Mast anchor pins secure but indica-
tors do not illuminate
Indicator lamp burned out Replace lamp.
Repair sticking switch linkage. Adjust limit switch.
Repair sticking switch linkage.
Replace faulty limit switch.
No power at switch or lamp Investigate. Correct deficiency.
Mast bounces during raising or low-
ering
Air trapped in cylinders Bleed air from hydraulic control cir-
cuit. Pressurize cylinders at end of
stroke and hold at pressure until
pressure reaches maximum.
Stroke cylinders to full length of
stroke.
Faulty counterbalance valve Replace counterbalance valve.
Hydraulic System..
Erratic movement of
hydraulic cylinder(s)
Air trapped in cylinder(s)
and/or hydraulic circuit
Bleed the circuit and stroke the
cylinder(s) full travel.
Binding mechanism Lubricate the mechanism.
Check alignment and repair any
deficiencies.
Replace failed cylinder
Hydraulic control circuit malfunc-
tion
lnvestigate cause of malfunction.
Hydraulic System. for information
BD120149 Mechanical Systems Manual Rotary Machinery
Sec12Rotary.fm -12.1- Section 12, Version 00 - 03/06
Section 12
Rotary Machinery
Figure 12-1: Carriage Assembly
BD0574a01
01
06
09 08
07
10
LEGEND
02. Pulldown Brake
03. Shipper Shaft
04. Pulldown Motor
06. Drive Pinion
07. Roller
08. Idler
10. Rotary Gearcase
Rotary Machinery BD120149 Mechanical Systems Manual
Section 12, Version 00 - 03/06 -12.2- Sec12Rotary.fm
12.1.1 Rotary Motor 83013-1
There are two rotary motors. The rotary drive motors are variable speed electric motors that are mounted to the top
of the rotary gearcase. Each motor is fitted with a pinion to transmit power to the intermediate drive shaft.
12.1.2 Rotary Gear Case R10678F2
Two reversible electric motors are coupled to a double-reduction rotary gearcase (refer to Figure 12-1). The motors
are mounted on top of the gearcase. The drive shaft spindle terminates at the drill pipe coupling, which connects to
the drill pipe. Internal lubrication is provided by a gear-driven oil pump. Pressurized bit air for the pipe string is con-
nected to the main drive shaft through a rotary seal and piping.
The rotary gearcase is mounted to the lower end of the carriage. Hoisting/pulldown components, which provide
vertical gearcase motion, are also mounted on the carriage. Refer to Section 14, Hoist/Pulldown Machinery. for
information.
12.1.3 Rotary Drill Pipe Coupling R12253F9
The rotary subassembly adapter is a short section of pipe that allows transition with the fine API thread on the
rotary head to the coarse BECO thread on the drill pipe.
The coarse BECO thread is used in mine drilling applications because it can better withstand the frequent coupling
and breaking of pipe without being damaged beyond use.
A Duraquest Smoothdrive shock sub is used as an adapter. This shock absorber coupling reduces the severity of
rotary and vertical vibrations. These are largely absorbed by the rubber element in the device. The reduction in
vibration severity translates into longer bit life and higher penetration rates. In addition, it will compensate for minor
drill stem misalignment.
Figure 12-2: Rotary Drill Pipe Coupling
Reducing the harshness vibrations also has benefits for the blasthole drill. These repeated shocks are often the
cause of fatigue cracks in the rotary head, mast and other structural components. Dampening these shocks can
reduce the amount of downtime for maintenance and increase the life of the drill and its components.
12.2 Rotary Machinery Maintenance
12.2.1 Rotary Motor 83013-1
There are two rotary motors. The rotary drive motors are variable speed electric motors that are mounted to the top
of the rotary gearcase. Each motor is fitted with a pinion to transmit power to the intermediate drive shaft.
12.2.1.1 Removal
The rotary carriage should be positioned at deck level to permit convenient access to the rotary gearcase. Support
the drive motor during removal using a suitable hoist or other appropriate means.
WARNING
!
Hazardous voltage can cause burns, injury, or death. Disconnect, lock out, and tag the
power source which feeds this device to prevent power from being applied while inspec-
tion and repairs are being performed. Before beginning repairs, try the operational con-
trols to verify that the intended power source is disconnected.
1. Disconnect, lock out, and tag the disconnect switch which feeds the machine to prevent power from being
applied while service is being performed.
2. Tag and disconnect the wiring to the motors.
3. Remove eight capscrews and lockwashers to free the motor.
Figure 12-3: Rotary Machinery
WARNING
!
Dropping or mishandling of heavy drill parts can cause personal injury, or death. Always
move heavy components using the auxiliary winch, or other suitable lifting device, and
slings for removal and installation. Provide support for components that may release or
move during any maintenance.
4. Carefully raise the motor straight up from the gearcase until the pinion clears the intermediate gear to prevent
damage to gear teeth.
5. Remove the hex nut and lockwasher from the motor shaft. Pull the pinion off the shaft using a suitable puller. It
may be necessary to heat the pinion before removal.
6. Remove the key from the motor shaft.
7. Place the motor in an appropriate repair area.
Clean and inspect parts as described in Appendix A of this manual. Repair consists of the replacement of worn or
damaged parts. Observe all safety precautions.
12.2.1.3 Assembly of Motor Pinion
1. Remove any scoring from the motor pinion bore and the motor shaft.
2. Thoroughly clean the bore of the pinion and the pinion seating surface on the motor shaft using Toluol or Per-
chloroethylene. Do not use kerosene.
3. Spot the pinion on the shaft by hand to obtain at least a 75% fit. Check the fit with bluing. Remove the pinion.
4. Break all sharp edges on the motor key and keyway with a file to obtain approximately 0.4 mm (1/64") radius at
each edge.
5. Install the key in the motor shaft to obtain a 75% fit. Check the fit with bluing.
Figure 12-4: Installing Motor Pinion
01
02 03 04
LEGEND
01. Motor
02. Pinion
03. Nut
04. Gear
6. Try the pinion on the shaft to be sure it does not bind on the key. Rework the key if binding is evident.
7. Clean the pinion and shaft again.
8. Place the pinion on the shaft and snap it into position by hand. Measure the cold position of the pinion using
a micrometer depth gauge. Mark the places where the depth gauge was resting so that measurements can be
made from the same positions after the pinion has been mounted.
CAUTION
Excessive heat can damage the pinion. The pinion must never be heated to a tempera-
ture above 374F (190C).
9. Remove the motor pinion from the motor shaft. Heat the pinion in a suitable oven to the temperature specified
in Table 12-1
10. If the pinion is heated in oil, the bore must be thoroughly cleaned before mounting. The use of an oven is rec-
ommended to avoid the cleaning step.
11. Pinion temperature is indicated as a temperature difference between the motor shaft and pinion. This tempera-
ture is estimated only, and can be adjusted to maintain the specified advance. Heat the pinion in the oven until
the temperature is uniform at the required number of degrees above the shaft temperature.
For example: if the shaft temperature is 25C (78F) and the estimated difference is 125C (225F), heat the
pinion to 150C (302F) for mounting.
Frame Shaft
Diameter
Pinion
Dimension
Shrunk On
Pinion
Advance
Estimated Temperature
Difference
D X C F
K504T 3.000" 2.9935" 4.75" .020 to .025" 70 126
Table 12-1: Pinion Mounting Data (refer also to Figure 12-5)
Figure 12-5: Pinion Dimensions
"X"
"D" .0015"
12. A quick accurate method must be provided for measuring pinion temperature and the shaft before mounting
the pinion. This can best be done with a hand pyrometer. When a hand pyrometer is not available, a celsius
thermometer can be used by placing putty over the thermometer to hold it against the pinion. Heat the pinion to
a few degrees above the desired temperature before removing the pinion from the oven. Wait until the pinion
has cooled to the desired temperature, remove the thermometer, and quickly mount the pinion as described in
the following steps.
A. After assuring that the pinion bore is clean, quickly mount the hot pinion on the motor shaft. When the pinion
is nearly engaged with the taper fit (but not in contact), snap it forcibly into place with a quick push. It is
important that the pinion be instantly snapped into position before it has cooled appreciably; otherwise the
pinion will freeze to the shaft and cannot be adjusted further.
B. Check the hot, or shrunk-on, position of the pinion on the shaft using a micrometer depth gauge. The
actual advance is the difference between the depth gauge readings at the hot and cold positions. To control
stresses in the pinion, the advance must be within the limits specified in Table 12-1.
C. If the advance is not within limits, the pinion must be pulled and remounted.
D. Assemble the lockwasher and hex nut on the motor shaft, tighten firmly, and then lock.
12.2.1.4 Motor Installation
. Refer to Figure 12-4 and proceed as follows:
1. Immediately before installation, thoroughly clean the mounting surfaces on the motor and gearcase with Per-
chloroethylene or Toluol. Keep dust off the surfaces.
2. Raise the motor with the winch and position it over the gearcase. Be sure that the motor duct is correctly posi-
tioned so it will mate with the blower duct when installed.
3. Apply a continuous, thin coat of non-hardening gasket sealer (Permatex No. 2 or equivalent) to the mounting
surface of the gearcase and around the eight bolt holes.
4. Without allowing extra setting up time for the sealer, mount the motor without damaging the sealer surface.
5. Carefully lower the motor straight down into the gearcase so the pinion engages the intermediate gear without
damage.
6. Apply a no gall thread lubricant to the entire thread and bearing surfaces of all eight mounting capscrews.
Remove excess lubricant.
7. Install the capscrews and the flanged lockwashers.
8. Torque the capscrews in stages to between 678 and 780 Nm (500 and 575 ft-lbs) using a tightening pattern.
NOTICE
Capscrews must be Grade 5 or better.
9. If any capscrews will not accept a torque wrench due to mechanical interference, use the following method:
A. Snug all capscrews to approximately the same initial torque, using a hand wrench.
B. Using a tightening pattern in several stages of tightening for all the accessible capscrews, torque to the
specified torque (preceding Step 8). Record how far the capscrews turn from the initial torque.
C. Using a hand wrench, tighten the remaining capscrews the same number of turns.
D. Retorque the original capscrews that were tightened down with a torque wrench.
E. Tighten the remaining capscrews the same amount.
10. Connect the electrical wiring to the rotary drive motor.
11. Check and fill the rotary gearcase to the required lubrication level. Refer to Subtopic 16.4.1.
12.2.2 Rotary Gear Case R10678F2
Figure 12-6: Rotary Gearcase
The gearcase assembly consists of gear-driven main and intermediate drive shafts, main-gear driven oil pump for
internal lubrication, bit air coupling and tubing, and gearcase housing with drive motor mounts, access covers, and
breather. The drive shafts are supported in tapered roller bearings. The main drive shaft is bored so that bit air
entering the shaft at the top flows through to the drill pipe coupling and drill pipe.
It should seldom, if ever, be necessary to remove the entire rotary gearcase assembly. All adjustments, service,
and repair of components can be accomplished in the field, except in the event of extreme damage to internal
parts.
LEGEND
01.Lubrication Pump Gear
02. Snap Ring
03. Lubrication Pump Mounting
05. Lock Washer
06. Plain Washer
07. Shoulder Bolt
08. Self-Locking Nut
09. Motor Pinion
10. Seal Retainer
11. Seal Retainer Gasket
12. Tapered Bearing
13. Spacer
14. Lock Washer
15. Take Up Nut
16. O-ring
17. Seal
18. Breather
19. Pipe Coupling
20. Pipe Nipple
21. Hose Assembly
22. JEC Male Pipe Elbow
23. Hose Assembly
24. Straight Fitting
25. Close Nipple
26. Hose Assembly
27. JIC Male Pipe Elbow
28. Hose Assembly
29. JIC Male Pipe Adapter
30. Fitting
31. Male Cross
32. Rotary Gear Case
33. Tapered Bearing
34. Snap Ring
35. First Intermediate Gear
36. Spacer
37. Intermediate Pinion
38. Tapered Bearing
39. Shim
40. Shim
41. Shim
42. O-ring
43. Pump Housing
44. Cover Gasket
45. Cover
46. Drain Cock
48. Lock Washer
49. Drill Head Capscrew
50. Lock Wire
51. Magnetic Plug
52. Seal Retainer
53. Seal Carrier
54. Grease Fitting
55. Seal
56. Seal Spacer
57. Relief Fitting
59. Main Rotary Shaft
60. Tapered Bearing
61. Spacer
62. Fitting
63. Magnetic Plug
64. Main Gear
65. Pipe Bushing
66. Close Nipple
67. Drain Cock
68. Cover Gasket
69. Gear Case Cover
71. Inspection Cover
72. Inspection Cover Gasket
74. Lubrication Pump
75. Key
76. O-ring
12.2.3 Bit Air Components
The bit air components consist of a rotary air pipe with seals, swivel housing, pipe joint, and air pipe with seals and
related hardware. These components are mounted above the main drive shaft on the gearcase.
The rotary machinery carriage should be positioned at deck level to permit convenient access to the gearcase
assembly. Refer to Figure 12-8 and proceed as follows:
Figure 12-8: Bit Air Components
LEGEND
01. Air Pipe
02. Hose Clamp
03. Air Hose
05. Stud
06. Housing Cover
07. Pipe Coupling
08. Air Swivel
09. Special Flange
10. O-ring
11. Take Up Nut
12. Lock Wire, Lock
14. Swivel Housing
WARNING
!
Inadvertent operation of the drill during service, inspection, or maintenance on the
machine can cause severe bodily injury, or death. Use lockout and tagout procedures to
prevent accidental operation of the drill.
1. Shut down the drill. Lock out and tag the disconnects that supply electrical power to prevent inadvertent move-
ment of the drill during inspection, service, or maintenance.
2. Disconnect and remove the flexible pipe joint (03) at the air pipe (01) and remove clamps (02) as required.
3. Remove air pipe (01) and pipe coupling (07) from the air swivel (08).
4. Disconnect lube hoses and related hardware (refer to inset A on Figure 12-6). If necessary, tie up the lower
lube hose to prevent oil from draining from the gearcase. Remove parts as required.
5. Remove lockwire (12) and capscrews (13) that attach swivel housing (14) to the gearcase. Remove housing.
This will expose the main drive shaft adjustment components and seals.
Clean and inspect parts as described in Appendix A of this manual. Observe all safety precautions. Replace all
worn or damaged parts. Refer to the LinkOne electronic parts manual for parts identification.
12.2.3.3 Assembly And Installation
Install parts in the reverse order of removal. Refer to Figures 12-6, and 12-8.
A. Position the swivel housing (14) on the gearcase so that the lube holes in the housing and in the seal
retainer are aligned. This is necessary to permit proper lube venting. Refer to Figure 12-9.
Figure 12-9: Swivel Housing and Air Pipe
01
BD0536a01
LEGEND
01. Housing
12.2.4 Oil Pump and Lines
The oil pump circulates lubricating oil to the gearing through hoses and fittings to both sides of the gearcase. The
pump is mounted behind the front covers on a bracket that is attached to the larger front cover. The main drive gear
meshes with the oil pump gear; meshing is adjustable. Oil flows through external hoses to fittings on top of the
gearcase.
12.2.5 Removal And Disassembly
assembly. Refer Figure 12-10 (see also Figure 12-6) and proceed as follows:
Figure 12-10: Oil Pump Arrangement
BD0633a01
WARNING
!
prevent accidental operation of the drill. Determine and provide support for components
which may release or move during any maintenance. Lock out and tag the disconnects
that supply electrical power to the drill to prevent inadvertent movement of the machin-
ery during inspection, service, or maintenance.
1. Shut down the drill. Lock out and tag the disconnects that supply electrical power to the drill, to prevent inad-
vertent movement of the machinery during inspection, service, or maintenance.
2. Drain the oil from the rotary gearcase.
3. Disconnect the external hoses at the fittings and indicator on the gearcase assembly.
4. Remove the lockwire and capscrews to detach the small cover and its gasket, and gain access to the oil pump.
5. Disconnect the hose from the gearcase cover bulkhead fitting to the pump flange.
6. Remove capscrews and lockwire to detach the large cover with attached pump, mount, and cover gasket.
7. Remove the retaining ring from the oil pump shaft. Pull the pump gear up off the pump shaft. The shaft is
keyed.
8. Remove socket head screws and lockwashers to detach the flange from the pump.
9. Remove two socket head screws and lockwashers to detach the pump from the mount.
10. Remove the capscrew and lockwasher from the slot in the pump mount.
11. Remove the capscrew and hex nut to detach the pump mount from the cover.
12. Remove fittings from the pump and case as required.
Refer to Figures 12-6, and 12-10 and proceed as follows:
WARNING
!
prevent inadvertent operation of the drill.
1. Lock out and tag the disconnects that supply electrical power to the drill to prevent inadvertent movement of
the machinery during inspection, service, or maintenance.
2. Install the fittings into the pump and case.
3. Install the capscrew and hex nut to attach the pump mount to the large cover. Install the capscrew and lock-
washer through the cover bracket and into the pump mount. Do not tighten at this time.
4. Attach the flange to the pump with four socket head screws and lockwashers.
5. Attach the oil pump with the flange to the pump mount with two socket head screws and lockwashers.
6. Push the pump gear onto the keyed pump shaft. Install the snap ring into the groove in the oil pump shaft to
secure the gear.
7. Position the large cover with attached pump and cover gasket on the gearcase. Apply a thin coat of sealant
(GE RTV-102 or Permatex No. 2) to the gasket and mounting surfaces. Install capscrews with lockwire to
secure.
8. Connect the hose from the gearcase bulkhead fitting to the pump flange.
9. Adjust the drive gear to pump gear mesh. Refer to the topic, Adjustment, below.
10. If removed, screw the indicator into the elbow.
11. Connect the hoses at the fittings on the gearcase assembly.
12. Apply a thin coat of sealant (GE RTV-102 or Permatex No. 2) to the small cover, gasket, and mounting sur-
faces. Install the small cover and gasket with twelve capscrews. Apply lockwire to the capscrews.
13. Check hose connections and fittings to be sure that connections are tight. Tighten loose connections as
required.
12.2.5.3 Adjustment
WARNING
!
2. Remove the lockwire and capscrews to detach the small cover and its gasket, and gain access to the oil pump.
3. Loosen the adjusting capscrew in the slot in the mount.
4. Loosen the pivot capscrew and hex nut slightly
5. While holding the pump gear against the main drive gear for full tooth engagement without binding, tighten the
adjusting capscrew. Then tighten the pivot capscrew and hex nut.
6. Install the small cover and gasket with twelve capscrews and lockwire.
12.2.6 Intermediate Drive
The intermediate shafts and gears are supported on roller bearings. Access is through the bottom of the gearcase
and the front cover. Shaft end play should be checked and adjusted anytime that the gearcase is down for other
service or repair.
12.2.6.1 Check And Adjust end play
Lower the carriage to a convenient level for access to the gearcase. A minimum of disassembly is required to
check and adjust intermediate shaft end play. The procedure is the same for each intermediate shaft. Refer to Fig-
ure 12-6 and proceed as follows:
WARNING
!
Inadvertent operation of the drill during service, cause severe bodily injury, or death.
Use lockout and tagout procedures to prevent inadvertent operation of the drill.
1. Disconnect, lock out, and tag the disconnect switch which feeds the machine to prevent power from being
2. Remove the two drain cocks (46) from their covers (45). Allow oil to drain from the gearcase into a suitable
container.
3. Remove socket head screws (47) and lockwashers (48) that attach the cover and gasket (44).
4. Remove plug (62). Install a dial indicator so that the spindle contacts the upper end of the intermediate shaft
through the plug hole. Zero the indicator.
5. Apply force to the bottom of the intermediate shaft and check the indicator reading. Intermediate shaft end play
should be 0.076 to 0.127 mm (0.003 to 0.005").
6. If end play is not within tolerance, remove lockwire (50) and capscrews (49) which attach the bearing housing.
Remove housing (43), O-ring (42), and shims (39, 40 and 41).
7. Adjust for correct end play using existing shims and shims from the available shim pack. Refer to Figure 11-12
for a sectional view of installation.
8. If further work is to be done on the rotary gearcase, shimming can be performed during assembly of the gear-
case. Note the thickness of the shim pack.
9. Apply a thin coat of sealant (GE RTV- 102 or Permatex No. 2) to the shims the mounting surface. Reinstall
pump housing and shims. Re-check end play.
10. Install cover (45) and gasket (44) with mounting hardware. Install lockwire (50) on capscrews (49) to secure the
housing. Apply lockwire to screw heads in pairs similar to the arrangement shown in Figure 12-9.
11. Install drain cock (46).
Figure 12-11: Intermediate Drive Shaft Installation
01
02
03 04 05
06
07
08
09
10
11
12
13
14
BD0538a01
LEGEND
01. Motor Pinion
02. Drive Motor
03. Intermediate Gear
04. Spacer
05. Intermediate Shaft
06. Main Drive Gear
07. Snap Ring
08. Socket Head Screws and
Lockwashers
09. Drain Cock
10. Housing with Shims
11. Capscrew with Lockwire
12. O-ring
13. Cover and Gasket
14. Roller Bearing
The rotary machinery carriage should be positioned at a convenient level to permit access to the gearcase assem-
bly. For drills with two drives the procedure is the same for each. Refer to Figure 12-6 and proceed as follows:
WARNING
!
move during any maintenance. Inadvertent operation of the drill during service, inspec-
tion, or maintenance on the machine can cause severe bodily injury, or death. Use lock-
out and tagout procedures to prevent inadvertent operation of the drill.
1. Disconnect, lock out and tag the disconnect switch that feeds the machine to prevent power from being applied
2. Check intermediate shaft end play. Refer to Subtopic 12.2.6.1.
NOTICE
Note the number and size of the shims. This will be helpful information when adjusting shaft end
play.
3. Remove the front cover and oil pump. Refer to Subtopic 12.2.4.
4. Remove the drive motor. Refer to Subtopic 12.2.1.
5. Remove snap ring (34) from intermediate shaft (37).
6. Support gear (35). Carefully push the intermediate shaft, with bearings in place, down through spacer (36), the
intermediate gear, and gearcase. Bearing (33) may tend to hang up and remain in its seat. To prevent damage
to the bearing, do not allow it to fall from the bearing seat.
7. 7. Remove bearings (33 and 38) from the shaft and gearcase.
8. Remove intermediate gear (35) and spacer (36) through the front case opening.
1. Position intermediate gear (35) in the gearcase above main gear (64), and over the intermediate shaft bore.
Support the intermediate gear to prevent binding and damage during installation of the shaft.
2. Install upper bearing (33) and lower bearing (38) on intermediate shaft (37).
3. Carefully push the intermediate shaft with bearings in place through the lower shaft bore, spacer (36), and gear
(35) so that the upper bearing seats in the upper bearing bore. Be sure that the splines on the shaft and in the
gear are aligned to prevent binding and possible damage to the splines.
4. Install retaining ring (34) on the intermediate shaft.
5. Support the intermediate shaft assembly while installing housing (43).
6. Install the shims and adjust end play. Refer toSubtopic 12.2.6.1.
7. Install the oil pump. Refer to Subtopic 12.2.4.
8. Install the drive motor and pinion. Refer to Subtopic 12.2.1.
9. Fill the gearcase with oil. Refer to Subtopic 16.3.1.
12.2.7 Main Drive
The main shaft rotates on roller bearings and is fitted with seals. Provision has been made for adjustment of bear-
ing preload. Refer to the topics, Main Drive Bearing Preload Check, and Main Drive Bearing Preload Adjustment.
assembly. Refer to Figure 12-6 and proceed as follows:
WARNING
!
WARNING
!
2. Drain the oil from the rotary gearcase.
3. Remove the bit air components on the gearcase. Refer to the topic, Bit Air Components.
4. 4. Remove lock washer (14), take up nut (15), and O Ring (16).
5. Remove retainer (10) and gasket (11). Remove seal (17) from the retainer.
6. Disconnect the lube hose that is connected to the seal carrier (53) on the bottom of the rotary gearcase. Cap
the hose to prevent leakage.
7. Remove lockwire (24), capscrews (64) and carrier (54) with retainers (53).
8. If necessary, remove lockwire (50), capscrews (58), retainer (52) and seals (55), and spacer (56), from carrier
(53).
CAUTION
!
The main drive shaft could slip out of the case, causing personal injury or equipment
damage. Provide support under the shaft when it is removed to prevent accidental dam-
age. Keep away from shaft during lifting, lowering, or moving.
9. Carefully push the main drive shaft at the top to force the shaft out of the main gear and gearcase. The lower
main bearing cone (60) will come out with the shaft (59).
10. Remove main bearing (12) and spacers (13 and 61).
11. Remove main bearing (60).
12. Remove gear (64) through the front opening in the gearcase.
12.2.7.2 Repair
1. Place gear (64) into the gearcase through the front opening so that it is aligned with the main shaft bore.
2. Install bearing cup (13) into upper main shaft gearcase bore.
3. Install main bearing (60) and spacer (61) onto main shaft (66).
4. Carefully push the assembled main shaft through the gearcase, main gear (64), spacer (13) and bearing (12)
until the lower bearing seats in the gearcase bore. Be sure that the splines on the shaft and in the gear are
aligned to prevent binding and possible damage to the splines. Secure the shaft in this position.
5. If necessary, install new seal (17) into retainer (10). The seal spring must face the oil side (downward).
6. Install retainer with seal and gasket (11).
7. Install O-ring (18) and take up nut (15). Torque the take up nut enough to secure the main shaft. Install lock-
washer (14).
8. If necessary, install new seals (55) and spacer (56) into carrier (53). The seal springs must face the oil side
(upward) with the spacer in between.
9. Install retainer (52) on carrier (53) with lockwire (50) and capscrews (58).
10. Install assembled carrier and seal unit with lockwire (50) and capscrews (58).
11. Adjust preload in accordance with instructions under Subtopic 12.2.7.5. Be sure O-ring (16) is in position in the
bottom side of the take up nut.
12. Install oil pump and lines. Refer to Subtopic 12.2.4.
13. Install the bit air components. Refer to Subtopic 12.2.3.
14. Check gearcase lubrication level and replenish if necessary. Refer to the Lubrication section.
15. If necessary, install the drill coupling components. Refer to Subtopic 12.1.3.
16. Start up and operate the drill to verify proper operation. Inspect for leakage. Correct any deficiencies.
12.2.7.4 Main Drive Bearing Preload Check
The rotary gearcase main bearing preload should be checked every 1000 hours of operation, or 6 months, as a
minimum. Refer to Figure 12-12 and proceed as follows:
1. While drilling a hole, stop operation with the rotary gearcase 3 to 4 feet from the drill platform.
2. With the drill pipe weight suspended on the machinery, mount a dial indicator on the main shaft spindle to indi-
cate to the bottom of the gearcase.
3. Apply a 311,360 N (70,000 lb) pulldown force and observe the dial indicator. Any dial movement indicates the
need for preload adjustment. No dial movement indicates that preload is correct.
4. Release the pulldown force and remove the dial indicator.
5. Proceed with operation. If necessary, schedule adjustment at the earliest opportunity.
Figure 12-12: Checking Main Drive Bearing Preload
01 02 03
04
BD0533b01
LEGEND
01. Rotary Gear Case
02. Dial Indicator
03. Coupling
04. Main Drive Shaft Spindle
12.2.7.5 Main Drive Bearing Preload Adjustment
The rotary machinery carriage should be positioned above deck level to permit convenient access to the gearcase
assembly. Support the unit so that it is stable during removal and installation of components. Refer to Figure 12-6
and proceed as follows:
WARNING
!
1. Shut down the drill. Lock out and tag the disconnects that supply electric power to the machine to prevent inad-
vertent movement of the machinery during inspection, service, or maintenance.
2. Disconnect and remove the bit air components from the gearcase. Refer to Subtopic 12.2.3.
3. Remove lockwasher (14) and remove the lockwasher.
4. Loosen take up nut (15), then Re-tighten to obtain zero main shaft end play. Check with a dial indicator.
5. Tighten take up nut from 9 to 15 beyond 0 end play to obtain 0.08 to 0.13 mm (0.003 to 0.005") preload on
the bearings.
6. Hold the position of the take up nut. Apply anti-seize compound to the main shaft threads. Wipe off excess
compound, then install lockwasher (14), lock down take up nut (15) and bend a tab on the lockwasher.
7. Install slinger ring (15) and retaining rings 16).
8. Install bit air components that were removed in Step 2. Refer to the topic, Assembly and Installation, under Bit
Air Components.
9. Check gearcase lubrication level and replenish if necessary. Refer to the Lubrication section.
12.2.8 Rotary Drill Pipe Coupling R12253F9
The rotary drill pipe coupling is a Duraquest Smoothdrive unit manufactured to a strict set of design specifica-
tions that ensure control over unwanted shock and vibrations, resulting in savings on equipment repair as well as
savings on the overall drilling operation.
Since the drill pipe coupling is designed to function as a system, all parts and components that are a part of the
system are required to ensure proper operation. Additionally, replacements should be made using OEM parts.
Figure 12-13: Rotary Drill Pipe Coupling
01
02 03 04 05 06
07 04 08
BD0571b01
LEGEND
01. Hex Head Cap Screws
02. Lift Ring
03. Pin Connection
04. Hex Head Bolt
05. Torque Limiter
06. Rubber Element
07. Housing
08. BECO Box Connection
WARNING
!
Inadvertent movement of the drill during maintenance activities can cause severe bodily
injury or death. When it is necessary to operate the machine before making an adjust-
ment, or during an operational inspection, obtain the assistance of a second operator
who is thoroughly familiar with the machine. Maintain constant communication and have
the operator at the control panel to be sure that nothing is actuated that can be hazard-
ous to you or the machine.
12.2.8.1 Inspection
The rubber element should be checked every 500 hours of operation as follows:
1. Drill down to the point where the rotary coupling is at eye level. Rest the drill bit at the bottom of the hole.
2. Inspect the rubber element. The rubber should maintain its original look and feel. If the rubber appears discol-
ored or deteriorated, or if it feels sticky or gummy, replace the element.
3. Inspect the housing in the area of the torque limiter lugs. If the lugs have peened the edge of the housing, the
metal could cut the rubber element. Remove peened metal from the housing using a hand grinder or sander.
The rotary machinery carriage should be positioned at deck level to permit convenient access to the rotary drill
coupling. Remove welded straps and disconnect the rotary drive shaft from the rotary coupler. Support the coupling
parts during removal of components. Refer to Figure 12-13 and proceed as follows:
WARNING
!
1. Disconnect, lock out, and tag the disconnect switch that feeds the machine to prevent power from being
2. Remove the lift ring capscrews and remove the lift ring from the rotary coupling.
3. Remove the torque limiter capscrews and discard them. Torque limiter capscrews should not be re-used.
4. Remove the torque limiter.
5. Remove the lower capscrews and discard them. Lower capscrews should not be re-used.
6. Remove the element from the housing.
7. If the body or the BECO box connector require replacement, remove them from the drill string.
Clean, inspect, and repair parts as described Appendix A. Observe all safety precautions. Replace all worn or
damaged parts. Refer to the LinkOne electronic parts manual for parts identification.
Support the coupling parts during installation of the components. Refer to Figure 12-13 and proceed as follows:
1. If the housing or the BECO box connector was removed, replace the housing and/or the BECO box connector
onto the drill string.
2. Place the new element into the housing.
3. Use new bolts. Visually inspect bolt threads prior to installation. Threads must be clean and free of damage,
and the yellow Nylok patch must be in good condition.
4. Spray bolt threads and threaded holes in the element with a light cote of dry film corrosion preventative and let
dry.
5. Apply a small amount of grease to the first two or three threads of the bolt and screw it into the rubber element
as far as possible by hand.
CAUTION
Install bolts slowly to minimize heat buildup, which could cause galling of the threads.
6. Using a 1" impact wrench, slowly run the bolts into the element the rest of the way.
7. Torque bolts to 3,000 ft-lbs (4067 Nm). Verify torque after application. Re-check torque after bolts have had a
chance to settle.
12.2.9 Gearcase Removal and Installation
The following procedures can be used if it is necessary to remove the entire gearcase. The pipe string must be
removed. Proceed as follows:
12.2.9.1 Removal
The rotary carriage positioned to permit convenient access to the gearcase assembly. The unit may be serviced
with the mast up or down. Use appropriate support in all cases.
WARNING
!
2. Drain the rotary gearcase.
3. Disconnect the bit air components. Refer to Subtopic 12.2.3.
WARNING
!
4. Remove the drive motors. Refer to Subtopic 12.2.1.
5. Remove the drill pipe coupling. Refer to Subtopic 12.1.3.
6. Disconnect the lube hose that is connected to the seal carrier on the bottom of the rotary gearcase. Cap the
hose to prevent leakage.
7. Place jack(s) underneath the rotary gearcase for support, and/ or a hoist from above.
8. Remove the idler pinions and related mounting parts. Refer to Section 14, Hoist/Pulldown Machinery..
9. Remove the lower guide rollers. Refer to Section 14, Hoist/Pulldown Machinery..
10. Remove lockwires, capscrews, bolts and nuts to detach the rotary gearcase.
11. If used, lower the jack(s) so that the rotary gearcase clears the carriage legs. Move the rotary gearcase to an
appropriate area for repair.
WARNING
!
WARNING
!
2. Position rotary gearcase between the carriage legs so that the mounting holes in the case and carriage pads
are aligned.
3. Install capscrews, bolts, and nuts. Install lockwire.
4. Install the idler pinions and related mounting parts. Refer to Section 14, Hoist/Pulldown Machinery..
5. Install the lower guide rollers. Refer to Section 14, Hoist/Pulldown Machinery..
6. Install the drive motor(s). Refer to Subtopic 12.2.1.
7. Install the drill pipe coupling. Refer to Subtopic 12.1.3.
8. Install the bit air components. Refer to Subtopic 12.2.3.
9. Connect the lube hose to the seal carrier on the bottom of the rotary gearcase.
10. Check and fill gearcase. Refer to Subtopic 16.4.1.
11. Be sure all fasteners and connections, electrical and hydraulic, are secure.
12. Start up and operate the drill to verify proper operation.
Table 12-2 provides general guidelines to aid in troubleshooting problems of the rotary machinery.
Problem Probable
Cause
Remedy
No Rotary
Power
No voltage to
drive motor
Check for tripped circuit breaker in power
or control circuits.
Investigate cause of power interruption.
Refer to Section 15 for troubleshooting of
electrical circuits. Repair deficiencies.
Faulty drive
motor or pin-
ion
If motor does not run, inspect rotary motor
for signs of overheating and burnout. Refer
to Section 15 for troubleshooting of motor.
Repair deficiencies.
If motor runs, drain gearcase.Remove front
cover and inspect for stripped pinion.
Repair as required
Damaged
rotary gear-
case
Check gearcase oil level and inspect for
leakage at seals.
Drain gearcase. Remove magnetic plug and
inspect for metal particles indicating exces-
sive wear or damage.
Remove front cover and inspect internal
components for wear and damage. Repair
as required.
Insufficient
Rotary Power
Faulty rotary
gearcase
Drain gearcase. Remove magnetic plug and
inspect for metal particles indicating exces-
sive wear.
Remove front cover and inspect internal
components for binding and damage.
Repair as required.
Incorrect
voltage to
drive motor
Investigate control and power circuits for
cause of incorrect voltage and repair any
deficiencies. Refer to Section 15 for trou-
bleshooting of electrical system.
Faulty drive
motor
If motor control and power circuits are
functioning properly, inspect rotary motor
for evidence of overheating or other dam-
age. Refer to Section 15 for troubleshooting
of motor. Repair deficiencies
Faulty rotary
gearcase
If motor control and power circuits are
functioning properly, check gearcase oil
level and inspect for leakage at seals.
BD120149 Mechanical Systems Manual Hoist/Pulldown Machinery
Sec13Pulldown.fm -14.1- Section 14, Version 00 - 03/06
Section 14
Hoist/Pulldown Machinery
Figure 14-1: Rotary Carriage Assembly
BD0574a01
01
02 04 05
06
09 08
07
10
03
LEGEND
02. Pulldown Brake
03. Shipper Shaft
04. Pulldown Motor
06. Drive Pinion
07. Roller
08. Idler
10. Rotary Gearcase
Hoist/Pulldown Machinery BD120149 Mechanical Systems Manual
Section 14, Version 00 - 03/06 -14.2- Sec13Pulldown.fm
The Hoist/Pulldown drive system is mounted in the Rotary Carriage (refer to Figure 14-1).
14.1.1 Pulldown Motor 83013-1
An electric motor is mounted to the upper end of the carriage. It is coupled to a two-reduction transmission. The
pulldown motor is cooled by air through an electric motor blower.
14.1.2 Pulldown Motor Blower R37819D2
The pulldown motor is air-cooled by the electric motor blower (2 HP, 380 V, 50 Hz @ 1470 RPM 3.2 F.L.A.)
attached to the motor housing.
Figure 14-2: Pulldown Motor
Figure 14-3:
14.1.3 Pulldown Transmission 914J434F1
The electric motor drives a triple-reduction pulldown gearcase (refer to Figure 14-4). A disc-type hydraulic brake is
attached to the transmission intermediate shaft to hold the carriage when it is at rest. This is a holding brake only.
Dynamic braking is accomplished using the electric motors reversing capabilities.
The transmissions output shaft, the shipper shaft, extends out both sides of the pulldown gearcase. On either end
of the shipper shaft is a pinion that meshes with racking that is attached to the mast legs. These pinions drive
against the racking to move the drill bit and pipe string.
14.1.4 Pulldown Drive Pinions R5544D1
The pulldown drive pinions are mounted to the ends of the shipper shaft, which is driven by the pulldown motor and
gearcase. The idler pulldown pinions are mounted on shafts on the rotary gearcase. Grease to lubricate the pull-
down pinion bearings and the gear racks is provided by the automatic lubrication system.
Figure 14-4: Pulldown Transmission
Figure 14-5: Pulldown Drive Pinion
14.1.5 Pulldown Idler Pinions R7560D3
The pulldown idler pinions are mounted to shafts that extend from the sides of the rotary gearcase. Grease to lubri-
cate the idler pinion bearings and the gear racks is provided by the automatic lubrication system.
The drive pinions and idler pinions engage the racks welded to the mast verticals.
Idler pinions do not drive, but engage the racks to provide stability in carriage movement. Guide rollers, mounted to
the carriage on the side opposite the pinions, maintain proper carriage tracking.
Figure 14-6: Pulldown Idler Pinion
Figure 14-7: Mast Racking (typical)
14.1.6 Upper Guide Rollers R54361F3
The upper guide roller mounts to the rotary carriage. It limits the movement of the carriage to maintain the correct
engagement between the drive pinion teeth and the mast racking teeth.
14.1.7 Lower Guide Rollers R54362F3
The lower guide roller mounts to the rotary carriage. It limits the movement of the carriage to maintain the correct
engagement between the idler pinion teeth and the mast racking teeth.
Figure 14-8: Upper Guide Roller
Figure 14-9:
14.1.8 Pulldown Brake 15R55D1
The hoist/pulldown brake is spring set and hydraulic released. Braking action is provided by a stack of two rotating
brake discs and three stationary plates (wear, center, and pressure). The lined brake discs are splined to a hub on
the pulldown gearcase intermediate shaft. When the brake is set, powerful springs apply braking force to the pres-
sure plate, holding the pulldown gearcase and preventing it from moving.
14.1.9 Pulldown Resolver Assembly 975N20F1
The pulldown resolver is attached through a flexible speedometer-type cable linkage to a shaft on the pulldown
brake. The resolver itself is mounted on a bracket inside the base. he resolver senses rotation of the pulldown
gearcase and signals the PLC, which translates pulldown movement into the corresponding drilling depth.
Figure 14-10: Pulldown Brake
Figure 14-11: Pulldown Resolver (typical)
14.2 Pulldown System Maintenance
14.2.1 Pulldown Motor 83013-1
Figure 14-12: Pulldown Assembly
LEGEND
02. Blower
03. Screw
04. Washer
05. Rain Shield
06. Gasket
07. Screw
08. Blower Base
09. Motor Gasket
10. Screw
11. Motor
12. Motor Support
13. Screw
14. Shim
15. Shim
16. Shim
17. Shim
18. Shim
19. Lock Washer
20. Screw
21. Special Washer
22. Conical Washer
23. Lock Nut
24. Pulldown Base
25. Tapped Block
26. Nut
27. Screw
28. Screw
30. Shim
31. Shim
32. Shim
33. Shim
34. Coupling
35. Screw
36. Motor Support
37. Pipe Cap
38. Nipple
39. Stopcock
40. Screw
41. Dowel
42. Magnetic Drain Plug
43. Coupling Guard
44. Top Guard
45. Front Guard
46. Screw
14.2.1.1 Removal
The machinery carriage should be positioned at deck level to permit convenient access and resting on the drill bit,
or otherwise supported, to prevent falling. Refer to Figure 14-12 and proceed as follows:
WARNING
!
work.
WARNING
!
WARNING
!
Dropping or mishandling of heavy drill parts can cause severe injury, or death. Always
move heavy components using the auxiliary winch, or suitable lifting device, and slings
for removal and installation. Determine and provide support for components, which may
release or move any during maintenance.
1. Disconnect, lock out, and tag the power source that feeds system to prevent power from being applied while
service is being performed.
2. Remove the blower. Refer to Subtopic 14.2.2.1.
3. Tag and disconnect wiring to the pulldown motor.
4. Remove the mounting hardware and disconnect the halves of coupling (34).
5. Refer to Figure 12-5. Remove locknuts (23), conical washers (22), washers (21), and capscrews (35) from the
motor flange.
6. Use a lifting device to support motor (11). Remove locknuts (23), conical washers (22), washers (21), and cap-
screws (13) to detach motor support (12) and motor. Record the thickness and number of shims (14 through
18). Maneuver the motor to clear the flanged support (36), and remove to an appropriate area.
7. Remove capscrews (20), washers (19), and support (12).
8. Remove the nut, bent washer, and key from the end of the motor shaft.
Refer to Figure 14-12 and assemble the pulldown motor components in the reverse order of disassembly. Note the
following:
1. On the coupling, bend the tab on the lockwasher to lock the nut.
Figure 14-13: Pulldown Motor Alignment
02
03
04
01
LEGEND
01. Adjusting Capscrew and Nut
02. 0.19" (4.8 mm) Shaft-to-Shaft Clearance
03. Key, Bent Washer, and Nut are supplied with the motor
04. Key is supplied with the pinion
2. Using a suitable lifting device, position motor (11), with support (12), over shims (14 through 18) on base (24).
Install the same shim stack that was removed.
3. Install the motor mounting hardware.
4. Refer to and align the motor to the transmission within 0.05 mm (0.002") TIR. If necessary, remove or add
shims to adjust the vertical position of the motor. Loosen nuts and adjust the capscrews to align the horizontal
position of the motor. Tighten the nuts after adjustment. Confirm that the coupling is aligned within 0.05mm
(.002") TIR.
5. Install the coupling mounting hardware.
6. Be sure all mounting hardware and electrical connections are tight.
14.2.2 Pulldown Motor Blower R37819D2
The machinery carriage should be positioned at deck level to permit convenient access and resting on the drill bit,
or otherwise supported, to prevent falling. The blower can be serviced in place unless complete replacement is
required. Proceed as follows:
Figure 14-14: Pulldown Motor Blower
LEGEND
01. Blower
02. Wheel
03. Motor
WARNING
!
Inadvertent machine movement can cause serious injury, or death. Do not perform main-
work.
WARNING
!
power source that feeds this device to prevent power from being applied while inspec-
2. Refer to Figure 14-12. Tag and disconnect wiring to the blower motor).
3. Remove locknuts (04), lock screws (05), and shield (06).
4. If necessary, remove lock screws (02) to remove blower (03), gaskets (07 and 09), and base (08).
5. Refer to Figure 14-14. Remove wheel (02) and motor (03).
Assemble the motor blower components in the reverse order of disassembly. Note the following:
1. Be sure that wheel (02, Figure 14-14) is locked and properly positioned on the shaft of motor (03). The wheel
should not contact the housing.
2. Be sure all mounting hardware and electrical connections are tight.
14.2.3 Pulldown Transmission 914J434F1
Figure 14-15: Pulldown Transmission
The pulldown gearcase assembly is a triple-reduction-type unit. The input pinion is direct-coupled to the pulldown
DC drive motor. Power is transmitted from the input pinion to the gear on the quill pinion-gear set, which rotates on
its own bearings on the shipper shaft. The quill pinion drives the low-speed gear that is splined to the low-speed
pinion. The low-speed pinion drives the main gear that is keyed to the shipper shaft. The pulldown brake is
mounted to the low-speed pinion. The pulldown gearcase can be serviced in place providing suitable lifting and
handling equipment is available to remove heavy components.
14.2.3.1 Removal
The rotary machinery carriage should be positioned at deck level to permit convenient access to the pulldown gear-
case and resting, or supported on the deck. Refer to Figure 14-15 and proceed as follows:
WARNING
!
work.Dropping or mishandling of heavy drill parts can cause severe injury or death.
Always move heavy components using the auxiliary winch, or suitable lifting device, and
slings for removal and installation. Provide support for components which may release
or move any during maintenance.
1. Lock out and tag the operator controls to prevent inadvertent machine start-up during maintenance work.
2. Disconnect coupling (34). Refer to Subtopic 14.2.1.
3. Remove the pulldown brake if desired. Refer to Subtopic 14.2.7.
LEGEND
01. Gearcase
02. Cover
03. Hex Hd Capscrew
04. Dowel
05. Locknut
06. Base
07. O-ring
08. Cover Gasket
10. Breather Filter
11. Lockwire
12. Drilled Head Cap-
screw
13. Pipe Nipple
14. Pipe Coupling
15. Breather Filter
16. Gear
17. Shipper Shaft
18. Key
19. Shipper Shaft
20. Snap Ring
21. Gear
22. Key
23. Ball Bearing
24. Spacer
25. Quill Pinion
26. Drilled Hd Capscrew
27. Retaining Ring
28. Seal
29. Seal
30. Lockwire
31. Seal Housing
32. Tapered Bearing
33. Ball Bearing
34. Input Pinion
35. Ball Bearing
36. Spacer
37. Roller Bearing
38. Shim
39. Shim
40. Shim
41. O-ring
42. Seal Housing
43. Seal
44. Lockwire
46. Gear
47. Oil Level Gauge
48. Pipe Reducer
49. Countersunk Plug
50. Ball Bearing
51. Seal
52. Seal
53. O-ring
54. Seal Housing
56. Disc Brake
57. Spacer
58. Low Speed Pinion
59. Ball Bearing
60. Shim
58. Shim
59. Shim
60. End Cover
4. Remove the pulldown pinions. Refer to Subtopic 14.2.4.
Figure 14-17: Rotary Carriage Components
5. Refer to Figure 14-17 and remove the spreader (03) from the mast to allow access to the pulldown machinery.
6. Remove bearing housings (01 and 31) from the mast.
7. Refer to Figure 14-15. Remove locknuts (23), capscrews (40), and conical washers (22) from the pulldown
gearcase base.
8. Remove pulldown gearcase assembly (01).
The machinery carriage should be resting or supported on the deck to permit convenient access to the pulldown
gearcase. Disassembly can be accomplished with the gearcase on the drill.
WARNING
!
work.
LEGEND
01. Bearing Housing
02. Angle Support
03. Spreader
04. Hex Nut
05. Cotter Pin
06. Hardened Washer
07. Guide Roller
09. Locking Compound
10. Conical Lockwasher
11. Retainer
12. Shim, 12GA
13. Shim, 16GA
14. Shim, .020"
15. Bushing
16. Spacer
17. Guide Roller Pin
18. Drilled Shank Capscrew
19. Shaft Retainer
20. Capscrew
21. Tie wire
22. Conical Washer
23. Drive Pinion
25. Bearing Retainer
26. Shim, .1046" thick
29. Spherical Bearing
30. Tapered Sleeve
31. Bearing Housing
32. Lock Nut
33. Hardened Washer
34. Hex Nut
35. Angle Support
36. Hex Coupling Bolt
38. Guide Roller
40. Snap Ring
42. Snap Ring
43. Spherical Bearing
44. Idler Pinion
45. Bearing Spacer
47. Idler Pinion Shaft
48. Relief Fitting
49. Bushing
51. Drilled Head Capscrew
54. Guide Roller Pin Retainer
55. Idler Shaft Retainer
56. Motor
57. Rotary Gearcase
58. Washer
60. Deflector Bar
61. Deflector Bar
62. Conical Lock Washer
64. Tie Wire
65. Tapped Block
66. Resolver Bracket
67. Pulldown Assembly
70. Air Pipe
71. Conduit U-Bolt
72. Hex Bolt
73. Moving End Bracket
74. Plain Washer
75. Locking Flange Nut
WARNING
!
Dropping or mishandling of heavy drill parts can cause severe injury, or death. Always
move heavy components using the auxiliary winch, or suitable lifting device, and slings
for removal and installation. Provide support for components which may release or
move any during maintenance.
Follow general maintenance instructions provided in Appendix A. Refer to Figure 14-15 and proceed as follows:
2. Remove the pulldown brake. Refer to Subtopic 14.2.7.
3. Drain the gearcase.
4. Remove lockwire (41) and capscrews (42). Pull seal housing (39) and shims (36, 37, and 38).
5. Remove capscrews (03) and locknuts (04). Remove cover (02) and gasket (07).
6. Lift the entire shipper shaft (with gears, spacers, and bearings) from gearcase base (06). Remove this unit to
an appropriate area for repair. Support the shaft and components on suitable blocking to permit disassembly.
Remove parts as required. Pinion (22) and gear (18) are keyed and held together with snap ring (17).
7. Remove lockwire (28) and capscrews (27). Remove end cover (60) and shims (57, 58, and 59).
8. Remove lockwire (12) and capscrews (52). Remove seal housing (51): O-ring (50), and seals (49 and 48).
9. Support gear (43). Push pinion (55), with bearing (56 and 47), from the base. Remove bearings and spacer
(54).
10. Remove pinion (55) from gear (43).
11. Remove the coupling halve from input pinion (32).
12. Remove lockwire (28) and capscrews (27). Remove the input pinion seal housing (29), O-ring (30), bearings
(31 and 33) with ring (24), and seals (25 and 26).
13. Remove lockwire (12) and capscrews (23). Remove ring (24) and seals (25 and 26).
14. Remove seal housing (29), O-ring (30), and bearings (31 and 33).
14.2.3.4 Assembly
Assemble parts in the reverse order of disassembly. Refer to Figure 14-15 and note the following:
1. Shim low-speed pinion (55) for 0.13 to 0.25 mm (0.005" to 0.010") axial endplay, using shims (57,58, and 59).
2. Shim shipper shaft (15) for 0.025 to 0.075 mm (0.001" to 0.003") axial preload using shims (36, 37, and 38).
3. When installing seals in housing (29), the lip (spring side) on inner seal (25) must face inward and the lip on
outer seal (26) must face outward. Fill the cavity between the seals with grease.
14.2.3.5 lnstallation
Install components in the reverse order of removal. Refer to Figure 14-12 and note the following:
1. Align coupling (34) as described under PULLDOWN MOTOR on page 12-6.
2. Be sure breather/filter (10: Figure 12-10) and stopcock (39, Figure 12-51 are installed properly,
3. Fill the pulldown gearcase with oil.
14.2.4 Pulldown Pinions R5544D1
The pulldown drive pinions are mounted to the ends of the shipper shaft, which is driven by the pulldown motor and
gearcase. The idler pulldown pinions are mounted on shafts on the rotary gearcase. Grease to lubricate the pull-
down and idler pinion bearings and the gear racks is provided by the automatic lubrication system.
14.2.4.1 Pinion Maintenance
The machinery carriage should be positioned at deck level to permit convenient access to the pulldown pinions,
and resting on the drill bit or otherwise supported to prevent falling.
WARNING
!
work.
2. Remove lockwire (08), capscrews (20), lockwashers (22), and drive pinions (23).
3. Remove snap ring (40).
4. Clean, inspect, and repair parts as described in Appendix A.
5. Install pinions in the reverse order of removal.
NOTICE
Be sure to align the indexing marks on the pinions (23) and shipper shaft splines.
14.2.5 Idler Pinions R7560D3
The idler pinions should be repaired or replaced if the splines are worn excessively, or if rotation is not true. The
mast should be lowered to its horizontal position to repair or replace the drive pinions. Refer to Figure 14-17 and
proceed as follow:
WARNING
!
1. Lock out and tag the drill operator controls to prevent inadvertent start-up during maintenance procedures.
2. Remove snap ring (40) and bearing retainer (41) from one idler pinion (44).
3. Remove second snap ring (42) from idler pinion shaft (47), and remove pinion (44) from the shaft. Remove a
third snap ring (40), spacer (46), and bearing (43) from pinion (44).
4. Remove capscrews (08), and lockwashers (10) from the rotary gearcase. Remove idler shaft retainer (55) and
shims (12, 13 and 14). Record the number of shims used.
5. Withdraw idler shaft (47) from the gearcase.
6. Repeat steps 2 through 5 for the other idler pinion.
7. Clean, inspect and repair parts as described in Appendix A.
8. Assemble and install parts in the reverse order of removal. Use shims (12, 13 and 14), as needed, so that the
shoulder on idler shaft (47) is tight against the gearcase.
9. Before operating the hoist/pulldown system, initiate a manual lubrication cycle to be sure that the pinions are
adequately greased.
14.2.6 Guide Rollers
14.2.6.1 Roller Adjustment
WARNING
!
Rotary Carriage Rollers must be maintained within specified parameters at all times. Fail-
ure to keep rollers properly adjusted could cause the drive and idler pinions to disen-
gage from the mast rack, allowing the rotary carriage to free-fall, resulting in severe
personal injury or death and substantial property damage.
1. Lower the rotary carriage to the lowest point on the mast.
2. Lower the mast so that the pinion shrouds are resting on the rack shrouds.
3. Remove the four socket head capscrews from the eccentric bushing.
4. Turn the eccentric bushing until a gap of 3mm (.125") is obtained between all of the rollers and the back of the
mast chord.
5. Follow steps 1 through 3 for all three remaining roller carriers.
Figure 14-19: Roller Adjustment
BD0552a01
14.2.6.2 Removal
Lower the mast so the weight of the carriage is resting on the pinions.
Figure 14-20: Roller Assembly Removal
01
02
03
04
05
06
07 08
09
10
01
06
03
04
05
07
08
09
10
02
BD0987a01
LEGEND
01. Cap Screw
02. Washer
03. Shim
04. Shim
05. Shim
06. Retainer
07. Pin
08. Roller Assembly
09. Spacer
10. Bushing
WARNING
!
work.
2. Refer to Figure 14-20 and remove the Guide Roller Assemblies from the rotary carriage as follows:
A. Remove capscrews (01) and lockwashers (02) from the rotary gearcase.
B. Remove guide roller pin retainer (06) and shims (03, 04, 05). Record the number of shims used.
C. Withdraw roller pin (07) with roller assembly (08) from the gearcase.
D. Remove spacer (09) and bushing (10).
E. Repeat steps A through D for the other guide rollers.
14.2.6.3 Upper Guide Roller R54361F3
Disassembly
Technician Tip
The Guide Roller Assembly must be removed from the rotary carriage (refer to Removal above)
before attempting to disassemble the guide roller.
Figure 14-21: Guide Rollers (Upper shown; Lower similar)
01
14
02
06
06
06
07
08
09
10
04
07
03
03
05
05
05
05
11
12
F7601A
LEGEND
01. Roller Carrier
02. Eccentric Bushing
03. Backup Roller with Bearings
04. Roller Pin
05. Thrust Washer
07. Hex Locking Nut
09. Hex Locking Nut
10. Bumper
11. Washer
12. Grease Fitting
1. Remove nuts (07) and capscrews (06) from roller pins (04). Remove roller pins (04), rollers (03) and thrust
washers (05).
2. Remove capscrews (06), washers (11) and bumper (10).
3. Remove capscrews (08) and eccentric bushings (02).
Cleaning, Inspection and Repair
Clean and inspect parts as described in Appendix A. Repair consists of the replacement of worn or damaged parts.
Observe all safety precautions.
Assembly
Assemble the rollers in the reverse order of disassembly. Refer to Figure 14-21.
1. Position eccentric bushing (13) so that the eccentric is closest to rollers (03).
2. Install one capscrew (08) and locknut (09) to attach the eccentric bushing until the guide rollers are installed.
Installation
1. Lubricate the guide rollers at installation.
2. Insert idler pin (07) through roller assembly (08), spacer (09) and bushing (10).
3. Mount roller assembly and pin to the mounting thrust washer on the gear case or the bearing housing (refer to
Figure 14-17)
4. Re-install shims (03, 04, 05) that were removed during the removal operation and assemble and install retainer
(06) using cap screws (01) and washers (02).
14.2.6.4 Lower Guide Roller Assembly R54362F3
The lower carriage roller assemblies are mounted on bearing housings and the rotary gearcase. The clearance
between the rollers and mast legs can be adjusted to maintain proper pinion contact with the pulldown racks.
14.2.6.5 Removal
The mast should be positioned in the down or lowered position so the weight of the carriage is resting on the pin-
ions. Refer to Figure 14-17 and proceed as follows:
WARNING
!
work.
2. Remove capscrews (08) and lockwashers (10) from the rotary gearcase. Remove guide roller pin retainer (54)
and shims (12, 13 and 14). Record the number of shims used.
3. Withdraw roller pin (17) with roller assembly (38) from the gearcase. Remove spacer (16) and bushing (15).
4. Repeat preceding steps 2 through 3 for the other guide rollers.
Technician Tip
The Guide Roller Assembly must be removed from the rotary carriage (refer to Removal above)
before attempting to disassemble the guide roller.
1. Remove nuts (07) and capscrews (06) from roller pins (04). Remove roller pins (04), rollers (03) and thrust
washers (05).
Figure 14-22: Upper Carriage Roller Assembly
01
14
02
13
03
05
05
04
06
06
07
08
09
10
11
12
F7602A
LEGEND
01. Roller Carrier
02. Eccentric Bushing
03. Backup Roller with Bearings
04. Roller Pin
05. Thrust Washer
07. Hex Locking Nut
09. Hex Locking Nut
10. Bumper
11. Washer
12. Grease Fitting
2. Remove capscrews (06), washers (11) and bumper (10).
3. Remove capscrews (08) and eccentric bushings (02).
Clean and inspect parts as described in Appendix A. Repair consists of the replacement of worn or damaged parts.
Assembly
Assemble the rollers in the reverse order of disassembly. Refer to Figure 14-21.
1. Position eccentric bushing (13) so that the eccentric is closest to rollers (03).
2. Install one capscrew (08) and locknut (09) to attach the eccentric bushing until the guide rollers are installed.
Installation
1. Lubricate the guide rollers at installation.
2. Insert idler pin (14) through each guide roller (07) and thrust washer (13), and mount on gearcase (47) or hous-
ing (01 or 22).
3. Assemble and install keeper plate (11) with mounting hardware in the reverse order of removal. Use shims (12)
as needed so that there is minimum clearance between the guide roller and thrust washer.
14.2.7 Pulldown Brake 15R55D1
The brake should be inspected for hydraulic leaks and disc contamination every month. Brake wear should also be
checked every month.
Figure 14-23: Pulldown Brake
LEGEND
02. Intermediate Shaft
03. Spacer
04. Brake Hub
05. Housing
06. Wear Plate
07. Brake Discs
08. Pressure Plate
09. Tapped Lifting Holes
10. Hydraulic Ports (2)
11. Resolver Shaft
12. Cover
13. Ring
14. Piston
15. Spring
16. Drive Plate
17. Shims
18. Center Plate
14.2.7.1 Inspection
The machinery carriage should be positioned at deck level to permit convenient access to the pulldown brake and
resting on the drill bit, or otherwise supported, to prevent falling. Proceed as follows:
1. Inspect the brake and lines for hydraulic leaks and disc contamination.
2. Listen for unusual noise or clatter when the brake is turning (released). This may indicate brake unbalance or
excessive wear.
3. Check for heat buildup after the brake has been free-running for a period of time. Excessive heat could indicate
insufficient clearance.
4. Visually inspect the area near the brake for friction pad particles, which would indicate a problem.
14.2.7.2 Checking Lining Wear
Lining wear is checked by measuring piston movement. Refer to Figure 14-24 and proceed as follows:
WARNING
!
Inadvertent machine movement or operation can cause serious injury, or death. When
necessary to operate the blasthole drill while making an adjustment or performing a
check, obtain the assistance of a second person who is thoroughly familiar with the
machine. Have the assistant at the control panel to be sure that nothing is actuated that
may be hazardous to you or the machine.
1. Lower the carriage to provide convenient access to the pulldown brake. The carriage must be resting on the
drill bit, or other suitable support.
Figure 14-24: Pulldown Brake Wear Check
01
A
B
C
02
03 04
LEGEND
01. Piston
02. Drive Plate
03. Stud Nut
04. Shims
A: Brake Set Position
B: Brake Released Position
C: Piston Stroke
2. With the brake set, measure and record how far the piston protrudes from the drive plate (Dimension A).
3. With the brake released, measure and record how far the piston protrudes from the drive plate (Dimension B).
4. The difference between Dimension A and Dimension B is the piston stroke. If the piston stroke exceeds
6.6 mm (0.260"), proceed as follows:
A. Release the brake.
B. Back off the stud nuts evenly and in steps until sufficient gap exists between the drive plate and the housing
to slide the drive plate back approximately 1.6 mm (1/16").
C. Spread a shim at the split line and remove it by slipping the shim over the drive plate.
D. Tighten the stud nuts to93.5 to 108 Nm (70 to 80 ft-lbs).
E. Engage the brake. Check for approximate 4 mm (0.16") stroke.
CAUTION
Before removing the second and third shims, remove the brake discs and inspect for
equal wear on the lining surfaces. If wear is unequal, interchange the positions of the
brake discs within the brake as an attempt to equalize wear. When all shims have been
removed and piston travel approaches 6.6 mm (.260"), the brake must be replaced.
SAFETY FIRST
Only qualified technicians should rebuild these brakes. P&H Mining Equipment recommends
that brakes be returned to the nearest P&H MinePro Services facility for rebuild.
Figure 14-25: Pulldown Brake Exploded View
LEGEND
01. Hex Nut
02. Lock Pin
03. Rod Bolt
04. Housing
05. Wear Ring
06. Brake Disc
07. Drive Plate
08. Shim
09. Pressure Plate
10. Center Plate
11. Hex Head Screw
12. Lock Washer
13. Cover
15. Spring
16. Breather
17. Piston
18. O-ring
19. O-ring
20. O-ring
21. Ring
22. Seal
23. Seal
The rotary machinery carriage should be positioned at deck level to permit convenient access to the brake and
resting on the drill bit, or otherwise supported, to prevent falling. Disassemble to the extent necessary to make
repairs.
WARNING
!
work.
CAUTION
!
High-pressure oil could cause the free lines to whip or spray hot oil, causing injury. Be
sure the hydraulic system is not pressurized before loosening or removing connections.
WARNING
!
Dropping or mishandling of heavy drill parts may cause personal injury, or death. Always
2. Remove the setscrew and disconnect the flexible shaft from the end of the resolver shaft. Refer to Figure 14-
23.
3. Refer to Figure 14-25. Remove cover screws (11), lockwashers (12), and cover (13).
4. Refer to Figure 14-23 Remove the shaft plate screws and resolver shaft.
5. Refer to Figure 14-25. Remove capscrews (14) from piston (16).
NOTICE
Do not remove stud nuts (01) while capscrews (14) are out. This will release brake spring pres-
sure and make assembly more difficult.
6. Pull piston (16) from drive plate (07). Two threaded bores in the piston facilitate piston removal.
7. Remove O-ring (17) and seal (21 and 22) from the piston. Remove O-rings and seals carefully to avoid
scratching or marring sealing surfaces, which could cause leakage and brake malfunction.
8. Remove ring (20) and O-rings (18 and 19).
9. Back off hex nuts (01) incrementally and uniformly to release spring pressure. Remove nuts and withdraw drive
plate (07) and remove shims (08).
10. Remove pressure plate (09), discs (06), center plate (10) and wear ring (05) from housing (04).
WARNING
!
To remove the entire assembled brake, remove nuts (01), support the brake with a suitable lifting device, and pull
the unit from the pulldown gearcase. Remove lock pins (02).
Clean and inspect parts as described in Appendix A of this manual. In particular, inspect brake discs for damaged
linings. Inspect plates for gouging of brake surfaces. Repair consists of the replacement of worn or damaged parts.
14.2.7.5 Assembly
Assemble the brake in the reverse order of disassembly. Note the following:
1. Clean the brake hub splines and brake disc splines. Apply a light coating of hydraulic oil to the splines. Refer to
Figure 14-23.
2. Refer to Figure 14-25. Install the same number of shims (08) as removed. If new brake discs (06) have been
installed, use three shims.
3. When installing drive plate (07), tighten hex nuts (01) uniformly and in a pattern to compress the brake springs
(15). Torque the stud nuts to 93.5 - 108 Nm (70 - 80 ft-lbs). Apply Loctite, or equivalent sealing agent, to the
stud nuts.
CAUTION
Do not permit outer O-rings or seals to become pinched when installing the ring and pis-
ton. If damaged, the O-rings or seals will not seal properly, causing leakage and malfunc-
tion.
4. Before installation, lubricate new O-rings and seals with a light coating of clean hydraulic oil.
14.2.8 Pulldown Resolver 75Z1252D6
14.2.8.1 Removal
The machinery carriage should be positioned so it is resting on the deck. Refer to Figure 14-26 and proceed as fol-
lows:
WARNING
!
Figure 14-26: Pulldown Resolver
LEGEND
01. Resolver Assembly
03. Tapped Plate
04. Rubber Shim
05. Resolver Bracket
06. Socket Head Set Screw
07. Hub (welded in place)
09. Tie Wire
10. Resolver Clamp
11. Plain Washer
13. Resolver
14. Flexible Shaft Coupling
15. Resolver Shaft
16. Flexible Shaft Cable
17. Insulating Bushing
18. Conduit
19. Insulated Clamp
work.
Proceed as follows:
2. Remove the hex socket capscrews in coupling (14).
3. Loosen nuts (12), and remove resolver (13).
4. Remove coupling (14) and shaft (15).
5. If cable (16) needs to be replaced, proceed as follows:
A. Remove the setscrew in the bushing on the flexible shaft cable at the resolver end.
B. Refer to Figure 12-9. Remove the setscrew and disconnect the flexible shaft cable from the brake end.
C. Remove setscrew (06) and withdraw cable (16).
D. Remove the cable from bushing (17) and conduit (18).
E. Remove bushing (17) and conduit (18) if replacement is required.
6. Remove bracket clamp (lo), bracket (05), plate (03), and shim (04) if necessary.
7. Remove related connecting parts for the cable that are on the pulldown brake as required. Refer to PULL-
DOWN BRAKE on page 12-1.
14.2.9 Cleaning, Inspection and Repair
1. Examine the coupling for stretching, bending, and twisting distortion. Replace damaged coupling.
2. Check for continuity across the resolver stator windings S1- S3 (terminals 2 and 5) and S2-S4 (terminals 4 and
6) and rotor winding R1-R2 (terminals 1 and 2) with an ohmmeter. Replace the resolver if there is an open or
dead short across any winding.
14.2.10 Assembly and Installation
Assemble and install parts in the reverse order of removal. Refer to Figure 14-26 and note the following:
1. After installing shaft (15) in cable (16), and tightening the cable setscrew, install coupling (14) on shaft (15).
2. Position resolver (13) in clamp (10) so the resolver keyway is in line with the case connector. Slide the resolver
into the coupling so there is approximately " (6.4 mm) between the resolver and coupling. Tighten the cou-
pling capscrews to10.8 to 13.6 Nm (8 to 10 ft-lbs)
3. Inspect the coupling to be sure it is not distorted. Apply Loctite, or equivalent sealant, to the coupling cap-
screws.
4. Start up the drill and check pulldown operation. Verify the zero setting of the resolver.
Erratic Hoist/Pulldown Operation Electrical malfunction Investigate control and power cir-
cuits for cause of incorrect opera-
tion.
Insufficient Hoist/Pulldown Power Pulldown brake not fully released Check operation of brake.
Mechanical failure of gearcase Inspect the pulldown gearcase for
interference, damaged components
or other malfunction.
Incorrect voltage to drive motor Investigate control and power cir-
cuits for cause of incorrect voltage.
Faulty drive motor If motor control and power circuits
are functioning properly, inspect
motor for evidence of overheating
or other damage.
No Hoist/Pulldown Power No voltage to drive motor Check for tripped circuit breaker in
power or control circuits. Investi-
gate cause of power interruption.
Motor blower inoperative Check blower operation. Failure
could cause motor overheating and
shutdown.
Faulty drive motor If motor does not run, inspect rotary
motor for signs of overheating and
burnout.
Broken drive coupling Check condition on coupling.
Failure of pulldown gearcase Check gearcase oil level and inspect
magnetic plug for evidence of inter-
nal failure.
Hoist/Pulldown Operation Stalls Pulldown brake does not release Inspect hydraulic lines and connec-
tions to brake.
Check hydraulic system.
Pinions jammed or damaged Clean any debris or other material
from racks.
Inspect pinions for damage.
Electrical malfunction Investigate control and power cir-
cuits for cause of lack of power and
repair any deficiencies.
Pulldown Brake does not hold Worn linings Remove shim
Replace brake discs
Damaged or broken springs Replace springs
Pulldown Brake does not release No hydraulic pressure to brake Inspect hydraulic lines for loose
connections (leaks) and breaks.
Check reservoir oil level.
Internal leakage in brake Replace brake seals.
Table 14-1: Troubleshooting
BD120149 Mechanical Systems Manual Pipe Handling Equipment
Sec14Pipes.fm -14.1- Section 14, Version 00 - 03/06
Section 14
Pipe Handling Equipment
Figure 14-1: Pipe Handling Equipment
01
02
03
04
05
06
07
08
09
10
10
BD0544a01
LEGEND
01. Upper Arm
02. Mast
03. Mast
05. Lower Arm
06. Pipe Holder
07. Pipe Rack (retracted)
08. Pipe Wrenches
09. Deck Wrenches
10. Hydraulic Hoses
Pipe Handling Equipment BD120149 Mechanical Systems Manual
Section 14, Version 00 - 03/06 -14.2- Sec14Pipes.fm
14.1.1 Pipe Racks
The pipe rack forms a long vertical cradle to handle a single length of drill pipe. Refer to Figure 14-1. The pipe rack
is connected to inside mast members at the top and bottom by swing arms that allow the rack to be lowered from
the retracted (stored) position to the drill centerline and vice versa. Movement of the pipe rack is accomplished by
extension or retraction of a hydraulic cylinder that is attached between the mast and lower arm. The pipe section is
held in the pipe rack by a pipe holder at the bottom and by a swing gate at the top. Two spring-loaded pipe
wrenches or pawls in the pipe holder grab the outside surface of the pipe to hold the pipe during disconnection
from the rotary head before returning the pipe to its stored position. The upper swing gate is opened or closed by a
hydraulic cylinder. Operation of the racks is controlled by the operator through the PLC. Limit switches signal the
PLC to indicate operational conditions of the pipe rack; that is, the pipe is in the pipe holder, the rack is retracted,
and the gate is closed. The deck wrench units each consist of a housing, a sliding body with spring-loaded pawl,
and a hydraulic cylinder that provides clamping power.
14.1.1.1 Left Pipe Rack 100J6766F6
The left pipe rack is a parallelogram-style pipe rack that is 11.3 meters (37 feet) in length. The rack is hydraulically
controlled to move inward or outward. A mechanical mechanism is used to lock the drill pipe into place while
stored. A hydraulic holdback system prevents the pipe rack from drifting into the drill string area when the drill is
operating.
14.1.1.2 Right Pipe Rack R4081F1
The right pipe rack is a parallelogram-style pipe rack that is 8.4 meters (27.5 feet) in length. The rack is hydrauli-
cally controlled to move inward or outward. A mechanical mechanism is used to lock the drill pipe into place while
stored. A hydraulic holdback system prevents the pipe rack from drifting into the drill string area when the drill is
operating.
14.1.2 Deck Wrench GH5007463
The deck wrench allows the operator to hold the pipe string while tools or pipe sections are being connected or dis-
connected. It consists of a pair of hydraulically actuated rams mounted on the drilling platform. Each ram is located
on opposite sides of the drill hole, just off of centerline.
14.1.3 Breakout Wrench R46448F1
The breakout wrench is used to loosen a pipe joint that is tighter than the joint at the rotary coupling. Refer to Fig-
ure 14-3.
The breakout wrench is permanently mounted to the mast structure, and is operated by a set of hydraulically actu-
ated cylinders. These cylinders operate in conjunction with each other to make the breakout wrench operation
smooth and simple.
The breakout wrench is stored in the retracted position. The breakout wrench is fitted with inserts for gripping the
drill pipe sections. These inserts are interchangeable, based on the drill pipe diameter being handled.
14.2 Pipe Handling Equipment Maintenance
NOTICE
Apply standard torque to fasteners unless otherwise specified. Refer to Appendix A for general
mechanical maintenance procedures, and to Appendix B for general hydraulic component
maintenance procedures. It is advisable to replace all seals and O-rings whenever hydraulic
Figure 14-3: Breakout Wrench
components are disassembled. Refer to the LinkOne electronic parts manual for identification
of components and service kits.
14.2.1 Pipe Racks
The two pipe racks are identical except for their length. The left-hand pipe rack (100J6766F6) is 11.3 meters (37 ft)
long, while the right-hand pipe rack (R4081F1) is 8.4 meters (27.5 ft) in length.
Figure 14-4: Pipe Rack
LEGEND
01. Link Actuator
02. Gate Arm Support
03. Bronze Bushing
04. Upper Arm
05. Upper Pin
06. Retaining Ring
08. Anchor Block
09. Upper Block
10. Anchor Block Shim
13. Washer
16. Lock Washer
17. Upper Rack Pin
18. Cylinder Link
19. Flat Bar
20. Grease Fitting
21. Pivot Pin
22. Rod Clevis
23. Limit Switch
24. Limit Switch Arm
25. Gate Limit Switch Bracket
27. Lock Washer
28. Gate Hydraulic Cylinder
30. Tie Wire
31. Cylinder Mount Plate
32. Tapped Block
33. Drill Pipe Rack
35. Cylinder Pin
36. Tapped Bar
37. Limit Switch Bracket
39. Lower Block
40. Lower Pin
41. Retaining Ring
42. Lock Washer
43. Hex Nut
44. Lower Arm
45. Spring Seat
46. Spring
47. Weldment Pin
49. Tie Wire
50. Limit Switch Cover
51. Limit Switch
52. Pipe Wrench Pin
53. Hex Nut
54. Socket Head Set Screw
14.2.1.1 Pipe Wrenches and Liners
Adjustment
Check engagement of the wrenches with pipe to be sure that the wrenches grab when pipe is being disconnected.
If not, loosen the locknut and adjust the setscrew at the front of the pot to obtain correct holding action. The set-
screw bears against the wrenches to set the closed position of the wrenches. Tighten locknut after adjustment. The
pipe wrenches are installed in the pipe holder. The liners are installed in the pipe holder and pipe gate. Refer to the
LinkOne electronic part manual for parts information.
Figure 14-6: Pipe Wrenches and Liners
02 03 02 04
05
06
01
07
08
01
BD0546a01
07
LEGEND
01. Wrench
02. Wrench Pin
03. Setscrew and Nut
04. Wrench Seat
05. Setscrew
06. Spring
07. Liner
08. Plunger
14.2.1.2 Pipe Rack Gate
Removal
WARNING
!
The rotating drill or its associated moving components can entrap and crush people,
resulting in severe injury, or death. Do not enter the drill string and mast area while the
drill is operating. Shut down the machine before performing inspections, service, or
maintenance. Establish a procedure to guard against inadvertent equipment operation
or movement while conducting inspections. Use lockout and tagout procedures prior to
conducting maintenance or service.
1. Disconnect, lock out and tag the power source that feeds the system to prevent power from being applied while
service is being performed.
WARNING
!
Falls from elevated mast can cause severe injury or death. Always use fall protection
devices, such as the Saf-T-Climb system, when climbing the mast ladder. Do not attempt
to perform maintenance or service from the ladder with the mast elevated. Lower the
mast or use appropriate work platforms to perform maintenance or service to the mast
or mast components.
Figure 14-7: Pipe Rack Gate Mechanism
01 04
05
06
01 02 03
BD0547a01
LEGEND
01. Gate Arm
02. Gate Arm Bearing
03. Clevis
04. Upper Rack
05. Limit Switch
06. Gate Cylinder
WARNING
!
Dropping or mishandling of heavy drill parts may cause severe personal injury, or death.
Always move heavy components using the auxiliary winch or other suitable lifting device
and rigging for removal and installation. Provide support for components which may
release or move during any maintenance.
Removal And Disassembly
The pipe rack should be in the drilling position to perform repairs which allows better access to components. It also
eliminates the possibility of the rack dropping from the stored position. Remove components selectively for repair
or replacement. Refer to Figure 13-6 and proceed as follows:
WARNING
!
The rotating drill or its associated moving components can entrap and crush people
resulting in severe injury or death. Do not enter the drill string and mast area while the
2. Refer to Subtopic 14.2.1.8, for service instructions for cylinder (29).
3. Remove cotter pins (20) and sleeve pins (21). Withdraw gate arm (01) and remove gate support (02) and
assembled sleeve (19).
4. Remove pivot pin (24) to detach assembled sleeve (19) with link (18) and bar (22).
5. Tie or otherwise support the upper end of the rack.
6. Remove capscrews (15) and lockwashers (16) to detach upper rack pin (17).
7. Loosen locknuts (14) and capscrews (07), remove retaining rings (06), and push out upper pin (05). Remove
upper arm (04).
Clean and inspect components in accordance with the general cleaning and inspection procedures in Appendix A
of this manual. Repair consists of the replacement of all worn or damaged components. Refer to the LinkOne elec-
tronic parts manual for component identification.
Install the components in the reverse order of removal. Refer to Figure 13-6. Note the following instructions.
1. Refer to Subtopic 14.2.1.8, for service instructions for the gate cylinder (29).
2. After installation, check gate operation. Gate arm (01) should fully close and limit switch (26) should trip with
the cylinder extended. Adjust the clevis on the cylinder rod to achieve these conditions.
3. If a new gate link and sleeve assembly are to be installed, the clearance between the gate arm bearing and the
sleeve should be 0.060" (1.5 mm). Refer to Figure 14-7. This dimension is set at assembly of the parts when
the sleeve assembly and gate arm are installed and clamped to dimension. Then the sleeve and arm can be
drilled to allow insertion of the roll pin. Hole size is " (12.7 mm).
4. Start the drill and operate to verify operation of the gates and latches.
14.2.1.5 Pipe Holder and Swing Arm
WARNING
!
Dropping or mishandling of heavy drill parts may cause severe personal injury, or death.
Always move heavy components using the auxiliary winch or other suitable lifting device
and rigging for removal and installation. Provide support for components which may
release or move during any maintenance.
Removal and Disassembly
eliminates the possibility of the rack dropping from the stored position. The location and arrangement of the pipe
holder (pot), lower swing arm and related parts are shown on Figure 14-4. Remove components selectively for
repair or replacement. Refer to Figure 14-4 and proceed as follows:
WARNING
!
The rotating drill or its associated moving components can entrap and crush people
resulting in severe injury or death. Do not enter the drill string and mast area while the
1. Disconnect, lock open, and tag the power source which feeds the system to prevent power from being applied
CAUTION
!
High-pressure hydraulic or air systems can spray with extreme force and noise causing
2. Remove the wrenches. Refer to Subtopic 14.2.1.1.
3. Remove the limit switch. Refer to Subtopic 14.2.2.
4. Tie or otherwise hold the bottom of the rack in position
5. Remove capscrews (15) and lockwashers (16) to detach pins (36 and 42).
6. Loosen hex nuts (45) and capscrews (40), remove retaining rings (43), and push out pin (42). Remove arm
(46).
7. Refer to Subtopic 14.2.1.6, for service instructions for the cylinder (35).
Clean and inspect components in accordance with the general cleaning and inspection procedures described in
Appendix A of this manual. Repair consists of the replacement of all worn or damaged components. Refer to the
LinkOne electronic parts manual for component identification.
Assembly and Installation
Refer to Figure 14-4 and install the components in the reverse order of removal. Note the following instructions:
1. Refer to Subtopic 14.2.1.6, for service instructions for cylinder (35).
2. Confirm that all grease fittings (23) are installed.
3. Confirm that the mounting and air and hydraulic connections are secure.
4. Start the drill and check operation of the racks and confirm that all functions work properly.
14.2.1.6 Pipe Rack Swing Cylinder
The pipe rack swing cylinder is a double-acting hydraulic cylinder with rod eye and clevis type mounting provi-
sions.
Removal
eliminates the possibility of the rack dropping from the stored position. Refer to Figure 14-4 and proceed as follows:
WARNING
!
cause severe bodily injury and/or death. Lock out and tag the drill operating controls to
prevent accidental operation.
Figure 14-8: Pipe Rack Swing Cylinder
LEGEND
01. Seal Kit
02. O-ring
03. Back-Up Ring
04. Wear Ring
05. Rod Seal
06. Rod Seal
07. Rod Wiper
08. Back-Up Ring
09. O-ring
10. Piston Seal
11. Wear Ring
CAUTION
!
High-pressure hydraulic systems can spray with extreme force and noise causing
2. Tag and disconnect the hydraulic hoses from swing cylinder (35). Cap or plug hydraulic fittings to prevent con-
tamination of the hydraulic system.
3. Support swing cylinder (35). Remove capscrews (15) and lockwashers (16) and withdraw pins (36). Remove
the cylinder.
Disassembly
1. Loosen and back out the cylinder head with a spanner wrench.
2. Remove the cylinder rod with head assembly and piston assembly from cylinder body.
3. Remove the piston and cylinder head assembly from the cylinder rod.
4. Remove and discard O-rings (02) and back-up ring (03) from the head.
5. Remove and discard wear rings (04), and seals (05 and 06) and wiper (07) from inside of the head.
6. Remove and discard wear ring (11), seal (10), O-ring (09), and back-up rings (08) from the piston.
Clean and inspect the hydraulic cylinder components in accordance with the general cleaning and inspection pro-
cedures in Appendix B of this manual. None of the components are repairable, and must be replaced if worn or
damaged. It is advisable to replace all parts in the seal kit whenever the unit is disassembled. Refer to the LinkOne
electronic parts manual for component identification.
Assembly
Lubricate all seals, O-rings, back-up rings and rod wiper with hydraulic oil prior to installation. Refer to Figure 14-8
and proceed as follows:
1. Install new wear O-rings (02) and back-up ring (03) on the head.
2. Install new wear rings (04), seals (05 and 06) and wiper (07) inside of the head.
3. Install new wear ring (11) and seal (10) on the piston.
4. Install new O-ring (09), and back-up rings (08) in the piston.
5. Install the assembled piston and cylinder head on the cylinder rod.
6. Install the cylinder rod with head assembly and piston assembly into the cylinder body.
7. Install the cylinder head with a spanner wrench.
1. Support swing cylinder (35) in position on the pipe rack and clevis.
2. Insert cylinder pin (36) into rack clevis and the head end of cylinder (35). Install capscrew (15) and lockwasher
(16) to secure the pivot pin.
3. Insert a second pivot pin (36) on the rod end of cylinder (35) as described in preceding step 2.
4. Connect the tagged hydraulic hoses to cylinder.
5. Start up the drill hydraulic system and bleed the hydraulic system at the cylinder.
6. Start the drill and confirm operation of the rack lower and retract action.
14.2.1.8 Pipe Rack Gate Cylinder
eliminates the possibility of the rack dropping from the stored position. Refer to Figure 14-4 and proceed as follows:
1. If necessary, lower the affected pipe rack to the drilling position.
WARNING
!
cause severe bodily injury and/or death. lock out and tag the drill operating controls to
CAUTION
!
High-pressure hydraulic systems can spray with extreme force and noise causing
3. Tag and disconnect the hydraulic hoses from gate hydraulic cylinder.
4. Plug and/or cap all hose assemblies and hydraulic fittings to prevent contamination of the hydraulic system.
5. Support cylinder (29). Remove the pivot pin from the cylinder clevis and the head end of cylinder. Remove the
attaching capscrews to detach the cylinder. Unscrew the clevis.
Clean and inspect the hydraulic cylinders in accordance with the general cleaning and inspection procedures in
Appendix B of this manual. Replace faulty cylinders.
The location and method of attachment is shown on Figure 13- 6. Assemble the cylinder and related hardware in
the reverse order of removal.
1. Support gate cylinder (29) in position on the pipe rack
2. Connect the tagged hydraulic hoses to the cylinder.
3. Start up the drill hydraulic system and bleed the hydraulic system at the cylinder.
4. Start the drill and check the operation of the rack gate and/or latch.
14.2.2 Limit Switches
There are three limit switches mounted on each pipe rack. If a fault or malfunction occurs that is related to the limit
switch functions, isolate the cause and locate the switch. Refer to Figures 14-4, and 13-10.
Figure 14-9: Pipe Holder Limit Switch
LEGEND
02. Lock Washer
03. Limit Switch
04. Mounting Base
05. Spring
06. Plunger
07. Roll Pin
08. Trip Bar
09. Roll Pin
Inspect the applicable switch for loose mounting and loose or disconnected wires. Repair any faulty condition. If the
wiring is good, inspect the switch for damage, distortion and wear. For the pot switch also examine the spring (Item
05, Figures 14-9,) and plunger (06). Replace all worn or damaged parts.
WARNING
!
cause severe bodily injury and/or death. Lock out and tag the drill operating controls to
2. Disconnect, lock out, and tag the power source which feeds the system to prevent power from being applied
3. Tag and disconnect the wiring from the limit switch.
4. Remove the mounting hardware and related parts to detach the switch.
5. Check the on-off switch functions with an ohmmeter while actuating the switch manually. Replace a switch that
does not operate properly.
6. Install a new switch with the same hardware and related parts.
7. Connect the wiring to the limit switch.
8. Start the drill and check operation of the limit switch.
14.2.3 Deck Wrench GH5007463
The deck wrench units each consist of a housing, a sliding body with spring-loaded pawl, and a hydraulic cylinder
that provides clamping power.
14.2.3.1 Removal
WARNING
!
cause severe bodily injury, or death. Lockout and tag the drill operating controls to pre-
vent accidental operation.
LEGEND
01. Capscrew
02. Lock Washer
03. Retainer
04. Grease Fitting
05. Housing
06. Cylinder
07. Body
08. Grease Fitting
09. Roll Pin
10. Compression Spring
11. Pawl
12. Anchor Pin
13. Cotter Pin
CAUTION
!
High-pressure hydraulic or air systems can spray with extreme force and noise causing
severe injury. Slowly release pressure or vent circuits before loosening fittings or con-
nections. Wear appropriate face, ear, and body protective devices while venting air or
hydraulic systems.
2. Tag and disconnect the hydraulic hoses from the deck wrenches.
3. Remove the hydraulic fittings from the deck wrenches.
4. Tag and disconnect the lubrication hose assemblies from the deck wrenches.
5. Plug and/or cap all hose assemblies and hydraulic fittings to prevent contamination of the hydraulic system.
6. Remove cotter pins (13) and withdraw anchor pin (12) to free each deck wrench.
1. Remove capscrews (1) and lockwashers (2). Separate retainers (3) and remove from the cylinder rod.
2. Withdraw housing (07) with pawl (11), spring (10), cylinder (06), and roll pin (09) from the working end of
wrench housing (05).
3. Drive out roll pin (09), and remove pawl (11) and spring (10).
4. Tag and disconnect the hydraulic hoses from the deck wrenches.
5. Remove cylinder (06) from body (07).
6. Remove grease fittings (04), if necessary to replace.
Clean and inspect the deck wrench components in accordance with the general cleaning and inspection proce-
dures provided in Appendix A of this manual. Repair consists of replacement of all worn or damaged components.
Refer to the LinkOne electronic parts manual for component identification.
14.2.3.4 Assembly
1. Install new grease fittings (04) if necessary.
2. Position hydraulic cylinder (06) in body (07).
3. Place spring (10) and pawl (11) in body (07). Align the mounting holes on the pawl and the body, and install roll
pin (09) to secure.
4. Install body (07) with pawl (11), spring (10), cylinder (06) and roll pin (09) into housing (05).
5. Place retainers (03) on rod end of cylinder (06). Install capscrews (01) and lockwashers (02) to secure the
retainers.
1. Place each deck wrench in its position on the drill platform. Install anchor pin (12) and secure with cotter pins
(13).
2. Repeat the preceding Step 1 for the other deck wrench.
3. Install the lubrication hose assemblies on the deck wrenches. Manually lubricate the wrench pawls, as speci-
fied in Section 16, Lubrication..
4. Install the hydraulic fittings on the deck wrenches.
5. Connect the hydraulic hoses to the deck wrenches. Bleed the hydraulic system.
6. Recheck the security of the mounting and hydraulic connections.
7. Start the drill and check operation of the deck wrenches to be sure all functions work properly.
14.2.4 Deck Wrench Cylinders GH5010453
The deck wrench cylinders are double acting hydraulic cylinders, which are ported through the rod end. One cylin-
der is located inside each wrench slide assembly. Refer to Subsection 14.2.3 for removal and installation proce-
dures.
1. Use a spanner wrench to loosen cylinder head (02); back it out, free of barrel (05).
2. Pull the entire piston and piston rod assembly out of barrel (05). Pull the assembly straight out, very carefully,
to avoid scoring the cylinder bore.
3. Remove locknut (04) and the slide piston assembly off piston rod (01).
Figure 14-11: Deck Wrench Cylinder
LEGEND
01. Piston Rod
02. Cylinder Head
03. Piston
04. Locknut
05. Barrel
06. Service Kit
07. Rod Wiper
08. Rod Seal
09. O-ring
10. Backup Ring
11. O-ring
12. Wear Ring
13. Seal Assembly
14. O-ring
4. Remove and discard O-ring (14) from inside of piston (03).
5. Remove two wear rings (12) and seal assembly (13) from the piston (03). Use care to avoid damage to the pis-
ton land areas during disassembly.
6. Remove cylinder head assembly off piston rod (01).
7. Remove backup ring (10) and O-ring (11) from the outside of cylinder head (02).
8. Remove rod wiper (07), rod seal (08), and O-ring (09).
Clean and inspect the hydraulic cylinder components in accordance with the general cleaning and inspection pro-
cedures described in Appendix B of this manual. None of the components are repairable, and must be replaced if
worn or damaged. Replace all seals and rings using available service kit. Refer to the LinkOne electronic parts
manual for component identification.
14.2.4.3 Assembly
1. Lubricate and install rod wiper (07), rod seal (08), and O-ring (09).
2. Install cylinder head (02) on piston rod (01).
3. Lubricate and install backup ring (10) and O-ring (11) on the outside of cylinder head (02).
4. Lubricate and install new O-ring (14) the inside of piston (03). Install piston with O ring on piston rod (01).
5. Lubricate and install two wear rings (12) and seal assembly (13) on piston (03). Use care to avoid damage to
the piston land areas during assembly.
6. Install locknut (04) on piston rod (01).
7. Lubricate the bore of barrel.
8. Install the entire piston and piston rod assembly into barrel (05). Insert the assembly, very carefully, to avoid
scoring the cylinder bore.
9. Install cylinder head (02) into the barrel, and torque securely with a spanner wrench.
Clean and inspect components in accordance with the general cleaning and inspection procedures described in
Appendix A of this manual.
14.2.5 Breakout Wrench R46448F1
The breakout wrench, the P&H SureWrench II, is used to assist in the separation of pipe joints. Refer to Figure
14-12 .
WARNING
!
The rotating drill string or its associated moving components can entrap and crush per-
sonnel, resulting in severe injury or death. Do not enter the drilling platform and/or mast
area while the drill is operating. Notify the operator to shut down the drill and use lock-
out/tagout procedures before conducting maintenance or service. When working in the
drilling and/or mast area while power is supplied to the drill, establish a procedure to
maintain communications between the work crew and the person controlling the drill
operation and shut down.
14.2.5.1 Sure Wrench Alignment
Figure 14-12: Breakout Wrench
01
02
03
04
05
06
07
08
09
02
10
BD0642a01
LEGEND
01. Pivot Tube
02. Lube Fitting
03. Jaw Die
04. Jaw Bushing
05. Jaw Pin Cover
06. Breakout Wrench Arm
07. Breakout Wrench
08. Clamping Cylinder
09. Wrench Pin Cover
10. Breaking Cylinder
Step 1: Mount wrench to mast.
Step 2: Add proper jaws and dies to match diameter of drill pipe. Refer to Subtopic 14.2.5.2.
Step 3: Swing the breakout wrench into position to clamp around the pipe.
Step 4: Loosen the bolts on the breakout wrench mounting bracket.
Step 5: Using the hydraulics, clamp the drill pipe with the wrench.
Step 6: Tighten the bolts on the mounting brackets to secure the position of the wrench.
Step 7: Swing the wrench in and out to check the final alignment. If better alignment is needed, repeat steps 3
through 7.
14.2.5.2 Jaw and Die Chart
CAUTION
Having unequal die lengths will result in the dies aligning incorrectly against the drill
pipe. The hydraulic force applied to the jaws as they are rotated can be sufficient to
cause the teeth to chip, resulting in slippage and premature wear on the dies.
Use the jaws and dies that correspond to the pipe diameter. Refer to Table 14-1.
14.2.5.3 Worn pins, bores, bushings, bushing guides, slots and pivots
As the working parts wear, the clamping and breaking performance will suffer. Wearing parts cause the Sure
Wrench geometry to be distorted when clamping around a drill pipe as designed. As a result, the dies will not main-
tain the required perpendicularity to the drill pipe. Thus, the dies will encounter point loading, which will result in the
dies slipping and chipping teeth instead of biting into the drill pipe as the jaws are rotated.
Part No. Pipe Size
(inch dia)
R46538F1 14 - 3/8
R46538F2 13 - 3/8
R46538F3 10 - 3/4
R46538F4 11- 3/4
Table 14-1: Jaw and Die Chart
14.2.6 Hydraulic Circuit Inspection and Adjustments
Table 14-2 shows tools, supplies, and parts required for the procedures that follow..
The procedures to adjust the hydraulic pressure (clamping force) will require two individuals with prior knowledge
of the P&H drill. It is essential that everyone working on this adjustment understand all aspects of the procedure
before work begins.
CAUTION
Remove dirt build-up from in and around the hydraulic fittings before repairs or adjust-
ments are made to limit contamination from entering the system.
* 1 ea. 0-5000 psi gage
1 ea. 5/32" allen wrench
1 ea. 9/16" open end wrench
1 ea. Spray Cleaner
2 ea. #8 JIC Cap, 44Z511D4
1 ea. #8 JIC Union, 44Q44D15
** 1 ea. #8 JIC Tee, 44Z487D6
** 1 ea. Test Gage Connector, 44Z2664D4
* Use pressure test kit provided with the drill.
** These components will remain with
the sequence valve.
Table 14-2: Tools, Supplies and Parts Required
14.2.6.1 Hydraulic Component Inspection
O
Figure 14-13: Sure Wrench Hydraulic Components
01 02
A
03
01
02
03
04
B
06
05
07
05
06
08
01
LEGEND
01. Sequence Valve
02. Break Sequence Car-
tridge Adjustment
03. Port H
04. Arm
05. Break Cylinder
06. Jaw Cylinder
07. Pivot
08. Slot
A = Install tee and test connector
B = Connect both hoses together using
the #8 JIC union
Refer to Figure 14-13 and inspect hoses, fittings, sequence valve and hydraulic cylinders for oil leaks on a regular
basis. Repair or replace damaged components before continuing on with the following steps:
14.2.6.2 Pressure Test Setup
Turn off power to the drill. Refer to Figure 14-13 and proceed as follows:
CAUTION
!
High pressure hydraulic systems can spray oil with extreme force, causing severe injury.
Test system pressure before loosening fittings or connections. Check pressure at Test
Ports GA7 and GB7 on Valve Bank 2. Pressure must be zero before loosening any fit-
tings or connections. Wear appropriate face, ear, and body protective devices when
venting hydraulic systems.
Step 8: Refer to Letter A on Figure 14-13. Remove the hose that connects the break cylinder to the sequence
valve H port. Temporarily cap the open end of the hose.
Step 9: Install the tee fitting to the male fitting on the open port of the sequence valve. Reconnect the hose to the
tee fitting.
Step 10: Install the test gage connector to the branch port of the tee fitting. Install the 0-5000 psi gage.
NOTICE
Tee fitting and test gage connector will remain with the sequence valve.
Step 11: Refer to Letter B on Figure 14-13. Remove both break cylinder hoses. Cap the open ports on the cylinder.
Connect the two hoses together using the union fitting.
14.2.6.3 Sure Wrench Jaw Cylinder Pressure Adjustment
Step 1: Start the drill. When the hydraulic oil reaches normal operating temperature, continue with the following
steps.
Step 2: From the operators cab, press and hold the rocker switch that controls the Sure Wrench Jaw and Break
motions. Observe the pressure reading on the test gage.
Step 3: Make the necessary adjustments by adjusting cartridge (02, Figure 14-13) on the dual sequence valve
facing towards the front of the drill. Turning the adjustment clockwise will increase pressure; turning anti-
clockwise will decrease the pressure.
NOTICE
There are two cartridges on the dual sequence valve. Be certain to adjust the cartridge that is
facing the front, not the cartridge that is facing the rear.
Step 4: Adjust cartridge (02, Figure 14-13) to 2400 psi.
Step 5: Turn power off; remove test gage.
Step 6: Reconnect hoses onto the Break Cylinder.
Step 7: Start the drill and operate the Sure Wrench. Check for oil leaks.
Figure 14-14: Jaw Cylinder Pressure Adjustment
1000
3000
4000
5000
P
S
I
er.0.9
2000
03
A
0-5000 psi
Table 14-3 provides basic guidelines to aid in the troubleshooting problems of the pipe handling equipment.
Deck Wrench Slide
Does Not Operate
Binding mechanism Clean and lubricate slide.
lnspect slide and housing for
galling.Repair as required.
lnspect for internal jamming.
Check parts and repair as nec-
essary.
Hydraulic control circuit
malfunction
lnspect hydraulic lines for leaks
and/or loose connections.
Repair any deficiencies.
Investigate control circuits for
cause of incorrect operation
and repair any deficiencies.
Hydraulic System. for trouble-
shooting of the auxiliary
hydraulic system.
Hydraulic cylinder malfunc-
tion
Repair or replace faulty cylinder.
Deck Wrench Pawl
Does Not Return to
Extended Position
Binding mechanism Clean and lubricate the pawl
mechanism.
Galled retainer pin. lnspect
parts and repair as necessary.
Weak or broken compres-
sion spring
lnspect spring for damage or
breakage. Repair faulty spring.
Pipe Rack Does Not
Swing Properly
Binding mechanism lnspect upper and lower swing
mechanisms for foreign mate-
rials. Remove any debris.
Lubricate pivot pins.
lnspect for broken or binding
arm pivot pins. Repair as
required.
lnspect for distortion of arms
and supports. Repair or
replace parts as necessary.
Hydraulic cylinder circuit
malfunction
lnspect hydraulic lines to swing
cylinder for leaks and/or loose
connections. Repair any defi-
ciencies.
Investigate control circuits for
cause of incorrect operation
and repair any deficiencies.
Hydraulic System. for trou-
bleshooting of the auxiliary
hydraulic system.
Swing hydraulic cylinder
malfunction
Repair or replace faulty cylin-
der.
Pipe Rack Gate
Does Not
Operate Properly
Gate mechanism out of
adjustment
Adjust mechanism linkage.
Binding gate mechanism. lnspect mechanism for broken
or binding pivot pins, rods,
levers and rod ends. Repair or
replace parts as required.
lnspect for broken or deformed
latch compression spring.
Replace faulty spring.
Pipe Rack Pot
Wrenches Do Not
Hold Pipe
Binding wrenches or
pivot pins
lnspect pot for foreign materi-
als. Remove any debris.
Lubricate wrench pins.
lnspect wrench pins for galling.
Replace damaged pins.
Wrenches our of adjust-
ment
Adjust wrench position in pot.
Weak or broken wrench
spring
Replace faulty springs.
Worn wrenches Replace worn wrenches.
BD120149 Mechanical Systems Manual Water Injection System
Sec15Water.fm -15.1- Section 15, Version 00 - 03/06
Section 15
Water Injection System
The water injection system injects a metered amount of water to the bit air to help control dust from drilling opera-
tions. The water flow is regulated and monitored by a control potentiometer and flow meter in the operators cab.
Figure 15-1: Water Injection System
01
01
02 03
05
07
09
04
06
LEGEND
01. 1000-Gallon Water Tank, Insulated
02. Water Pump
03. Variable Speed Motor
04. Air Piloted Water Dump Valve
05. Relief Valve
06. Heated, Insulated Enclosure
07. Solenoid Operated Pilot Valve
08. Flow Transducer
09. Butterfly Valve
Water Injection System BD120149 Mechanical Systems Manual
Section 15, Version 00 - 03/06 -15.2- Sec15Water.fm
The system consists of a 1000 gallon (3785 liter) water tank, motor-driven pump, flow sensor, check valve, direc-
tional control valve, relief valve, and related lines and fittings. Refer to Figure 15-1.
NOTICE
The water injection system should not normally be operated in sub-freezing ambient conditions.
The pump, the air-piloted dump valve, and the relief valve are mounted in the water tank. Water from the pump is
discharged through the relief valve, which is factory preset at 55 psi (3.8 bar). A multipoint level switch, consisting
of three float switches, is mounted inside the water tank. The normally open switches close when the tank is filled
with water, and send signals to the PLC as follows:
High water level switch HWLS opens to indicate that the tank is less than full.
Quarter water level switch QWLS opens to indicate that the tank is less than full.
Empty water level switch EWLS opens to indicate that the tank is empty.
Figure 15-2: Multipoint Level Switch
The GUI in the operators cab indicates the level of water in the tank as well as the flow rate to the bit. Refer to Fig-
ure 15-3
The pump is operated from the cab by turning the water injection switch ON. Water flow is adjusted with the flow
control knob. Refer to Figure 15-4
For the water injection pump to operate, bit air must be ON, bit air pressure must be at least 15 psi, the tank level
must be above empty, and the drill must be in drill or hoist mode.
Figure 15-3: Water Level Indicators
Figure 15-4: Water Injection Controls
15.2 Water Injection System Maintenance
Figure 15-5: Water Tank
15.2.1 1000 Gallon Water Tank R33238F1
CAUTION
Never weld to the water tank. The tank is lined with epoxy on the inside. Epoxy will burn,
causing corrosion on the inside of the tank.
The water tank is mounted on the left-hand platform. It is a steel tank, lined with epoxy on the inside, and is heated
and insulated. The tank holds the pump and motor assembly as well as associated components.
15.2.1.1 Installation and Removal
The tank is mounted to the left-hand platform by 12 hex head capscrews, nuts and washers. Torque fasteners as
indicated in Appendix A of this manual.
15.2.2 Submersible Water Pump 37U152D3
The submersible water pump has an integral sealed electric motor, check valve and suction screen. The unit is not
field repairable and must be replaced if failure occurs.
The pump rests at the bottom of the tank in a 15 angle support. The angle provides drainage when the tank is
emptied to prevent trapped water from freezing and damaging the water pump. The water pump can produce 5
gpm @ 75 psi.
LEGEND
01. 250 Watt Strip Heater
02. Flat Washer
03. Lock Washer
05. Strip Heater Guard
07. Strip Heater Spacer
08. Slotted Pan Head Machine
Screw
09. Lock Washer
10. Heater Control Thermoswitch
11. Hex Nut
12. 1000 Gallon Tank, Insulated and
Epoxy Coated
13. Self-Adhesive Gasket
14. Junction Box
15. Padlock Handle
16. Adjustable Latch
17. Hex Nut
18. Water Level Indicator Multi-
switch
19. Swivel Fitting
20. Reducer Fitting
21. Air Piloted Solenoid Valve
22. Breather
24. Lock Washer
26. Top Clamp Plate
27. Hose Clamp Body
28. Hose Assembly
29. Plug Fitting
30. Hose Assembly
31. Plug Fitting
33. Top Clamp Plate
34. Hose Clamp Body
35. Fitting
36. Flow Transducer Valve
37. Male Fitting
38. Nipple
39. Female Cross Fitting
40. Hex Nipple Fitting
41. Relief Valve
42. Hose Assembly
43. Elbow Fitting
44. Reducer Fitting
45. Check/Relief Valve
46. Hex Nipple Fitting
47. 2 HP Pump
48. Gasket
49. Submersible Pump Frame
50. Mounting Plate
51. Water Pump Cap
52. Lock Washer
54. Chain
55. Chain Link Connector
56. Hose Assembly
57. Elbow Fitting
58. Air Piloted Valve
59. Fitting
60. Plug Fitting
61. Plug Fitting
62. Plug Fitting
63. Drain Valve Gasket
64. Drain Valve Gasket
65. Drain Valve Assembly
15.2.2.1 Removal
WARNING
!
Hazardous voltage can cause burns, injury, or death. Disconnect, lock open, and tag the
1. Disconnect, lock open, and tag the power source which feeds the system to prevent power from being applied
2. Tag and disconnect the wiring to the pump at the electrical junction box on the tank.
3. Disconnect the water discharge hose from the access cover on the tank.
4. Pull the lock pins that secure the access cover to the tank.
WARNING
!
5. Attach a suitable hoist to the lifting chains attached to the access cover. Lift the cover, pump and related hose,
valve, cradle, frame and fittings from the tank, tanking care not to damage parts in the process.
6. Remove the hose, electrical wiring and fittings from the pump. Use these parts to install the new pump.
7. Remove the pump caps and pump.
15.2.2.2 Repair
Clean and inspect parts as specified in Appendix A. Replace deteriorated hose, gasket and wiring.
1. Install the new pump on the cradle with the pump caps. Be sure that the check valve is pointed straight up
before locking the pump in the cradle.
2. Install the hose, electrical wiring and fittings on the pump. Use pipe thread sealant in threaded fittings.
3. Attach a suitable hoist to the lifting chains attached to the access cover. Lower the cover, pump and related
hose, valve, cradle, frame and fittings into the tank, tanking care not to damage parts in the process.
4. Position the access cover on the tank. Use a new cover gasket if necessary.
5. Install the lock pins to secure the cover.
6. Connect the water discharge hose to the access cover.
7. Connect the wiring to the pump at the electrical junction box on the tank.
8. Operate the system to verify proper operation.
15.2.3 Pressure Relief Valve R12410D1
15.2.3.1 Replacement
CAUTION
!
Pressurized water systems can spray with extreme force, causing severe injury. Shut
down the system and slowly release pressure or vent circuits before loosening any fit-
tings or connections. Wear appropriate face, ear and body protective devices while vent-
Figure 15-7: Pressure Relief Valve
01
02
03
04
05
06
07
BD0550a01
LEGEND
01. Cap
02. Spring
03. Locknut
04. Outlet Port
05. Poppet
06. Valve Body
07. Inlet Port
ing pressurized water systems.Inadvertent operation of the blasthole drill during
maintenance could cause severe bodily injury and/ or death. Lockout and tagout the drill
operating controls to prevent accidental operation.
1. Lockout and tagout the drill operating controls to prevent inadvertent start-up of the drill during maintenance
activities.
2. Disconnect the water discharge hose from the access cover on the tank.
3. Pull the lock pins that secure right side of the access cover to the tank. Swing the cover open.
4. Remove the pressure relief valve and close nipple.
5. Check the pressure setting of the relief valve or its replacement on a test stand. The correct relief pressure set-
ting is 80 psi (5.5 bar). Adjust as necessary. If a test stand is not available, check and adjust as specified in
topic, Relief Valve Adjustment.
6. Install the relief valve and nipple.
7. Close and secure the tank cover. Connect the water discharge hose.
15.2.3.2 Adjustment
The pressure relief valve is set to 55 psi (3.8 bar). The valve can be adjusted on a test stand or using a setup simi-
lar to the one shown in Figure 15-8. To adjust the valve on the drill, proceed as follows:
1. Lock and tag out the drill and relieve pressure. Open the tank cover as described under Subtopic 15.2.3.1.
2. Assemble test components as shown in Figure 15-8.
3. Remove the elbow from the cover and install the test equipment. Place the free end of the hose in the tank,
open the test valve.
Figure 15-8: Relief Valve Adjustment
01
02
03
04
05
06
07 08 07 09 10
07
BD0551a01
LEGEND
02. Water Tank Access Cover
03. Reducer, 1.00" - .50"
04. Pressure Gauge 0 - 150 psi
(0-10 bar)
05. Reducer .50" - .25"
06. " Valve
07. " Nipple
08. " Elbow
09. Hose Clamp
10. Drain Hose
NOTICE
To start the water pump without the main air compressor running, temporarily jumper the main
air pressure switch (MAPS) (item 7, Figure 6-55).
4. Turn ON the water injection system switch to start the water pump. Adjust water flow with the control potenti-
ometer.
5. When water is flowing through the test equipment and back into the tank, partially close the test valve until the
pressure gauge reads 80 psi (5.5 bar).
6. Confirm that the valve starts to vent at 80 psi (5.5 bar). Tighten the locknut after adjustment to retain the set-
ting.
7. Check the pressure setting by opening and partially closing the test valve several times to be sure that the
relief valve continues to vent at the setting.
8. Shut down the water injection system.
9. Remove the test equipment from the tank.
10. Remove the jumper from the MAPS.
15.3 Sensing Components
The sensing components such as the level switches, flow sensor and two-way valve should be inspected in place
before service. If these parts do not function, check the electrical connections and lines to other electrical parts
before replacement. Replace any faulty parts. The location and method of installation are shown on the applicable
exploded view illustrations. After replacement check all joints and connections for security.
The following table provides general troubleshooting information on the water injection system.
Pump does not run. No water in tank Check if tank empty light (red) is
on. Add water to tank as required
Bit air off Turn on bit air
Drill in propel mode Place drill in hoist or drill mode
Insufficient bit air pressure Investigate cause of low bit air
pressure. Correct deficiency
No power to pump Check power and control circuits to
pump. Correct deficiency
Broken drive belt (if applicable Replace belt and adjust
Faulty bit pressure switch Check pressure switch and replace
if faulty
Faulty pump or pump motor Replace pump or motor
Pump runs erratically Faulty relief valve Check relief valve setting and
adjust as required. If valve will not
hold setting, disassemble and clean
valve. Repair or replace valve
Low voltage or control circuit mal-
function
Check power and control circuits to
pump. Correct deficiency.
Faulty pump or pump motor Remove and inspect pump and
motor. Replace faulty pump or
motor.
Tank will not vent Faulty check valve Inspect check valve and replace if
faulty.
Faulty two-way valve Check two-way valve and replace if
faulty.
Water flow is low Leak at hoses or connections Check condition of hoses and tight-
ness of connections. Replace faulty
hoses. Tighten all connections.
Loose pump drive belt (if applica-
ble)
Adjust belt tension
Faulty flow control valve Inspect flow control valve and cir-
cuits. Repair valve
Faulty control potentiometer Inspect control potentiometer and
circuits. Correct deficiency
Obstructed pump inlet Remove and inspect inlet strainer.
Clean strainer as required. Drain
and clean tank interior to remove
debris as required.
Faulty pump or pump motor Remove and inspect pump. Replace
faulty pump or motor
Water flow meter does not register Open circuit between flow sensor
and flow meter
Inspect and check wiring between
sensor and flow meter. Correct
deficiency.
Faulty flow sensor Replace sensor
Faulty flow meter Replace flow meter.
Water being added to bit air with
pump off
Faulty check valve Clean check valve or replace if
damaged
BD120149 Mechanical Systems Manual Lubrication
Sec16Lube.fm -16.1- Section 16, Version 00 - 03/06
Section 16
Lubrication
16.1 General
16.1.1 P&H Lubricant Specifications
NOTICE
Without reference to specific lubricant manufacturers products, this manual makes reference
only to the appropriate P&H Mining Equipment lubricant specifications. P&H Mining Equipment
lubricant specifications are listed in their entirety under Subsection 16.8. Each P&H material
specification pertaining to lubricants provides the equipment owner with the minimum require-
ments for the lubricant. Conformance to these requirements does not constitute the only basis
of acceptance. Lubricants must be judged further on their satisfactory field performance.
In order for equipment to perform properly, the lubricant supplier and the equipment owner must work together to
determine if the type of lubricant being considered will meet P&H Mining Equipment lubricant requirements (that is,
specifications and performance). The lubricant supplier must confirm that the lubricant meets specifications; the
equipment owner must confirm that the lubricant is suitable for and performs in the operating environment.
16.1.2 Operating in Cold Conditions
Automatic lubrication systems can malfunction when the lubricant becomes too cold to flow smoothly or vent prop-
erly. This can cause the system cycle to end before lube points are properly lubricated.
16.1.2.1 Possible Effects Of Excessively Cold Lubricant
Improper venting after the cycle may prevent the injectors from reloading. If pressure is not vented back to
the tank, the injector springs stay compressed and can not reload. The next cycle the injectors will not out-
put any lube if they have not recharged. As a result, the lube points may not receive proper lubrication.
Cold grease can make it difficult to pump the lubricant. A restriction to flow in one area can cause a local
pressure drop to some components. The pressure switch on the lubrication control panel may reach the set
point pressure before it is high enough to cycle all the injectors. The lube pump turns off prematurely before
the lube points get the needed lubricant.
If cold weather problems occur, contact your P&H MinePro Services representative to assist in choosing which of
the following solutions should be selected.
16.1.2.2 Possible Solutions
Use a grease more appropriate for colder temperatures. Refer to the lubrication specifications in this section
of this manual for details.
Lubrication BD120149 Mechanical Systems Manual
Section 16, Version 00 - 03/06 -16.2- Sec16Lube.fm
Slow the lubrication pump to allow more time for the cold grease to move through the lube piping. Refer to
Section 8, Automatic Lubrication System. for more details.
16.1.3 Viscosity
The viscosity is a critical parameter in determining film thickness under operating conditions. Too low viscosity will
allow tooth surfaces to contact each other. Viscosity varies exponentially with operating temperature.
The viscosity grade selection is dependent on the maximum and minimum operating temperatures. If the extreme
or peak operating sump temperatures are not known, measure the sump oil temperature during a period of
extreme or peak ambient temperature, after working the machine continuously for at least shift.
Maximum oil viscosity (and, therefore, its suitability for application in cold weather) is also temperature-dependent
and is primarily determined by the pour point of the oil. Refer to minimum operating sump temperatures in Table
16-1.
NOTICE
The maximum sump temperatures are based on a minimum allowable viscosity of 400 cSt.
Exceeding limits, especially the maximum limits, for even short periods can result in progres-
sive surface deterioration. If maximum and minimum temperature limits cannot be met with any
one product, seasonal oil changes should be considered. In cold environments exceeding lower
limits, drives should be run at no load to warm up the oil prior to operation. Sump temperatures
should be monitored in extreme ambient conditions.
Oil Grade P&H
Specification
Viscosity (cSt) Max Operating
Sump Temp
Min Operating
Sump Temp
40C 100C C F C F
ISO 150 497 152 16 28 82 -24 -11
ISO 220 497 223 20 30 87 -21 -6
ISO 320 497 320 24 37 98 -18 0
ISO 460 497 452 30 42 107 -15 5
ISO 680 497 680 36 48 118 -12 10
ISO 1000 497 1070 55 55 131 -6 21
SYN 220 474 210 25 32 89 -37 -35
SYN 320 474 305 35 39 102 -34 -30
SYN 460 474 440 45 46 115 -29 -20
SYN 680 474 645 60 54 129 -26 -15
SYN 1000 474 947 80 62 143 -31 -24
SYN 1500 474 1387 102 69 156 -26 -15
Table 16-1: Gear Oil Operating Limits
The channel point of an oil is about 8-14F below the pour point. If the ambient temperature drops below the pour
point, the oil will not flow through a pump. This condition is unacceptable, even though some lubrication of gearing
might be possible if the gearing dips into oil in a sump. If the ambient temperature falls below the channel point, no
lubrication is possible as the oil will become semi-solid and will be displaced (channeled) as the gearing dips into
the sump. This condition will result in destruction of the gearing.
If it is desired to use a single grade of oil year round, users must be certain that at no time will either the maximum
or minimum operating sump temperature be exceeded for the grade of oil being used.
The minimum operating sump temperature represents the pour point of the oil, but it is still possible to operate the
machine if the ambient temperature drops below the pour point. Temperature below the pour point is mainly a con-
cern if the machine is not operating. If a machine has been shut down for an extended period of time, and the ambi-
ent temperature drops below the pour point during this time, observe carefully while the motions are run slowly
under no load. Warm up the oil to the point where it will flow before putting the gearing under load. This task is crit-
ical to avoid serious damage to gearing. If the sump temperature is still below the pour point, a lighter grade of oil
should be used.
Oil selection will affect filter performance. When selecting filter elements, the viscosity, grade, and operating tem-
perature must be considered. The viscosity of the oil will change with temperature. Normally, a 10 psi pressure
drop is permitted across filters. To ensure that the filter element type and mesh is appropriate for the oil viscosity at
the highest and lowest temperature, the oil temperature, oil viscosity at that temperature, and the flow through the
filter must be known. Generally, the curves for filter elements are available from filter suppliers.
The selection of gearcase oils must be made on the basis of conformance to P&H Specification 497 or 474, on the
minimum viscosity requirements of 400 cSt at maximum operating temperature, and on the pour point of the oil vs.
the minimum ambient temperature.
16.1.4 ISO Grade
It is recommended that only oils with an ISO grade designation be used. If a type of oil other than an ISO grade is
to be used, consult with the manufacturer. Oils of the same ISO grade will typically have similar viscosity and pour
point parameters. If unsure, compare proposed oils properties with those listed in Table 16-1. If significantly differ-
ent, consult the manufacturer regarding suitability.
NOTICE
If the lubrication service recommendations in this manual conflict with those of the original
equipment manufacturer, the original equipment manufacturers specifications take prece-
dence.
CAUTION
Grease lubricants with different formulation bases are incompatible. Before using a dif-
ferent grease, check to be sure that the base of the new grease is compatible with the
original. If not, all components in contact with the lubricant, including shafts and bear-
ings, must be thoroughly purged of the old grease, removed from the system, and
cleaned with solvent. Component failure will result if thorough cleaning is not done.
16.2 Automatic Lubrication System
The automatic lubrication system supplies grease lubricant, Material Specification P&H 472 to specified lube points
on the upper machinery, the crawlers, and each of the four leveling jacks. The NLGI grade of the grease must be
appropriate for the prevailing ambient temperature range. P&H 472C is the preferred grade for all temperature
ranges; however, at lower ambient temperature ranges, P&H 472A or 472B may be recommended by the lubrica-
tion supplier.
Check the lubricant level at least weekly. Refill the reservoir as necessary.
The auto lube system is controlled by the programmable logic controller (PLC). Refer to Section 8, Automatic
Lubrication System. for a complete description.
16.3 Oil Bath Lubrication
All gear drives, including the pump drive transmission, and some of the other rotating equipment on the blasthole
drill, are lubricated through self-contained oil bath reservoirs. Most of the equipment units that have self-contained
lubricant reservoirs lubricate their internal components by immersion in the oil bath, or by splashing lubricant from
the surface of the oil bath. The equipment within this category includes the following:
16.3.1 Pulldown Gearcase
The pulldown gearcase uses oil, Material Specification P&H 497. Viscosity is indicated by a letter, and should be
selected according to expected extreme ambient temperatures. Refer to Table 16-2
Check oil level at the sight glass every week and add oil as required. Change oil as specified in Table 16-9 or as
indicated by oil analysis.
Figure 16-1: Lubrication, Pulldown Gearcase
<-20F
(<-29C)
-20 to +20F
(-29 to -7C)
+20 to 110F
(-7 to 43C)
> 110F
(>43C)
Capacity
497C 497D 497F 497H 70 Gallons
(265 liters)
Table 16-2: Lubrication, Pulldown Gearcase
01
02
LEGEND
01. Oil Level
Sight Gauges
with Breather
16.3.2 Hydraulic Pump Drive Transmission
The hydraulic pump drive transmission uses gear oil, Material Specification P&H 497. Viscosity is indicated by a
letter, and should be selected according to expected extreme ambient temperatures. Refer to Table 16-3
Check oil level on the dipstick every month and add oil as required. Change oil as specified in Table 16-9 or as indi-
cated by oil analysis.
Figure 16-2: Lubrication, Hydraulic Pump Drive Transmission
< 85F
(<29C)
>85F
(>29C)
Capacity
497F 497H 2 Gallons
(7.6 liters)
Table 16-3: Lubrication, Hydraulic Pump Drive Transmission
02
03
BD0362b01
01
LEGEND
01. Magnetic Drain Plug
02. Vent Plug
03. Dipstick
16.3.3 Auxiliary Winch Gear Reducer
The auxiliary winch gear reducer uses gear oil, Material Specification P&H 497. Viscosity is indicated by a letter,
and should be selected according to expected extreme ambient temperatures. Refer to Figure 16-3.
Check oil level in the auxiliary winch gear reducer every month and add oil as required. Change oil as specified in
Table 16-9 or as indicated by oil analysis.
Lubricate the auxiliary winch wire rope as required using Open Gear and Wire Rope Lubricant, Material Specifica-
tion P&H 464.
Figure 16-3: Lubrication, Auxiliary Winch Gear Reducer
<-20F
(<-29C)
-20 to +20F
(-29 to -7C)
+20 to 110F
(-7 to 43C)
> 110F
(>43C)
Capacity
497C 497D 497F 497H 1.3 Gallons
(4.9 liters)
Table 16-4: Lubrication, Auxiliary Winch Gear Reducer
BD0554a01
01
02
03
LEGEND
01. Relief Breather
02. Fill Plug
03. Drain Plug
16.3.4 Cable Reel Gear Reducers
The cable reel gear reducers use gear oil, Material Specification P&H 497. Viscosity is indicated by a letter, and
should be selected according the expected extreme ambient temperatures. Refer to Table 16-5.
Check oil level at the level plugs every week and add oil as required. Change oil as specified in Table 16-9 or as
On either side of the frame, lubricate drum bearing grease fittings every week or after 40 hours of operation using
extreme pressure grease, Material Specification P&H 472. P&H 472C is the preferred grade for all temperature
Figure 16-4: Lubrication, Cable Reel Gear Reducer
<-20F
(<-29C)
-20 to +20F
(-29 to -7C)
+20 to 110F
(-7 to 43C)
> 110F
(>43C)
Capacity
497C 497D 497F 497H Right Angle Gear Drive
1.3 quarts (1.2 liter)
Planetary Drive
5 quarts (4.7 liter)
Table 16-5: Lubrication, Cable Reel Gear Reducer
03
02
01
BD0555a01
LEGEND
01. Right Angle Gearcase
02. Drum Bearing Grease Fitting
(both sides)
03. Planetary Gear Reducer
ranges; however, at lower ambient temperature ranges, P&H 472A or 472B may be recommended by the lubrica-
tion supplier.
16.3.5 Propel Transmissions
The propel transmissions use gear oil, Material Specification P&H 497. Viscosity is indicated by a letter, and should
be selected according to the expected extreme ambient temperatures. Refer to Table 16-6
Check oil level at the level plugs every week and add oil as required.Change oil as specified in Table 16-9 or as
Figure 16-5: Lubrication, Propel Transmission
<-20F
(<-29C)
-20 to +20F
(-29 to -7C)
+20 to 110F
(-7 to 43C)
> 110F
(>43C)
Capacity
497C 497D 497F 497H 9.5 Gallons
(36 liters)
Table 16-6: Lubrication, Cable Reel Gear Reducer
BD195a01
01
02
03
LEGEND
01. Drain Plug
02. Fill/Level Plug
03. Housing
16.4 Oil Pressure Lubrication
The rotary gearcase and the air compressor have enclosed, dedicated oil lubrication systems.
16.4.1 Rotary Gearcase
The rotary gearcase is a sealed unit with a self-contained oil bath sump and gear-driven pump that circulates lubri-
cating oil, under pressure, to the bearings and gears.
The rotary gearcase uses gear oil, Material Specification P&H 497. Viscosity is indicated by a letter, and should be
selected according the expected extreme ambient temperatures. Refer to
Check oil level at the level plugs every week and add oil as required. Change oil as specified in Table 16-9 or as
Figure 16-6: Lubrication, Rotary Gearcase
<-20F
(<-29C)
-20 to +20F
(-29 to -7C)
+20 to 110F
(-7 to 43C)
> 110F
(>43C)
Capacity
497C 497D 497F 497H 40 Gallons
(151 liters)
Table 16-7: Lubrication, Rotary Gearcase
02
01
03
BD0556b01
LEGEND
01. Breather 02.Dipstick 03.Drain Plug
16.4.2 Air Compressor
16.4.2.1 T-Tank
The air compressor uses Dexron ATF in all ambient temperatures. The capacity is 100 US Gallons (378.54 liters).
Check the oil level at the T-Tank sight gauge each shift or after each 8 hours of operation. Change oil as specified
in Table 16-9 or as indicated by oil analysis.
Figure 16-7: Lubrication, Air Compressor T-Tank
02
01
03
BD0557b01
LEGEND
01. Fill Plug 02.Sight Gauge 03.Manual Drain Valve
16.4.2.2 Main Air System Oil Filters
16.4.2.3 Compressor Oil Filters
Oil filters associated with the main air compressor are (refer to Figure 16-9):
The Main Compressor Oil Filter (01), mounted on the compressor, is a replaceable-element filter that filters
the majority of the oil returning to the compressor from the T-Tank.
Figure 16-8: Main Air System Oil Filter Locations
Figure 16-9: Compressor Oil Filter Locations
01
02
03
BD0729a01
04
LEGEND
01. Main Compressor Oil Filter (on compressor)
03. Oil Removal Filters (T-Tank)
04. Scavenger Oil Filter (on air control panel)
01
02
03
BD0729a01
04
LEGEND
01. Main Compressor Oil Filter (on compressor)
02. Compressor Bearing Oil Filter (on compressor)
03. Oil Removal Filters (T-Tank)
04. Scavenger Oil Filter (on air control panel)
The Compressor Bearing Oil Filter (02), mounted on the compressor, is a spin-on filter that filters the oil
used to lubricate the bearing on the air end.
The two Oil Removal Filters (03) are an integral part of the T-Tank. They remove the oil vapor from the out-
going pressurized air for return to the compressor.
The Scavenger Oil Filter (04), mounted on the air control panel, is a spin-on filter that filters the oil returning
through the scavenger lines from the Oil Removal Filters (03).
Check the condition of the Main Compressor Oil Filter and the two Oil Removal Filters every week or after 40 hours
of operation. Refer to and check the filters as follows:
Figure 16-10: Checking Filter Pressure Differentials
CIPS MAPS
SUB PILOT
VALVE OPENS
AT 58 PSI
TANK FILTER
COMP. FILTER
COPS
BAPT
02
MAPT
BD0509d01
01
LEGEND
01. Oil Separator Filter Pressure Differential Switch and Gauge
02. Main Compressor Oil Filter Pressure Differential Switch and Gauge
Check the Oil Separator Filters by observing the gauge on valve (01) while turning the handle first to one position
and then the other. Follow the same procedure for the Main Compressor Oil Filter by using valve (02). In both
instances, if the difference in pressure is greater than 8 psi, change the filter. Procedure to change the main oil filter
follows this subtopic; for the procedure to change the separator filters, refer to Subsection 6.3.4.1.
WARNING
!
lubrication tasks.
Lock out and tag out the operator controls to prevent inadvertent drill operation.
CAUTION
!
Change the Compressor Bearing Oil Filter and the Scavenger Oil Filter every month or after 160 hours of opera-
tion. Remove the filter by rotating the filter body anticlockwise. To install an new filter, coat the gasket with ATF and
rotate the new filter body clockwise to thread it onto the stem.
The main compressor oil filter has an indicator to help determine when the filter needs to be changed. Change the
element in the main compressor filter after 160 hours of operation or when the filter indicator indicates in the
CHANGE FILTER area (refer to
Refer to Figure 16-12 and change the element as follows:
Figure 16-11: Main Compressor Oil Filter Indicator

C
H
A
N
G
E

F
I
L
T
E
R

C
H
A
N
G
E

F
I
L
T
E
R
BD0558a01
Normal Operation Change Filter condition
WARNING
!
lubrication tasks.
1. Lock out and tag out the operator controls to prevent inadvertent drill operation.
2. Change the filter element if any of the following conditions exists:
the filter indicator is in the red CHANGE FILTER position;
the GUI has issued a fain compressor oil filter fault;
it has been more than six months since the last filter element change; or
the differential switch and gauge on the air control panel registers a difference of 8 psi or greater.
Figure 16-12: Changing Main Compressor Oil Filter
01
02
03
04 05
06
07
08
09
10
11
12
BD0559a01
13
LEGEND
01. Spring
02. Filter Element
03. Seal
04. Baffle
05. Head O-ring
06. Indicator O-ring
07. Snap Ring
08. Tee Handle O-ring
09. Tee Handle
10. Head Assembly
11. Indicator Assembly
12. Housing
13. Flow Switch
CAUTION
!
A. Vent any residual air from the T-Tank.
B. Remove the filter head (10) by rotating handle (09) anticlockwise until the head is free of the housing (12).
C. Hold the baffle (04) down and push down on the indicator assembly (11) to be sure it moves freely up and
down within the baffle.
D. Remove the baffle (04) and check the bore for nicks. Smooth the bore if necessary and replace seal (03) if it
is damaged.
E. Remove the element (02) from the housing (12). Remove the indicator assembly (11) from the element
using a screwdriver between the indicator assembly and the element cap and carefully prying downward.
Inspect the O-ring (06) and replace it if necessary.
F. Remove the O-ring (05) from the head (10) and replace it if necessary. Clean the O-ring area of the head,
lubricate a new O-ring with oil and reinstall the O-ring in the head.
G. Install indicator assembly (11) into the new element(02). Place the element into housing (12) being sure the
large diameter of spring (01) contacts the new element. Install the baffle (04).
H. Place the head (10) on the housing (12) and turn the handle (09) clockwise until it is hand tight. Do not
exceed 20 ft-lb (26 Nm).
I. If leakage appears around the handle (09), remove the snap ring (07) and remove the handle from the head.
Discard the O-ring (08) and reassemble the unit with a new O-ring.
16.5 Hydraulic Tank
The hydraulic tank uses Dexron ATF. Check the sight gauge at the beginning of each shift or after 8 hours of
operation. Replenish the oil level using the supplemental oil tank mounted near the air compressor.
Every week of operation, inspect the visual indicators on the suction filters and on the return filters. Also check the
color of the desiccant in the breather cartridge. Change the filters and the breathers when indicated.
Drain, flush and refill the hydraulic system as specified in Table 16-9 or as indicated by oil analysis.
The stated capacity of the hydraulic tank is 125 US Gallons (482 liters); however, the placard next to the sight
gauge is the final determiner of maximum and minimum oil levels, depending on the physical condition of the drill
(mast up or down, jacks extended or retracted). Refer to Figure 16-14.
01
03
04
06
09
08
BD0361a01
02
05
07
10
11
LEGEND
01. Suction Filters
03. Hydraulic Tank
05. Breather
06. Return Filters
07. Oil Level Gauge Placard
008.Oil Level Sight Gauge

NOTICE
P&H Mining Equipment recommends that a sample of oil be drawn from the hydraulic tank
annually. This sample should be about two quarts (two liters) and should be taken when the oil
is warmed through normal operation. The sample should be analyzed by a qualified lubrication
specialist to determine whether it is suitable for continued use. The interval between oil
changes may be extended based upon the operating conditions and on the care used in han-
dling oils and in keeping them clean during the handling process.
Figure 16-14: Hydraulic Tank Level Sight Gauge and Temperature Gauge
MAXIMUM MAST DOWN AND JACKS FULLY RETRACTED
MAXIMUM MAST UP AND JACKS FULLY RETRACTED
MAXIMUM MAST DOWN AND JACKS FULLY EXTENDED
MAXIMUM MAST UP AND JACKS FULLY EXTENDED
MINIMUM
3.2 GALLONS / INCH 4.8 LITERS / CENTIMETER
| | | | | | | | | | | | | | | | | | | | | | | | | | | | | |
BD0560a01
16.6 Manual Lubrication Points
WARNING
!
lubrication tasks.
16.6.1 General
16.6.1.1 Lube Points Without Fittings
Miscellaneous pins, levers and linkages that move but are not considered wear surfaces should be lubricated
weekly or as required by administering a few drops of motor oil as indicated on Figure 16-8.
16.6.1.2 Lube Points with Grease Fittings
Lubrication points that are provided with grease fittings use extreme pressure lithium grease, Material Specification
P&H 472. The preferred grade is a synthetic grade NLGI #1. A non-synthetic grade NLGI #2 is a suitable alterna-
tive. A non-synthetic NLGI #1 or #0 may be required for proper dispensing at low temperatures or by centralized
lubrication systems.
< 20F
(< -7C)
+20 to 110F
(-7 to 43C)
>110F
(>43C)
SAE 10W SAE 15W40 SAE 30
Table 16-8: Lubrication, Miscellaneous Pins, Levers and Linkages
16.6.2 Pipe Rack
Lubricate pivot points with motor oil weekly or as required. Refer to Subtopic 16.6.1.1.
Lubricate grease fittings on the pipe racks with EP grease every week of operation. Refer to Subtopic 16.6.1.2.
Figure 16-15: Lubrication, Pipe Racks
01
02
01
01
BD0544b01
LEGEND
01. Grease Fittings
(7 fittings per pipe rack)
02. Pivot Points
(4 lube points per pipe rack)
16.6.3 Mast Back Braces
Every month of operation, lubricate slide areas with EP Grease (refer to Subtopic 16.6.1.2) and lubricate pins on
the mast back brace with motor oil (refer to Subtopic 16.6.1.1).
Figure 16-16: Lubrication, Mast Back Braces
01
01
01
01
02
02
BD0562a01
LEGEND
01. Pin (4 pins)
02. Slide Area (6 slide areas)
16.6.4 Rotary Carriage Roller Assemblies
Lubricate the fittings on the rotary carriage roller carrier eccentric bushings with IP grease every month of opera-
tion. Refer to Subtopic 16.6.1.2.
Figure 16-17: Lubrication, Backup Roller Assemblies
BD0552b01
01
01
LEGEND
01. Grease Fittings
(4 fittings total)
16.7 Lubrication Schedule
16.7.1 Reference Numbers
Figure 16-18 and Figure 16-19 provide reference numbers for the Lubrication Schedule in Figure 16-9.
Figure 16-18: Manual Lubricant Point Reference Diagram #1
01
01
07
08
09 10
11
12
BD00356b01
02
03
04
05
06
Figure 16-19: Manual Lubrication Point Reference Diagram #2
BD0378e01
101
102
103
104
105
106
107
108
109
110
111
114
115
117
118
116
113
16.7.2 Lubrication Schedule
Time Interval Ref Num-
ber from
Diagram
Component Description Required
Service
References
Weekly or As
Required
Miscellaneous Pins, Levers and Linkages
without grease fittings
Lubricate Table 16-8
Figure 16-15
Figure 16-16
Figure 16-16
114 Auxiliary Winch Wire Rope Lubricate Figure 16-3
Daily or
Every 8-12 Hours
104 Hydraulic Oil Reservoir Check Level Figure 16-13
101 Air Compressor Oil Reservoir
(T-Tank)
Check Level Figure 16-7
Weekly or
Every 75-100
Hours
02 Pipe Racks Lubricate Figure 16-15
05 Pulldown Gearcase Check Level Figure 16-2
03 Rotary Gearcase Check Level Figure 16-6
11 Propel Transmission Check Level Figure 16-5
108 Hydraulic Suction Filters Check
Indicators
Figure 16-13
106 Hydraulic Return Line Filters Check
Indicators
113 Air Compressor Oil Filter Check
Indicator
Figure 16-8
103 Air Compressor Oil Separator Check Gauge Figure 16-10
107 Auto-Lube Grease Reservoir Check
Dipstick
Subtopic
16.8.3
Monthly or
Every 250-300
Hours
08 Cable Reel Right Angle Gear Reducer Check Level Figure 16-4
10 Cable Reel Drum Bearings Lubricate
07 Rotary Carriage Roller Assemblies Lubricate Figure 16-16
115 Auxiliary Winch Gear Case Check Level Figure 16-3
109 Pump Drive Transmission Check
Dipstick
Figure 16-2
Table 16-9: Lubrication Schedule
16.8 Lubricant Specifications
16.8.1 Material Specification P&H 464
Open Gear Lubricant
Ver 09, 04-93
CAUTION
Using incorrect lubricants can cause substantial equipment damage. The material speci-
fications listed in this manual are current at the time of publication, and are intended to
be used for reference only. Contact your local P&H MinePro Services representative for
the current specifications.
1.0 SCOPE
1.1 This specification covers open gear lubricants with highly fortified blends of viscous oils combined with addi-
tives to form a stable, long lasting, high load carrying and wear resistant films that lubricate under boundary condi-
tions.
1.2 Materials furnished under this specification are intended to lubricate open gears, racks, bushings, rails, rollers,
dipper handles and walk mechanisms. These applications are subject to extreme contact pressures, reversing
loads and peripheral speeds of up to 1,200 feet per minute/366 meters per minute, while operating under varied
weather conditions.
Semi-Annually or
Every 1800-2000
Hours
04 Rotary Gearcase Change Oil Figure 16-6
12 Propel Transmission Change Oil Figure 16-5
112 Main Compressor Bearing Oil Filter Replace Figure 16-8
102 Main Compressor Oil Change Oil Figure 16-7
110 Pump Drive Transmission Change Oil Figure 16-2
111 Charge Filters Replace Subsection
4.3.6
Annually or
Every 3600-4000
Hours
09 Cable Reel Right Angle Drive Reducer Change Oil Figure 16-4
116 Auxiliary Winch Gear Case Change Oil Figure 16-3
06 Pulldown Gearcase Change Oil Figure 16-2
105 Hydraulic Tank Change Oil Figure 16-13
Figure 16-14
Time Interval Ref Num-
ber from
Diagram
Component Description Required
Service
References
Table 16-9: Lubrication Schedule
1.3 Materials furnished under this specifications are intended to be dispensed intermittently by centralized lubrica-
tion systems of the single line parallel, single line progressive series, and/or dual line progressive construction.
1.4 This specification covers all grades of open gear lubricants that are usable from -50F/-46C to 120F/49C. The
particular grade selected must perform in the specific temperature range in which it is utilized.
1.5 Materials furnished under this specification may be semi-fluid asphaltic or non-asphaltic, greases or pastes.
Specific product selection will depend on climate, application, performance and regulatory requirements.
1.6 Materials furnished under this specification are not intended for use in moderate to high speed anti-friction
bearings.
2.0 REFERENCE DOCUMENTS
2.1 ASTM D92/ISO 2592 - Flash Point, COC Method
2.2 ASTM D1404 - Deleterious Particles Test
2.3 ASTM D1743 - Rust Protection
2.4 ASTM D2266 - Four Ball Wear Test
2.5 ASTM D2596 - Four Ball EP Test
2.6 ASTM D4048 - Copper Strip Corrosion Test
2.7 Grease Pumpability, Lincoln Ventability (Ventmeter) test
3.0 PHYSICAL CHARACTERISTICS
3.1 These open gear lubricants must have excellent adhesive and cohesive qualities, must not chip or throw off,
and must provide sufficient film thickness to prevent metal to metal contact between applications under all operat-
ing conditions.
3.2 These open gear lubricants must have excellent water resistant and rust preventive qualities.
3.3 These open gear lubricants must have retarded dripping qualities for operation at various temperatures.
3.4 These open gear lubricants must be specifically formulated to protect surfaces, reduce wear, and provide nor-
mal component service life under all anticipated operating conditions.
3.5 These material shall meet applicable safety, health and environmental regulations.
4.0 PERFORMANCE REQUIREMENTS
PROPERTY REQUIREMENT
Flash point, ASTM D92/ISO 2592, minimum F/C 175/79
Four ball EP test, ASTM D2596, weld point, minimum
kgf,
Asphaltic Compounds
Non-asphaltic Compounds, Greases, Pastes
250
400
Table 16-10: Performance Requirements, Material Specification P&H 464
(1) Consult lubricant system component manufacturer regarding any deviations from this requirement.
5.0 SPECIAL CONSIDERATIONS
5.1 The material furnished under this specification must be dispensable through the distribution lines of a central-
ized lubrication system to the most remote application point, at the lowest anticipated operating temperature. It
must not plate or plug components of the centralized lubrication system such as injectors, metering blocks or spray
nozzles.
5.2 When the material furnished under this specification is formulated with solid film additives, particle size must
not exceed 100 microns.
5.3 Should the material furnished under this specification contain a diluent to improve dispensability, special care
must be exercised to insure its compatibility with all centralized lubrication system components, i.e., gaskets, o-
rings, vent valves, etc.
5.4 Diluent containing lubricants furnished under this specification must conform to the performance requirements
provided in Section 4.0 after the diluent has evaporated.
6.0 IDENTIFICATION AND PACKAGING
6.1 Containers must be clearly identified by the supplier with the following information:
6.1.1 Purchase Order Number
6.1.2 Supplier's Name and Product Trade Name
6.1.3 P&H Material Specification Number followed by a brief description:
6.1.3.1 P&H No. 464 - Asphaltic Type Open Gear Lubricant
or
6.1.3.2 P&H No. 464 - Paste Type Open Gear Lubricant
6.1.4 Material Safety Data Sheet (MSDS) - One (1) with each shipment
Four ball wear test, ASTM D2266, 60 minutes @ 40 kgf,
maximum scar, mm
1.0
Rust protection, ASTM D1743 Rating Pass
Copper strip corrosion, ASTM D4048 Max. rating, 24hrs
@ 100C/212F
1b
Deleterious particles, ASTM D1404, Max. number of
scratches
20
Adhesive properties Must adhere to surfaces at
lowest anticipated tempera-
ture
Pumpability, Lincoln ventability test, nominal maximum
psi @ lowest anticipated ambient temperature
400
(1)
6.2 The lubricant furnished under this specification must be supplied in clean containers of the size(s) as specified
on the purchase order.
7.0 INSPECTION AT PURCHASER'S WORKS
7.1 Acceptance of material furnished under this specification shall be subjected to confirmation by Customer's
Quality Assurance Department.
7.2 The purchaser shall have the option of accepting or rejecting any material failing to meet the requirements of
this specification.
8.0 ADDITIONAL CRITERIA OF ACCEPTANCE
8.1 Conformance to all specified requirements shall not constitute the sole basis of acceptance since all lubricants
must be judged further on their satisfactory field performance Harnischfeger Corporation equipment.
8.2 Relubrication volume and frequency can directly affect the performance of a lubricant and the economies of
operation. Consult the equipment shop manual and lubricant supplier for the relubrication volume, and frequency
for each application.
8.3 The suitability of a lubricant is highly dependent upon environmental conditions. It is the consumer's responsi-
bility to provide lubricant suppliers with the following:
8.3.1 Actual application and copy of this specification.
8.3.2 Environmental data - temperature range and weather conditions.
8.3.3 Type of centralized lubrication system(s).
8.4 It is the responsibility of the consumer to verify that lubricants conform to applicable environmental and safety
codes governing their use and disposal.
Grease - Multi-purpose, Extreme Pressure, Aluminum Complex Soap Base, Liquilon
Solid Lubri-
cant Additive
Ver 01, 01-80
CAUTION
1.0 SCOPE
1.1 Material furnished under this specification is a multi-purpose aluminum complex soap grease lubricant. It is
characterized by its excellent water resistance, thermal and shear stability, and compatibility with all other types of
greases.
1.2 This grease contains a derivative of polytetrafluoroethylene as a solid lubricant additive. This additive has the
registered trade name LIQUILON.
1.3 This grease is intended for lubricating components during assembly. It can be sued in equipment having grease
fittings and in centralized distribution systems. (Note (a) under Paragraph 2).
2.0 PHYSICAL PROPERTIES
2.1 This lubricant must be an Aluminum Complex Soap Base, Multi-Purpose Extreme Pressure Grease containing
LIQUILON. It must be formulated to resist oxidation and corrosion, oil separation, caking, and water washout.
2.2 Material furnished under this specification shall conform to the following physical requirements.
P&H Grade 469 469A
N.L.G.I. Consistency #2EP #1EP
Suggested Operating Temperature Range
o
F (a)
0 to +400 -15 to +400
Penetration at 77
o
F Worked 60 Strokes
265-295 330-340
Dropping Point
o
F Minimum
475 475
Bomb Oxidation Stability Pressure Drop
100 Hours, ASTM D942, Latest Issue
5 psi 5 psi
Oil Separation 50 hours at 210
o
F
5.0% Max. 7.0% Max.
Extreme Pressure Properties
Timken OK Load, Lbs.
Weld Point Kg, Minimum
75
325
75
325
Table 16-11: Physical Requirements, Material Specification P&H 469
(a) Consult manufacturer's manual for correct consistency when used in centralized distribution systems.
2.3 Conformance to the above requirements shall not constitute the sole basis of acceptance since all lubricants
must be judged further on their satisfactory field performance in Harnischfeger equipment.
3.0 PACKAGING
3.1 This grease lubricant is available in 400 lb. drums, 120 lb. kegs, 35 lb. pails, and hand gun cartridges. The con-
tainer shall be specified on the purchase order to the supplier.
4.0 IDENTIFICATION
4.1.3 P&H Material Specification Number as specified by Purchase Order
5.1 Acceptance of material furnished under this specification shall be subject to confirmation by Customer's Materi-
als Engineering Department.
5.2 The Purchaser shall have the option of accepting or rejecting material that fails to meet any of the requirements
of this specification.
5.3 In the event of rejection, the supplier will be notified, and the material will be returned at his expense.
6.0 SUPPLIERS AND TRADE NAMES
6.1 WESO Corporation
P&H 469 - Allex EP-2L
P&H 469A - Allex EP-1L
Mineral Oil Specifications
Viscosity @ 100
o
F
Viscosity @ 210
o
F
800-1200
75-90
800-1200
75-90
Flash Point
o
F Minimum
425 425
Pour Point
o
F Maximum
0 0
Table 16-11: Physical Requirements, Material Specification P&H 469
Multipurpose Grease Extreme Pressure (EP)
Ver 12, 03-01
CAUTION
Using incorrect lubricants can cause substantial equipment damage. The material spec-
ifications listed in this manual are current at the time of publication, and are intended to
1.0 SCOPE
1.1 This specification covers premium multipurpose, extreme pressure greases with essential properties and char-
acteristics that make them suitable for use in diversified applications through a wide range of ambient tempera-
tures. Both mineral and synthetic base oils may be used to formulate greases that comply with this specification.
1.2 Materials furnished under this specification are intended to lubricate bushings, plain and rolling element bear-
ings, and miscellaneous items on Harnischfeger Corporation equipment requiring a grease.
1.3 Materials furnished under this specification may be applied by hand, hand pressure guns, pneumatic or electric
pressure guns, or centralized lubrication systems of the single line parallel, single line progressive series, and/or
dual line progressive construction.
1.4 P&H 472 (no suffix) from Issue No. 9 is the same as P&H 472C in this specification.
1.5 P&H 472D is primarily intended to lubricate bearings in Magnetorque Assemblies, and bearings and gears in
hoists and cranes where long life of lubricant is demanded, and high temperature operation may be expected in
both intermittent and continuous duty. Other product uses include high speed electric motor bearings; ball, roller
and journal bearings - medium to high temperature and high temperature applications; bearings subject to water,
steam, chemicals and contaminants; and bearings subject to heavy thrust or shock loads.
2.1 ASTM D217/ISO 2137 - Determination of Cone Penetration
2.2 ASTM D445/ISO 3104, D 2161 - Kinematic Viscosity
2.3 ASTM D566/ISO 2176 - Determination of Dropping Point
2.4 ASTM D942 - Oxidation Stability, Oxygen Bomb Method
2.5 ASTM D1264 - Water Washout Resistance
2.6 ASTM D1404 - Deleterious Particles Test
2.8 ASTM D1831 - Roll Stability Test
2.9 ASTM D2265 - Determination of dropping point over a wide temperature range
2.10 ASTM D2509 - Timken EP Test
2.13 DIN 51 802/IP220, EMCOR Rust Protection Test
2.14 Grease Pumpability, Lincoln Ventability (Ventmeter) Test
3.1 These lubricating greases shall be manufactured with a lithium 12-hydroxystearate, lithium complex, or other
thickeners provided care is taken by the end user to avoid grease incompatibility in Harnischfeger equipment.
Thickeners such as clay base, polyurea or calcium may result in incompatibilities. Always consult lubricant suppli-
ers before changing types or brands of greases.
3.2 These lubricating greases must contain extreme pressure additives, and be formulated to resist oxidation, cor-
rosion, separation, and water washout.
3.3 These lubricating greases must have chemical and mechanical stability to maintain consistency and perfor-
mance characteristics throughout their intended service life.
3.4 The NLGI grade of the grease must be appropriate for the prevailing ambient temperature range. A lithium
complex synthetic grease which meets the requirements of P&H 472B is the preferred grade for all temperature
ranges. A lithium complex non-synthetic grease which meets the requirements of P&H 472C is a suitable alterna-
tive. At lower ambient temperature ranges, a lithium complex non-synthetic grease which meets the requirements
of P&H 472A or P&H 472B may be recommended by the lubrication supplier.
3.5 These materials shall meet applicable safety, health, and environmental regulations.
P&H Grade 472A 472B 472C 472D
NLGI grade
(1)
0 1 2 2
Worked penetration ASTM D217/ISO
2137 @ 60 strokes, 25C/77F
355-385 310-340 265-295 265-295
Dropping point, ASTM D566/ISO 2176
or ASTM D2265, Min., C/F
Not Applicable 177/350 177/350 260/500
Base fluid viscosity, ASTM D445/ISO
3104; D2161, Min. mm
2
/s @ 40C
68 100 220 220
Oxidation stability, ASTM D942, Max.
pressure drop @ 100 hrs., kPa/psi
35/5 35/5 35/5 35/5
Roll stability, ASTM D1831 Max. points
change
30 30 30 30
Water washout, ASTM D1264, Max. %
loss @ 79C/175F
Not Applicable 10 10 10
Rust Protection, ASTM D1743 Rating
Pass Pass Pass Pass
EMCOR Rust Protection DIN 51 802/IP
220, Min. rating
0,0 0,0 0,0 0,0
Copper strip corrosion, ASTM D4048
Max. rating, 24 hrs @ 100C/212F
2 2 2 2
Timken EP Test, ASTM D2509 Min OK
value, kg/lbs
20/45 20/45 20/45 20/45
Four ball EP, ASTM D2596 - Weld load,
Min. kgf
Load wear index, Min. kgf
315
45
315
45
315
45
315
45
5.1.2 Suppliers Name and Product Trade Name
5.1.3 P&H Material Specification Number followed by a letter which will indicate a particular consistency grade in
accordance with the following:
5.1.3.1 P&H Number 472A - NLGI #0 EP
5.1.3.2 P&H Number 472B - NLGI #1 EP
5.1.3.3 P&H Number 472C - NLGI #2 EP
5.1.3.4 P&H Number 472D - NLGI #2 EP
5.1.4 Material Safety Data Sheets (MSDS) - One (1) with each shipment.
5.2 The lubricant furnished under this specification shall be supplied in clean containers of the size(s) as specified
6.1 Acceptance of material furnished under this specification shall be subjected to confirmation by purchaser's
this specification.
7.1 Conformance to all specified requirements shall not constitute the sole basis of acceptance, since all lubricants
must be judged further on their satisfactory field performance in Harnischfeger Corporation equipment
Deleterious particles, ASTM D1404,
Max. number of scratches
20 20 20 20
Pumpability
(2)
, Lincoln Ventability test,
Nominal max. psi @ lowest anticipated
ambient temperature,
400
(3)
400
(3)
400
(3)
400
(3)
(1) The preferred grade is NLGI #2. However, an NLGI #1 or #0 may be required for proper dis-
pensing at low temperatures, or by centralized lubrication systems. See section 7.3
(2) This is applicable for use only in centralized lubrication systems.
(3) Consult lubrication system component manufacturer regarding any deviations from this require-
ment.
operation. Consult the equipment shop manual and lubricant supplier for the proper relubrication volume and fre-
quency for each application.
7.3.2 Environmental data - ambient temperature range and weather conditions.
7.3.3 Type of centralized lubrication system(s).
NOTICE
The preferred grade is a synthetic grade NLGI #1. A non-synthetic grade NLGI #2 is a suitable
alternative. A non-synthetic NLGI #1 or #0 may be required for proper dispensing at low tem-
peratures or by centralized lubrication systems. See Section 7.3
Synthetic Gear Oil - Extreme Pressure (EP)
Ver 05, 02-95
CAUTION
Using incorrect lubricants can cause substantial equipment damage. The material spec-
ifications listed in this manual are current at the time of publication, and are intended to
1.0 SCOPE
1.1 This specification covers premium gear oils produced from synthetic or semi-synthetic base stocks and com-
pounded with extreme pressure additives for high load carrying ability.
1.1.1 Materials furnished to Issue No. 3 of this specification had a single flash point requirement whereas this issue
now covers a variety of ambient temperatures.
1.2 Materials furnished under this specification are intended to lubricate gears, bushings, plain and rolling element
bearings, sprockets, chain drives, and other components enclosed in oil-tight housings, and operating under high
speed, high torque, high shock load, and/or high speed, low torque conditions. WARNING: Do not use oils contain-
ing EP additives or other friction modifiers in applications containing internal mechanical load brakes, backstops or
clutches. Additionally, certain EP formulations may not be compatible with bronze gears as found in worm gear
cases.
1.3 Materials furnished under this specification may be used in sump (splash), circulating, or total-loss applications.
1.4 Materials furnished under this specification may be used as replacements for P&H specification 496 or 498
gear oils, when extremes in ambient temperatures require seasonal changes to different viscosities. Consult Har-
nischfeger Corporate Engineering or Service prior to making such a substitution.
1.5 Materials furnished under this specification are intended for use in applications where MIL-L-2105 (latest issue)
and/or API Service GL-5 gear oils are a requirement.
1.6 Materials furnished under this specification are not intended for use in applications where bulk oil operating
temperatures routinely range from 77C/170F to 107C/225F.
2.2 ASTM D97/ISO 3016 - Pour Point
2.3 ASTM D130/ISO 2160 - Copper Strip Corrosion Test
2.4 ASTM D445/ISO 3104, D2161 - Kinematic Viscosity
2.5 ASTM D665/ISO 7120 - Rust Test
2.6 ASTM D892 - Foam Stability
2.7 ASTM D2270/ISO 2909 - Viscosity Index
2.8 ASTM D2422/ISO 3448 - ISO Viscosity Classifications
2.9 ASTM D2711 - Demulsibility
2.10 ASTM D2782 - Timken EP Test
2.12 ASTM D2893 - Oxidation Stability
2.13 DIN 51 354 - FZG Test
3.1 These gear oils must be formulated with full synthetic or semi-synthetic base fluids.
CAUTION
Numerous types of synthetic and semi-synthetic fluid formulations may be applicable to
this specification, some of which may be chemically incompatible. Therefore, to avoid
equipment damage, different brands or types of synthetic or semi-synthetic fluids
should not be intermixed such as during system top-off, without consulting the lubricant
supplier(s).
3.2 These lubricants may not contain viscosity or viscosity index enhancers that are subject to breakdown under
extended shearing conditions.
3.3 These lubricants must have chemical and physical stability to maintain viscosity and performance characteris-
tics throughout their intended service life.
3.4 Any EP or other friction modifiers used in the formulation of these lubricants must be fully oil soluble, and/or be
in a stable colloidal suspension.
3.5 These materials shall meet applicable safety, health and environmental regulations.
4.0 P&H IDENTIFICATION NUMBER AND VISCOSITY GRADE
P&H No. 474A, ISO VG 32, AGMA 0 EP
P&H No. 474B, ISO VG 46, AGMA 1 EP
P&H No. 474C, ISO VG 68, AGMA 2 EP
P&H No. 474D, ISO VG 100, AGMA 3 EP
P&H No. 474E, ISO VG 150, AGMA 4 EP
P&H No. 474F, ISO VG 220, AGMA 5 EP
P&H No. 474G, ISO VG 320, AGMA 6 EP
P&H No. 474H, ISO VG 460, AGMA 7 EP
P&H No. 474I, ISO VG 680, AGMA 8 EP
P&H No. 474J, ISO VG 1000, AGMA 8A EP
P&H No. 474K, ISO VG 1500, AGMA 9 EP
Viscosity grade ISO VG 32 - 1500, AGMA 0EP - 9EP. In accor-
dance with ASTM D2422/ISO 3448
Viscosity In accordance with ASTM D445/ISO 3104/
D2161
Viscosity index, ASTM D2270/ ISO
2909, Min.
120
(1)
Cleanliness Must be free of visible contaminants
Additive solubility Must be filterable to 25 microns (Beta 25 = 200
filter rating) without loss of additive(s)
Pour point, ASTM D97/ISO 3016,
Max.
5C/9F below the lowest anticipated ambient
temperature
Flash point, ASTM D92/
ISO 2592, Min.
240C/464F
Rust Test, ASTM D665/ ISO 7120
Procedure A
Procedure B
Pass
Pass
Copper strip corrosion, ASTM
D130/ISO 2160, 3hrs @ 100C/
212F, Max.
1b
Oxidation stability, ASTM D2893,
@ 121C/250F Max. % viscosity
increase
6 (Viscosity grades 32 thru 680)
Foam Suppression,
ASTM D892
Must be within these lim-
its:
Temperature Max. volume of
foam (ml) after:
5 min blow 10 min blow
Seq. I 24C/75F 75 10
Seq. II 93.5C/200F 75 10
Seq. III 24C/75F 75 10
Table 16-14: Additional Performance Requirements, Material Specification P&H 474
(1) Esters having a lower viscosity index and meeting all other requirements of this specification may be used in
specific applications where proper viscosity at operating temperature has been verified.
(2) Polyglycols which will not pass the demulsibility test, but meet all other requirements of this specification, may
be used in specific applications where there is no danger of water contamination.
6.1.3 P&H Material Specification Number followed by a letter which will indicate a particular viscosity grade in
6.1.3.1 P&H No. 474A, ISO VG 32, AGMA 0 EP
6.1.3.2 P&H No. 474B, ISO VG 46, AGMA 1 EP
6.1.3.3 P&H No. 474C, ISO VG 68, AGMA 2 EP
6.1.3.4 P&H No. 474D, ISO VG 100, AGMA 3 EP
6.1.3.5 P&H No. 474E, ISO VG 150, AGMA 4 EP
6.1.3.6 P&H No. 474F, ISO VG 220, AGMA 5 EP
6.1.3.7 P&H No. 474G, ISO VG 320, AGMA 6 EP
Demulsibility,
ASTM D2711
Must be within these lim-
its:
(2)
Max % water in oil after
5 hr test
1.0
Max cuff after centrifug-
ing
2.0 ml
Min total free water col-
lected during entire test
(start with 90 ml water)
60.0 ml
Four ball EP test,
ASTM D2783
Weld load, Min. kgf
Load wear index, Min.
kgf
250
55
Timken EP test, ASTM
D2782
Min. OK value, kg/lbs 27/60
FZG test, DIN 51 354
with A/8.3/90C
parameters, Min. fail
stage > 12
Table 16-14: Additional Performance Requirements, Material Specification P&H 474
6.1.3.8 P&H No. 474H, ISO VG 460, AGMA 7 EP
6.1.3.9 P&H No. 474I, ISO VG 680, AGMA 8 EP
6.1.3.10 P&H No. 474J, ISO VG 1000, AGMA 8A EP
6.1.3.11 P&H No. 474K, ISO VG 1500, AGMA 9 EP
6.1.4 Material Safety Data Sheet (MSDS) - One (1) with each shipment.
7.1 Acceptance of material furnished under this specification shall be subjected to confirmation by customer's
this specification.
must be judged further on their satisfactory field performance in Harnischfeger Corporation equipment.
8.2 Lubricant change frequency, or relubrication volume and frequency, can directly affect the performance of a
lubricant and the economies of operation. Consult the equipment shop manual, and lubricant supplier for the
proper change frequency, or relubrication volume and frequency, for each application.
8.3.3 Type of centralized lubrication system(s), including pump, filtration and reservoir data, when applicable.
Gear Oil - Single Viscosity Grade, Extreme Pressure (EP)
Ver 07, 02-93
CAUTION
1.0 SCOPE
1.1 This specification covers premium single grade gear oils produced from refined mineral oil base stocks, and
compounded with extreme pressure additives for high load carrying ability. Synthetic lubricants are not covered in
this specification.
1.2 Materials furnished under this specification are intended to lubricate gears, bushings, plain and rolling element
bearings, sprockets, chain drives and other components enclosed in oil-tight housings, and operating under high
speed, high torque, high shock load, and/or high speed, low torque conditions.
WARNING
!
Use of oils containing EP additives or other friction modifiers in applications containing
internal mechanical load brakes, backstops or clutches could cause equipment failure,
resulting in death or severe personal injury. Do not use oils containing EP additives or
other friction modifiers in applications containing internal mechanical load brakes, back-
stops or clutches. Additionally, certain EP formulations may not be compatible with
bronze gears as found in worm gear cases.
1.3 Materials furnished under this specification may be used in sump (splash) circulating, or total loss applications.
1.4 When extremes in ambient temperatures may dictate seasonal changes to different viscosity grades, or where
MIL-L-2105 oils are required, P&H specification 496 or 498 gear oils may be suitable substitutions for these single
grade EP gear oils. Consult Harnischfeger Corporation Engineering or Service prior to making such a substitution.
1.5 The designations 497A and 497B are being reserved for lighter viscosities than ISO VG 68 if required in the
future. P&H 497A, B, and C from Issue No. 6 do not match the same designations in this specification.
1.6 Materials furnished under this specification are not intended for use in applications where MIL-L-2105 (latest
issues), and/or API Service GL-5 gear oils are a requirement.
2.1 ASTM D92/ISO 2592, Latest Issue: Flash Point, COC Method
2.2 ASTM D97/ISO 3016, Latest Issue: Pour Point
2.3 ASTM D130/ISO 2160, Latest Issue: Copper Strip Corrosion Test
2.4 ASTM D445/ISO 3104, D2161, Latest Issue: Kinematic Viscosity
2.5 ASTM D892, Latest Issue: Foam Stability
2.6 ASTM D665/ISO 7120, Latest Issue: Rust Test
2.7 ASTM D2270/ISO 2909, Latest Issue: Viscosity Index
2.8 ASTM D2422/ISO 3449, Latest Issue: ISO Viscosity Classifications
2.9 ASTM D2711, Latest Issue: Demulsibility
2.10 ASTM D2782, Latest Issue: Timken EP Test
2.11 ASTM D2783, Latest Issue: Four Ball EP Test
2.12 ASTM D2893, Latest Issue: Oxidation Stability
2.13 DIN 51 354, Latest Issue: FZG Test
3.1 These gear oils must be manufactured from highly refined mineral oil base stocks.
3.2 These lubricants may not contain viscosity or viscosity index enhancers that are subject to breakdown under
extended shearing conditions.
3.3 These lubricants must have chemical and physical stability to maintain viscosity, and performance characteris-
tics throughout their intended service life.
3.4 Any EP or other friction modifiers used in the formulation of these lubricants must be fully oil soluble, and/or be
in a stable colloidal suspension.
3.5 These materials shall meet applicable safety, health and environmental regulations.
4.0 P&H IDENTIFICATION NUMBER AND VISCOSITY GRADE
4.1 P&H No. 497C, ISO VG 68. AGMA 2 EP, SAE 80W
4.2 P&H No. 497D, ISO VG 100. AGMA 3 EP, SAE 80W
4.3 P&H No. 497E, ISO VG 150. AGMA 4 EP, SAE 85W
4.4 P&H No. 497F, ISO VG 220. AGMA 5 EP, SAE 90
4.5 P&H No. 497G, ISO VG 320. AGMA 6 EP, SAE 90
4.6 P&H No. 497H, ISO VG 460. AGMA 7 EP, SAE 140
4.7 P&H No. 497I, ISO VG 680. AGMA 8 EP, SAE 140
4.8 P&H No. 497J, ISO VG 1000. AGMA 8 A EP, SAE 250
4.9 P&H No. 497K, ISO VG 1500. AGMA 9 EP, SAE 250
Viscosity Grade ISO VG 68 - 1500, AGMA 2EP-9EP. In accordance
with ASTM D2422/ISO 3448
Viscosity In accordance with ASTM D445/ISO 3104/D2161
Viscosity index, ASTM D2270/ISO 2909, Min. 90
Cleanliness Must be free of visible contaminants
Additive solubility Must be filterable to 25 microns (Beta 25 = 200 fil-
ter rating) without loss of additive(s)
Pour point, ASTM D97/ISO 3016 Max.
5
o
C/9
o
F below the lowest anticipated ambient tem-
perature
Flash point, ASTM D92/ISO 2592, Min.
204
o
C/400
o
F
Rust test, ASTM D665/ISO 7120,
Procedure A
Procedure B
Pass
Pass
Copper strip corrosion, ASTM D130/ISO 2160 3 hrs @
100
o
C/212
o
F, Max.
1b
Oxidation stability, ASTM D2893, @ 121
o
C/250
o
F Max. %
viscosity increase
Foam Suppres-
sion,
ASTM D892
Must be within these limits:
Temperature Max. volume of foam (ml) after:
5 min blow 10 min blow
Seq. I 24
o
C/75
o
F
Seq. II 93.5
o
C/200
o
F
Seq. III 24
o
C/75
o
F
75
75
75
10
10
10
Demulsibility,
ASTM D2711
Must be within these limits: Viscosity Grades
68-460 680-1500
Max % water in oil after 5 hr test
Max cuff after centrifuging
Min total free water collected during
entire test (start with 90 ml water)
2.0
1.0 ml
80.0 ml
2.0
1.0 ml
50.0 ml
Four ball EP test, ASTM D2783
Weld Load, Min. kgf
Load wear index, Min. kgf
250
55
Timken EP test, ASTM D2782
Min. OK value, kg/lbs
27/60
FZG test, ASTM D5182 with A/8.3/90
o
C parameters, Min.
fail stage
>12
6.1.2 Suppliers Name and Product Trade Name
6.1.3 P&H Material Specification Number followed by a letter which will indicate a particular viscosity grade in
6.1.3.1 P&H No. 497C, ISO VG 68. AGMA 2 EP, SAE 80W
6.1.3.2 P&H No. 497D, ISO VG 100. AGMA 3 EP, SAE 80W
6.1.3.3 P&H No. 497E, ISO VG 150. AGMA 4 EP, SAE 85W
6.1.3.4 P&H No. 497F, ISO VG 220. AGMA 5 EP, SAE 90
6.1.3.5 P&H No. 497G, ISO VG 320. AGMA 6 EP, SAE 90
6.1.3.6 P&H No. 497H, ISO VG 460. AGMA 7 EP, SAE 140
6.1.3.7 P&H No. 497I, ISO VG 680. AGMA 8 EP, SAE 140
6.1.3.8 P&H No. 497J, ISO VG 1000. AGMA 8 A EP, SAE 250
6.1.3.9 P&H No. 497K, ISO VG 1500. AGMA 9 EP, SAE 250
6.1.4 Material Safety Data Sheet (MSDS) - One (1) with each shipment
7.1 Acceptance of material furnished under this specification shall be subjected to confirmation by purchaser's
this specification.
must be judged further on their satisfactory field performance in Harnischfeger Corporation equipment.
8.2 Lubricant change frequency, or relubrication volume and frequency, can directly affect the performance of a
lubricant and the economies of operation. Consult the equipment shop manual, and with the lubricant supplier for
the proper change frequency, or relubrication volume and frequency, for each application.
8.3.3 Type of centralized lubrication system(s), including pump, filtration and reservoir data, when applicable.
Sealing Grease - Petroleum Resistant
Ver 02, 06-70
CAUTION
1.0 SCOPE
1.1 This specification covers a petroleum resistant sealing compound properly formulated to have oil sealant quali-
ties.
2.0 APPLICATION
2.1 This sealing grease is intended for use in certain applications which require the use of a suitable sealant.
2.2 This sealing grease is primarily used as an oil seal on shafts, hubs and other keyway assemblies. The com-
pound need not serve primarily as a lubricant but should not interfere with lubrication.
2.3 This sealing grease may also be used in other applications (as an oil seal) that are satisfied by a compound of
this type.
3.0 PHYSICAL PROPERTIES
3.1 The material furnished under this specification shall conform to the following characteristics, requirements and
conditions:
3.1.1 Insoluble in petroleum oil and petroleum by-products.
3.1.2 Have shelf life in excess of one year.
3.1.3 Must retain insolubility and exhibit no dispersal in mineral oil when in contact with agitated or flowing oil within
a temperature range of -20
o
F to +225
o
F.
3.1.4 Must retain the properties of a high viscosity paste without hardening in application to machinery with rotating
parts and adjacent moving surfaces.
3.2 The above mentioned properties are not a complete description of the product required and stated only as ref-
erence material for descriptive purposes. Conformance to the physical properties shall not constitute the sole basis
of acceptance or application.
4.0 GENERAL INFORMATION
4.1 The accepted symbol used in the petroleum products industry to designate this standard is S.C.
5.0 PACKAGING
5.1 Sealing grease used for this purpose shall be supplied in cartons containing clean, one pound cans; unless oth-
erwise specified on the Purchase Order.
6.0 IDENTIFICATION
6.1.2 Supplier's Name and Trade Name
6.1.3 P&H Material Specification Number
7.0 REJECTION
7.1 The purchaser shall have the option of accepting or rejecting material that fails to meet any of the requirements
of this specification.
8.0 SUPPLIERS AND TRADE NAMES
8.1 General Electric Supply Co.
G.E. Sealing Grease D6AD2
16.8.7.1 Multi-service Mining Lubricant
Ver 00, 03-97
CAUTION
Using incorrect lubricants can cause substantial equipment damage. The material
specifications listed in this manual are current at the time of publication, and are
intended to be used for reference only. Contact your local P&H MinePro Services repre-
sentative for the current specifications.
1.0 SCOPE
1.1 Multi service lubricants specified herein are partially or fully synthetic premium quality semifluid EP greases or
polymer/gel thickened which are specifically formulated to provide the necessary load carrying and wear resisting
characteristics required in a variety of applications found in large surface mining equipment in continuous opera-
tion.
1.2 These lubricants are intended to lubricate open gears, racks, bushings, rails, rollers, handles, walk mecha-
nisms, multi-row slewing bearings, and low to moderate speed plane and rolling element bearings. These applica-
tions are subject to extreme contact pressures reversing loads that may dwell at zero velocity while loaded, gear
peripheral speeds over 2000 feet per minute/610 meters per minute, and bearing speeds approaching 1000 rpm.
1.3 Lubricants furnished under this specification are intended to be dispensed intermittently from centralized lubri-
cation systems of the single line parallel, single line progressive, and/or dual line progressive construction at the
ambient operational temperature at which the equipment operates.
1.4 Lubricants furnished under this specification are not intended to lubricate electric motor bearings, Magna-
torque clutches, and other applications where there may be service requirements of the lubricant that differ from
or are beyond those described in this specification. Depending upon the consistency of semi-fluid products, they
may not be appropriate for use in couplings or with labyrinth seals.
2.2 ASTM D445/ISO 3104/D2161 - Standard Test Method for Kinematic Viscosity
2.4 ASTM D2266 - Four Ball Wear Test
2.5 ASTM D2509 - Timken EP Test, Grease
2.6 ASTM D2596 - Four Ball EP Test, Grease
2.7 ASTM D3279 - n-Heptane Insolubles Test
2.9 US Steel Lubrication Manual - Grease Mobility Test
2.10 US Steel Lubrication Manual - Timken Retention Test
2.11 US Steel Lubrication Manual - Lincoln Ventmeter Test
3.1 Multi service lubricants specified herein must have the necessary adhesive and cohesive properties to resist
chipping, throw off, and run off, and provide the necessary film thickness and lubricating properties to prevent
metal to metal contact between application intervals under all operating conditions.
3.2 These lubricants must be specifically formulated to protect surfaces from wear, have excellent water resisting
and rust preventing properties, and have the necessary properties to provide exceptional service life of the compo-
nents which they lubricate under all operating conditions.
3.3 Multi service lubricants specified herein must be dispensable through the distribution lines of a centralized lubri-
cation system to the most remote application point at the lowest anticipated operating temperature. They must not
plate or plug components of the centralized lubrication system such as injectors, metering blocks, lines, or spray
nozzles.
3.4 When a lubricant furnished under this specification is formulated with a diluent to improve dispensibility, the
lubricant must meet the performance requirements of section 4.0 both before and after the diluent has evaporated.
3.5 Materials specified herein must meet the performance requirements of section 4.0 when tested with samples
taken from production batches of the lubricant.
3.6 Materials specified herein shall meet all applicable safety, health, and environmental regulations.
* Note for diluent containing lubricants: Although the flashpoint requirement applies to the mixture of diluent and
lubricant, it should be noted that the flashpoint of a diluent alone (i.e. the flashpoint of the diluent when it is not
mixed with the lubricant) may be considerably lower than the flashpoint of the mixture of lubricant and diluent.
** Note: While 300 cSt is the minimum viscosity required for most climates, it may be necessary to formulate prod-
ucts with slightly lower base oil viscosity for use in arctic conditions. In such cases, these products should only be
applied within their intended temperature range.
5.1 Containers must be clearly marked by the supplier with the product name and, if appropriate, the grade (i.e.
arctic, heavy, summer, etc.)
5.2 Identification must remain legible upon outdoor storage of the containers.
5.3 If appropriate, a shelf life should be clearly marked on the container.
5.4 Any special considerations regarding the storage of the product such as protection of container openings, elim-
ination of water build up, etc. should be clearly communicated to the end user.
5.5 Material Safety Data Sheets (MSDS) must be supplied to the end user for each product delivered.
Property Test Method Requirement
Flash point ASTM D92/ISO 2592 130C (266F) minimum*
Copper Strip Corrosion ASTM D4048, 24 hrs @ 100C 1b maximum
Rust Protection ASTM D1743 Pass
Four Ball Wear Test ASTM D2266, scar diameter,
60 minutes at 40 kgf
0.7mm maximum
Four Ball EP Test
Load Wear Index
ASTM D2596, weld point 500 kg minimum
70 minimum
Timken EP Test ASTM D2509, no score 50 lb minimum
US Steel Retention Test
(Timken)
US Steel DM51, 4 grams, no refill,
33 lbs for 30 minutes
pass
Base Oil Viscosity ASTM D445/ISO3104/D2161 300 cSt minimum @ 40C**
Solid Lubricant Particle
Size
20 micron maximum
Asphaltene Content ASTM D3279 less than 0.10%
Pumpability US Steel Mobility Test, DM 43, Test run
at 150psi
Lincoln Ventmeter Test, VE-1, Test run
for 30 seconds
0.30 g/m minimum @ low-
est operating temperature
400 psi maximum @ lowest
operating temperature
6.1 Conformance to all specified requirements shall not constitute the sole basis of acceptance since all lubricants
must be judged further on their satisfactory field performance on the type and model equipment which they are
intended to lubricate.
operation. Consult the equipment shop manual and lubricant supplier for the relubrication volume and frequency
for each application.
6.3 The suitability of a lubricant is highly dependent upon environmental conditions. It is the consumers responsi-
bility to provide the lubricant supplier(s) with the appropriate application data, material specification(s), environ-
mental data such as temperature and weather conditions, and type of centralized lubrication system.
BD120149 Mechanical Systems Manual Preventive Maintenance
Sec17PM.fm -17.1- Section 17, Version 00 - 03/06
Section 17
Preventive Maintenance
17.1 General
This section outlines the maintenance procedures that should be performed on the drill at regular intervals to
ensure optimum performance. Each maintenance item is listed in one of the maintenance check sheets provided in
this section. Specific descriptions of each maintenance or lubrication item are provided. Use these descriptions in
conjunction with the maintenance check sheets to ensure that each item is performed at the prescribed time inter-
val.
17.2 Lubrication
Preventive Maintenance means performing inspections and services that are necessary to keep the drill operating
at peak performance. Lubrication is an essential component of Preventive Maintenance. The breakdown of lubrica-
tion services that must be performed are covered in detail in Section 16, Lubrication., and there are lubrication ser-
vice checklists starting at Topic 16.7. Those procedures are incorporated in the recommended Preventive
Maintenance procedures by reference.
17.3 Bolt Lubrication
Unless otherwise specified, all capscrews, bolts, and nuts used to secure or attach major components and assem-
blies should be lubricated with an anti-seize thread lubricant when repairs or replacements are made. Lubricant
should be applied to the threads of fasteners and to the friction-bearing surface of bolt heads, nuts, and washers.
Additionally, the threaded connections of all drill pipe joints, rotary head coupling- to-pipe, and drill bit-to-stabilizer
connections must be lubricated with a silicone thread lubricant.
17.4 Bolts And Bolt Torques
Recommended bolt torques are listed in Tables 17-1, through 17-3. Unless otherwise specified, these torque val-
ues apply to all component mounting bolts that attach structural members of all machinery. At least bi-annually, all
mounting and attachment bolts and capscrews should be checked using a torque wrench to ensure compliance
with Table 17-1. Heavy duty mounting hardware as described in this manual is equivalent to SAE grade 5 hardware
or equal. English to metric conversion factors are presented in Table 17-2.
Preventive Maintenance BD120149 Mechanical Systems Manual
Section 17, Version 00 - 03/06 -17.2- Sec17PM.fm
17.4.1 Bolt Torques -- American Standard Coarse Thread
Screw, Stud,
or Bolt
Diameter
(inches)
Grade 2
(ft.-lbs)
Studs
only
Grade 4
(ft.-lbs)
Grade 5
(ft.-lbs)
Grade 7
(ft.-lbs)
Grade 8
(ft.-lbs)
Coarse Threads
UNC & 8UNC
1/4 6 10 9 11 12
5/16 11 20 17 21 25
3/8 20 36 31 38 44
7/16 32 58 50 61 70
1/2 49 90 75 93 106
9/16 70 130 109 135 154
5/8 97 180 150 185 212
3/4 172 315 266 330 380
7/8 170 505 430 530 610
1 250 760 650 800 910
1-1/8 355 1,075 800 1,130 1,290
1-1/4 500 1,520 1,120 1,590 1,820
1-3/8 660 1,990 1,470 2,090 2,390
1-1/2 870 2,640 1,950 2,770 3,160
1-3/4 1,370 4,160 3,080 4,370 49,90
2 2,060 6,250 4,630 6,570 7,500
2-1/4 3,020 9,140 6,770 9,600 10,970
2-1/2 4,130 12,500 9,250 13,130 15,000
2-3/4 5,590 16,950 12,540 17,800 20,400
3 7,390 22,390 16,570 23,500 26,900
3-1/4 9,520 28,850 21,350 30,290 34,600
3-1/2 12,030 36,450 26,970 38,300 43,800
3-3/4 14,940 45,300 33,500 47,600 54,400
4 18,280 55,400 41,000 58,200 66,500
The above values assume dry As Received threads. The use of thread lubricant (oil, grease, etc.) will lower recommended
torque values by approximately 25%. Type of lubricant used can cause significant variation.
Table 17-1: Recommended Torque Values for American Standard Threads (Coarse Threads)
17.4.2 Bolt Torques -- American Standard Fine Thread
Screw, Stud,
or Bolt
Diameter
(inches)
Grade 2
(ft.-lbs)
Studs
only
Grade 4
(ft.-lbs)
Grade 5
(ft.-lbs)
Grade 7
(ft.-lbs)
Grade 8
(ft.-lbs)
Coarse Threads
UNC & 8UNC
1/4 6 11 9 11 13
5/16 12 22 18 23 26
3/8 22 39 33 41 47
7/16 34 62 52 65 74
1/2 53 95 81 100 114
9/16 75 136 115 142 163
5/8 105 190 162 200 228
3/4 183 332 282 350 400
7/8 180 530 450 560 635
1 260 790 670 830 945
1-1/8 380 1,150 850 1,200 1,380
1-1/4 525 1,600 1,180 1,680 1,910
1-3/8 710 2,150 1,590 2,260 2,580
1-1/2 930 2,820 2,090 2,960 3,380
1-3/4 1,500 4,540 3,360 4,770 5,450
2 2,270 6,860 5,080 7,210 8,240
2-1/4 3,260 9,860 7,300 10,360 11,830
2-1/2 4,500 13,630 10,100 14,310 16,360
2-3/4 6,030 18,260 13,500 19,170 21,910
3 7,860 23,800 17,600 25,010 28,600
3-1/4 10,040 30,400 22,500 32,000 36,500
3-1/2 12,600 38,200 28,200 40,100 45,800
3-3/4 15,500 47,100 34,800 49,400 56,500
4 18,900 57,300 42,400 60,100 68,700
The above values assume dry As Received threads. The use of thread lubricant (oil, grease, etc.) will lower recommended
torque values by approximately 25%. Type of lubricant used can cause significant variation.
Table 17-2: Recommended Torque Values for American Standard Threads (Fine Threads)
Bolt Torques -- Metric Thread
Screw, Stud
or Bolt
Diameter (inches)
Nominal Size (mm)-
Thread Pitch (mm)
kg-m (ft.-lbs) kg-m (ft.-lbs) kg-m (ft.-lbs)
M6-1 0.4-0.5 (2.89-3.61) 0.88-1.08 (6.37-7.81) 1.59-1.95 (11.5-14.1)
M8-1.25 0.98-1.2 (7.09-8.68) 2.2-2.6 (15.9-18.8) 3.9-4.7 (28.2-34.0)
M8-1 1.04-1.26 (7.52-9.11) 2.3-2.7 (16.6-19.5) 4.1-4.9 (29.7-35.4)
M10-1.5 2.0-2.4 (14.5-17.4) 4.2-5.2 (30.4-37.6) 7.6-9.4 (55.0-68.0)
M10-1.25 2.1-2.5 (15.2-18.1) 4.4-5.4 (31.8-39.1) 8.1-9.8 (58.6-70.9)
M12-1.75 3.3-4.1 (23.9-29.7) 7.3-8.9 (52.8-64.4) 13.1-16.1 (94.8-116)
M12-1.25 3.6-4.4 (26.0-31.8) 7.8-9.6 (56.4-69.4) 14.1-17.3 (102-125)
M14-2 5.3-6.5 (38.3-47.0) 11.5-14.1 (83.2-102) 21-25 (152-181)
M16-2 8.1-10 (58.6-72.3) 17.5-21.5 (127-155) 31-39 (224-282)
M16-1.5 8.5-10.3 (61.5-74.5) 18-22 (130-159) 33-41 (239-296)
M18-2.5 11.2-13.6 (81.0-98.4) 24-30 (174-217) 44-54 (318-390)
M18-1.5 12.6-15.4 (91.1-111.4) 27-33 (195-239) 50-60 (362-434)
M18-2.5 11.2-13.6 (81.0-98.4) 24-30 (174-217) 44-54 (318-390)
M20-2.5 15.8-19.2 (114-149) 34-42 (246-304) 61-75 (441-542)
M20-1.5 17.1-20.9 (124-151) 37-45 (288-325) 67-81 (485-585)
M22-2.5 21-25 (152-181) 46-56 (333-405) 83-101 (600-730)
M22-1.5 24-30 (174-217) 52-63 (376-456) 95-115 (687-832)
M24-3 27-33 (195-238) 58-72 (420-521) 106-130 (767-940)
M24-2 29-35 (210-253) 63-77 (456-557) 114-138 (825-998)
M27-3 40-48 (289-347) 86-106 (622-766) 156-190 (1,128-1,374)
M30.3.5 54-66 (390-477) 118-144 (853-1041) 211-259 (1,526-1,873)
M30-2 59-71 (427-513) 128-156 (926-1,128) 229-281 (1,656-2,032)
M33-3.5 73-89 (528-644) 158-194 (1,143-1,403) 285-349 (2,061-2,524)
M36-4 95-115 (687-831) 204-250 (1,476-1,808) 368-450 (2,662-3,255)
M36-3 98-120 (709-868) 215-261 (1,555-1,888) 385-471 (2,785-3,406)
Table 17-3: Recommended Torque Values for Metric Threads
4T 4T 7T 7T 10T 10T
17.4.3 Metric Conversion Charts
Figure 17-1: Metric Conversion Chart
Multiply by to get equivalent
number of:
Multiply by to get equivalent
number of:
Inch 25.4 milimetres (mm)
Foot 0.3048 metres (m)
Yard 0.9144 metres
Mile (Statute) 1.609 kilometres (km)
LENGTH
Inch 645.2 milimetres (mm)
6.45 centimetres (cm)
Foot 0.0929 metres (m)
Yard 0.8361 metres
AREA
in-lbs 0.11298 newton-metres (N.m)
ft-lbs 1.3558 newton-metres
ft-lbs 0.1383 kg-m
TORQUE
Horsepower 0.746 kilowatts (kW)
POWER
Inches of
mercury 3.377 kilopascals (kPa)
water 0.2491 kilopascals
Pounds/sq.
in. (psi) 6.895 kilopascals
in. (psi) 0.069 bars
PRESSURE OR STRESS
Inch 16 387 mm
16.387 cm
0.0164 litres (l)
Quart 0.9464 litres
Gallon 3.7854 litres
Yard 0.7646 metres (m)
VOLUME
Pound 0.4536 kilograms (kg)
Ton (Short) 907.18 kilograms
Ton (Short) 0.907 tonne (t)
MASS
BTU 1 055. joules (J)
Foot-pound 1.3558 joules
Kilowatt-
hour 3.6 x 10 or joules (J = one W.s)
3600000
ENERGY OR WORK
Miles/hour 1.6093 kilometres/hr (km/h)
VELOCITY
Kilogram 9.807 newtons (N)
Ounce 0.278 newtons
Pound 4.448 newtons
FORCE
200 160
140
120 80
59
50 40
32
10
15 0
0
F
-40
-40
C
-20
F
212
100
C
20 40 80
60
CONVERSION CHART
TEMPERATURE
F = 9
5
(C + 32)
C = 5
9
(F - 32)
6
17.4.4 Temperature Conversion Chart
Figure 17-2: Temperature Conversion Chart
Celsius ( C)
C = F - 32 x 5/9
Fahrenheit ( F)
F = C X 9/5+ 32
-273.15 -459.67
-200 -328
-180 -292
-160 -256
-140 -220
-120 -184
-100 -148
-80 -112
-60 -76
-40 -40
-20 -4
-17.77 0
0 32
5 41
10 50
15 59
20 68
25 77
30 86
35 95
40 104
45 113
50 122
55 131
60 140
65 149
70 158
75 167
80 176
85 185
90 194
95 203
100 212
105 221
110 230
115 239
120 248
140 284
160 320
180 356
200 392
250 482
300 572
350 662
400 752
17.4.5 Special Bolt Tightening Requirements
Any special bolt tightening requirements that differ from standard torque values are identified within the appropriate
assembly and installation instructions of this manual.
17.5 Maintenance Schedule Check Sheets
The actual operating environment of the drill governs the maintenance schedule. The check sheets on the follow-
ing pages indicate the areas of the drill to be checked and the suggested intervals at which they should be
checked. The order in which the items are listed is suggested only and does not constitute the order of perfor-
mance. Maintenance items may be performed in any order desired within a given time interval.
The following suggested schedule check sheets are based on average operating conditions. The type of work
being done, the type and hardness of the materials being drilled, and the ground and weather conditions are all
factors that must be considered when establishing a maintenance schedule for this drill. The suggested schedule is
given for hours of operation and calendar intervals.
Any changes in the established schedule check sheets should be preceded by a complete re-evaluation of drill
operation. Carefully study previous maintenance check sheets and records before making changes in, or extend-
ing, the maintenance check intervals.
17.6 Using The Maintenance Schedule Check Sheets
The maintenance schedule check sheets are designed as a preventive maintenance guide until adequate experi-
ence is obtained to establish a schedule to meet a specific operating environment and machine. Detailed proce-
dures for each check sheet operation are provided following the check sheets. The check sheets can be
reproduced on any copy machine.
Maintenance personnel should indicate on the sheet that the required check has been completed, and that the drill
will be ready for continued operation until the next scheduled check is due. Completed check sheets should be
retained as a permanent part of the drill maintenance records for future reference.
.The following topics describe the maintenance procedures to be performed on this blasthole drill. Each topic cov-
ers a specific time period. Detailed maintenance instructions are provided for the individual lubrication and service
points listed on the corresponding maintenance check sheets. The maintenance person may use the following pro-
cedures in conjunction with the maintenance check sheets to ensure that all service and lubrication points are cor-
rectly serviced at the appropriate time interval. The lubrication charts and figures shown in the Lubrication Section
provide general locations of the individual service points and list the type of lubricant which should be used for each
component. Refer to these charts for the location of lubrication points on this drill. The location of service points
other than lubrication points are described in the following paragraphs as applicable.
P&H Model 120A Rotary Blasthole Drill
A Maintenance Checks (Daily / 8-12 hours)
Maintenance Person:
Date Performed:
Machine Serial Number:
Machine Hours:
WARNING
!
Unexpected machine movement can cause severe personal injury or death. Shut down
the machine before performing inspections, service or maintenance. Establish a proce-
dure to guard against inadvertent equipment operation or movement while conducting
inspections.
Use lockout and tagout procedures prior to conducting maintenance or service.
ITEMS TO BE VERIFIED REF COMMENTS

Note and record any faults on the GUI Fault Log Subsec-
tion
17.7.1
Fill water tank Subsec-
tion
17.7.2
Inspect machine for damage and leaks Subsec-
tion
17.7.3
Check hydraulic oil reservoir level Subsec-
tion
17.7.4
Check main air compressor oil reservoir level Subsec-
tion
17.7.5
Inspect operators cab air filter Subsec-
tion
17.7.6
Inspect drill pipe sling Subsec-
tion
17.7.7
Inspect auxiliary winch and rope Subsec-
tion
17.7.8
Table 17-4: A Maintenance Checks
Check rotary gearcase oil level Subsec-
tion
17.7.10
Check pulldown gearcase oil level Subsec-
tion
17.7.11
Check oil pressure to auto lube pump Subsec-
tion
17.7.12
Check deck wrenches Subsec-
tion
17.7.13
Inspect pipe racks Subsec-
tion
17.7.14
Inspect crawlers Subsec-
tion
17.7.15
Inspect jack shoes and retaining pins Subsec-
tion
17.7.16
A Maintenance Checks (Daily / 8-12 hours)
Maintenance Person:
Date Performed:
Machine Hours:
WARNING
!
inspections.

Table 17-4: A Maintenance Checks
B Maintenance Checks (Weekly / 40-100 hours)
Maintenance Person:
Date Performed:
Machine Hours:
WARNING
!
inspections.

Perform A Maintenance Checks
Inspect hydraulic system components Subsec-
tion
17.8.1
Check Cable Reel Oil Level Subsec-
tion
17.8.2
Inspect Breakout Wrench Subsec-
tion
17.8.3
Inspect Mast Racks and Pinions Subsec-
tion
17.8.4
Inspect Rotary Machinery Subsec-
tion
17.8.5
Inspect Bailing Air System Components Subsec-
tion
17.8.6
Inspect Crawler Belt Tension Subsec-
tion
17.8.7
Check Hydraulic Charge Filters Subsec-
tion
17.8.8
Table 17-5: B Maintenance Checks
Check Hydraulic Return Line Filters Subsec-
tion
17.8.9
Check Main Compressor Oil Filter Subsec-
tion
17.8.10
Check Main Compressor Oil Separator Filters Subsec-
tion
17.8.11
Check Main Compressor Air Intake Filters Subsec-
tion
17.8.12
Check Autolube Grease Reservoir Level Subsec-
tion
17.8.13
Inspect Trail Cable Subsec-
tion
17.8.14
B Maintenance Checks (Weekly / 40-100 hours)
Maintenance Person:
Date Performed:
Machine Hours:
WARNING
!
inspections.

Table 17-5: B Maintenance Checks
C Maintenance Checks (Monthly / 160-250 hours)
Maintenance Person:
Date Performed:
Machine Hours:
WARNING
!
inspections.

Repeat a and b maintenance checks
Inspect mast back braces and slides Subsec-
tion
17.9.1
Inspect mast Subsec-
tion
17.9.2
Inspect auxiliary winch sheave Subsec-
tion
17.9.3
Clean main compressor and hydraulic oil cooler Subsec-
tion
17.9.4
Inspect main frame Subsec-
tion
17.9.5
Inspect crawler frames Subsec-
tion
17.9.6
Check auxiliary winch oil level Subsec-
tion
17.9.7
Inspect cable reel components Subsec-
tion
17.9.8
Table 17-6: C Maintenance Checks
Clean/flush water tank Subsec-
tion
17.9.9
Check pump drive transmission oil level Subsec-
tion
17.9.10
Change main compressor bearing oil filter Subsec-
tion
17.9.11
Check propel transmission oil level Subsec-
tion
17.9.12
Clean/inspect machinery house blowers and filters Subsec-
tion
17.9.13
Inspect rotary carriage rollers Subsec-
tion
17.9.14
C Maintenance Checks (Monthly / 160-250 hours)
Maintenance Person:
Date Performed:
Machine Hours:
WARNING
!
inspections.

Table 17-6: C Maintenance Checks
17.7 A Maintenance Checks
The A Maintenance Checks should be performed daily, or at the beginning of each work shift. Park the drill on
level ground or use the jacks to level the drill prior to the inspection. If an item is found to be incorrect, the problem
must be corrected prior to start-up to ensure satisfactory operation of the drill.
17.7.1 Note and Record Any Faults on GUI Fault Log
The Graphical User Interface (GUI) provides a fault log that indicates conditions that need attention. To access the
GUI fault log, proceed as follows:
Touch the MAINTENANCE block on the GUI Main Page (Figure 17-3)
Figure 17-3: GUI Main Page, Maintenance
Touch the applicable block on the First Sub-Page, Maintenance (Figure 17-4).
If, for example, the Fault List block is touched, a fault list is displayed. The fault list is similar in appearance to the
one shown in Figure 17-5.
Figure 17-4: First Sub-Page, Maintenance
Figure 17-5: Typical Fault List
BD158a01
000524.alg
WinView Alarm Log File (c) 1995 Rockwell Software Inc.
IN ALARM - B4/2 02:44:25PM 00/05/24 HYDRAULIC FLUID LEVEL LOW FAULT
IN ALARM - B4/6 02:44:25PM 00/05/24 PROGRAMMABLE LIMIT SWITCH FAULT
IN ALARM - B4/13 02:44:25PM 00/05/24 MAIN TRNSFMR OVERTEMP WARNING
IN ALARM - B4/14 02:44:25PM 00/05/24 MAIN TRNSFMR OVERTEMP FAULT
IN ALARM - B4/34 02:44:25PM 00/05/24 RELAY SUPPLY LOSS OC
IN ALARM - B4/39 02:44:25PM 00/05/24 24VDC SUPPLY LOSS FAULT
IN ALARM - B4/64 02:44:25PM 00/05/24 HOIST DRIVE FAULT
IN ALARM - B4/65 02:44:25PM 00/05/24 ROTARY DRIVE FAULT
IN ALARM - B4/66 02:44:25PM 00/05/24 HOIST DRIVE DID NOT RESET
IN ALARM - B4/67 02:44:25PM 00/05/24 ROTARY DRIVE DID NOT RESET
IN ALARM - B4/97 02:44:25PM 00/05/24 PLS CABLE DISCONNECT FAULT #1
IN ALARM - B4/115 02:44:25PM 00/05/24 24 VAC SUPPLY FAULT
IN ALARM - B4/2 03:50:49PM 00/05/24 HYDRAULIC FLUID LEVEL LOW FAULT
IN ALARM - B4/2 03:50:49PM 00/05/24 PROGRAMMABLE LIMIT SWITCH FAULT
IN ALARM - B4/13 03:50:49PM 00/05/24 MAIN TRNSFMR OVERTEMP WARNING
IN ALARM - B4/14 03:50:49PM 00/05/24 MAIN TRNSFMR OVERTEMP FAULT
IN ALARM - B4/34 03:50:49PM 00/05/24 RELAY SUPPLY LOSS OC
IN ALARM - B4/39 03:50:49PM 00/05/24 24VDC SUPPLY LOSS FAULT
IN ALARM - B4/64 03:50:49PM 00/05/24 HOIST DRIVE FAULT
IN ALARM - B4/65 03:50:49PM 00/05/24 ROTARY DRIVE FAULT
IN ALARM - B4/66 03:50:49PM 00/05/24 HOIST DRIVE DID NOT RESET
IN ALARM - B4/67 03:50:49PM 00/05/24 ROTARY DRIVE DID NOT RESET
IN ALARM - B4/97 03:50:49PM 00/05/24 PLS CABLE DISCONNECT FAULT #1
IN ALARM - B4/115 03:50:49PM 00/05/24 24 VAC SUPPLY FAULT
17.7.2 Fill Water Tank
The optional water tank is located on a platform at the left, rear outer side of the drill. At the start of each work shift
or after each 8 hours of operation, fill the tank with water. The tank should be filled to approximately 1 inch (25 cm)
from the bottom lip of the access cover.
17.7.3 Inspect Machine For Damage And Leaks
Make a complete and thorough visual inspection of the mast, jacks, lower frame, and underside of the drill, looking
for leaks, loose connections, or any other unsatisfactory conditions. Ensure that problems found during inspection
are corrected prior to continued drill operation. If repairs are necessary, refer to the applicable section of this man-
ual, for detailed instructions. Additional specific inspection procedures are outlined elsewhere in this manual for
various time intervals. This topic is intended to locate potentially hazardous conditions before they result in equip-
ment damage or personal injury.
17.7.3.1 lnspect Air Lines For Leaks
Visually inspect each air system hose and pipe for leaks, abrasion, damage, kinks, or other signs of wear or decay.
Report any problems. Damaged hoses and piping must be replaced prior to continued operation of the drill.
17.7.3.2 lnspect Hoses And Hydraulic Lines
Visually inspect each hydraulic and lubrication hose, and tubing for abrasion, damage, kinks, or other signs of wear
or decay. Report any problems which are found. Damaged hoses and piping must be replaced prior to continued
operation of the drill.
17.7.3.3 lnspect Hydraulic Fittings For Leaks
Refer to Appendix B and inspect all hydraulic and lubrication connections as described, and if necessary use the
appropriate tightening sequence to secure the connection.
17.7.3.4 lnspect Dust Curtain
Weekly, or every 40 hours of operation, inspect the condition of the dust curtain. Visually inspect the curtain for
damage caused by flying rocks and debris. Operate the dust curtain through a full cycle to ensure that it operates
correctly. Repair or replace damaged dust curtains prior to continued drill operation.
17.7.4 Check Hydraulic Tank Oil Level
The hydraulic tank is located in the lubrication room on the right front corner of the machine. With the drill on level
ground, check the oil level by reading the oil level sight glass, located on the side of the tank. The legend along
side of the sight glass indicates the correct minimum and maximum permissible oil levels for the following positions
of the mast and drill leveling jacks:
MAX. MAST DOWN AND JACKS RETRACTED
MAX. MAST UP AND JACKS RETRACTED
MAX. MAST DOWN AND JACKS EXTENDED
MAX. MAST UP AND JACKS EXTENDED
MIN. MAST DOWN AND JACKS RETRACTED
MIN. MAST UP AND JACKS RETRACTED
MIN. MAST DOWN AND JACKS EXTENDED
MIN. MAST UP AND JACKS EXTENDED
CAUTION
Adding unfiltered oil can introduce contaminants that can damage the hydraulic system
and its components. Always filter oil that is added to the hydraulic tank.
Fill the hydraulic oil tank as needed, using either the Wiggins Quick Fill system or by adding filtered oil directly to
the hydraulic tank. Refer to Topic 16.5.
NOTICE
P&H Mining Equipment recommends that a sample of oil be drawn from the hydraulic tank at
least annually. The sample should be about two quarts and should be taken when the oil is
warmed through normal operation. The sample should be analyzed by a qualified lubrication
specialist to determine whether it is suitable for continued use. The interval between oil
changes depends upon operating conditions, on the care used in the handling of oils, and
cleanliness during the handling process.
Figure 17-6: Hydraulic Tank Sight Glass
MAXIMUM MAST DOWN AND JACKS FULLY RETRACTED
MAXIMUM MAST UP AND JACKS FULLY RETRACTED
MAXIMUM MAST DOWN AND JACKS FULLY EXTENDED
MAXIMUM MAST UP AND JACKS FULLY EXTENDED
MINIMUM
3.2 GALLONS / INCH 4.8 LITERS / CENTIMETER
| | | | | | | | | | | | | | | | | | | | | | | | | | | | | |
BD0560a01
17.7.5 Check Main Air Compressor Oil Reservoir Level
The main air compressor oil reservoir (T-Tank) contains the lubricant for the compressor components, including the
screws, bearings, and gears. The reservoir is located on a platform on the left side of the drill, outside the machin-
ery house. Check the oil level in the main air compressor oil reservoir as follows:
1. With the drill parked on level ground, check the reservoir oil level at the sight glass on the reservoir T-tank.
CAUTION
Operating the air compressor with insufficient oil can cause severe damage to the com-
pressor lobes. Never operate the main air compressor when the oil level is below the
LOW mark. Add oil of the type specified in the Lubrication Section any time the oil level
falls below the LOW mark.
2. Wait for the main air system pressure to completely vent through the muffler.
Figure 17-7: T-Tank Sight Glass
CAUTION
!
Pressurized oil will spray with extreme force from the reservoir when opening the filler
plug and can cause severe injury. Shut down the air compressor and allow air pressure
vent before opening the filler plug. Wear appropriate face, ear, and body protective
devices while venting the main air system and/or opening the filler plug.
3. Add oil to the main compressor oil tank by opening the filler plug, located on top of the tank. Add oil to the full
mark on the sight gauge. Use the type specified in the Lubrication Section.
4. Install the filler plug. Use pipe thread sealant and tighten securely to prevent leakage.
17.7.6 lnspect Operator Cab Air Filter
The operator cab is pressurized with filtered air for operator comfort. To ensure that air entering the operator cab is
satisfactorily filtered, the filter assembly must be visually inspected on a daily basis.
Visually inspect the operator cab air filters in the machinery house for dirt and contamination. If the filters are
fitted with a restriction indicator, visually check the indicator. When the indicator or visual inspection reveals
the need to change the filters, install a new filters.
Visually inspect the air recirculation filter behind the panel in the ceiling of the operators cab. Replace the fil-
ter when it has accumulated a thin layer of dust.
17.7.7 lnspect Drill Pipe Sling
The pipe sling is located approximately half-way up the mast. It is a rigid structural framework and cable that
serves to catch a loose pipe section and keep it from falling free of the mast should it separate from the rotary head
coupling. Visually inspect the pipe sling components for damage, cracks, or missing hardware. All mounting hard-
ware should be properly torqued. Replace any damaged or missing sections and/or hardware.
17.7.8 lnspect Auxiliary Winch Rope
The auxiliary winch used to raise and lower tools on the mast assembly utilizes a steel wire rope. Care of this wire
rope is critical to the safe operation of the winch. Visually inspect the wire rope using the following procedure:
17.7.8.1 Daily Inspection
Visually inspect the winch rope at the start of each shift. This inspection is general, for the purpose of discovering
gross damage, such as:
Distortion
Corrosion
Broken or cut strands.
Excessive broken wires.
Presence of these conditions will prompt further inspection or rope replacement.
17.7.8.2 250-Hour Inspection
A periodic detailed rope inspection will show damage over the entire rope. All individual outer wires in the strands
of the rope are inspected, and any deterioration resulting in significant loss of original strength will be a factor in
determining whether further use of the rope would constitute a hazard.
A full written report of rope condition should be made by the inspector. This report must be dated, signed, and kept
on file where it is readily available to designated personnel.
The monthly inspection should be aimed at determining the degree of deterioration at the worst lay, since this will
determine the suitability for continued service. By definition, a rope lay is the axial distance along the rope in which
one strand makes one complete turn around the rope. These visual observations should be concerned with discov-
ering damage, such as listed below:
1. Reduction of rope diameter below normal due to loss of core support, internal or external corrosion or wear of
outside wires.
2. A number of broken outside wires and the degree of distribution or concentration of such broken wires.
3. Worn outside wires.
4. Corroded or broken wires at the end connections
5. Corroded, cracked, bent, worn, or improperly applied end connections.
6. Distortion of the rope, such as kinking, crushing, unstranding, birdcaging, main strand displacement, or core
protrusion.
7. Evidence of improper lubrication. When such damage is discovered, the rope should be removed from service
and replaced.
17.7.9 lnspect Winch
The winch is mounted inside the machinery house at the base of the mast, and is used for hoisting of drill pipe, drill
bits, and other accessory tools and equipment. At the beginning of every shift, inspect the winch for loose mounting
hardware, frame cracks, loose or leaking hydraulic hoses and fittings, and incorrectly spooled cable. Also confirm
that the cable clamps attaching the hook to the cable are securely tightened.
17.7.10 Check Rotary Gearcase Oil Level
The rotary gearcase is mounted to the lower end of the rotary carriage. This double-reduction gear reducer drives
the rotary head coupling, the drill bit, and the pipe string. Use the following procedure to check the rotary gearcase
oil level at the start of each shift, or each 8 hours of operation (see Figure 17-3):
1. With the mast in the vertical position, lower the rotary carriage to the bottom of the mast and shut down opera-
tion of the drill.
WARNING
!
operator controls to prevent inadvertent machine start-up during maintenance.
2. Lock out and tag the operator controls to prevent inadvertent start-up of the machinery. Follow the lockout and
tagout procedures outlined at the front of this manual.
3. Ensure that the machine is level, or as near level as possible. Check the oil level by inspecting the dipstick,
located on the top surface of the rotary gearcase.
CAUTION
Operating the rotary machinery when the rotary gear case has been overfilled with oil
will cause overheating and will damage gearcase components. Never operate the rotary
gearcase when the oil level is below the LOW level or above the FULL level.
4. .The oil level must be maintained between the upper and lower windows in the sight glass. Add oil of the type
specified in the Section 16, Lubrication. through the vent pipe on top of the gearcase housing.
5. Recheck the oil level after adding oil. If oil appears in the upper sight glass, drain enough oil from the gearcase
to maintain the oil level between the upper and lower sight glasses.
6. Securely reinstall the vent cap.
Figure 17-8: Rotary Carriage
BD0870b01
01
02
LEGEND
01. Inspection Cover with Breather: Fill gear
case through this port.
02. Oil Level Sight Gauge: Oil should appear
to fill the lower glass; the upper glass
should appear empty.
17.7.11 Check Pulldown Gearcase Oil Level
The pulldown gearcase is mounted at the upper level of the rotary carriage assembly. The torque output from this
gear reducer drives the rotary carriage assembly up and down the mast. Use the following procedure to check the
pulldown gearcase oil level at the start of each shift, or after each 8 hours of operation (see Figure 17-3):
1. Lower the rotary carriage to the bottom of the mast, and shut down operation of the drill.
WARNING
!
3. Ensure that the drill is level, or as nearly level as possible. View the oil level on the sight gauge located on the
right rear side of the pulldown gearcase.
CAUTION
Operating the pulldown gearcase after it has been overfilled with oil will cause overheat-
ing and will damage gearcase components. Never operate the pulldown gearcase when
the oil level is either below the LOW level or above the FULL level on the sight gauge.
4. The oil level must be maintained between the LOW and FULL level markings on the sight gauge. As neces-
sary, add oil of the type specified in Section 16, Lubrication. through the breather on top of the pulldown gear-
case housing. Use care to avoid over-filling of the gearcase.
5. Apply pipe thread sealant to the male threads of the breather pipe, and install the breather pipe securely.
17.7.12 Check Grease Pump Hydraulic Supply Pressure
6. The hydraulic oil supply to operate the autolube grease pump comes from the low-pressure hydraulic system.
Pressure is limited by a pressure reducing valve (the bottom valve in the first stack on the low pressure hydrau-
lic valve bank). Check the pressure to confirm that the pressure is set at 220 psig (15.2 bar). The oil supply
pressure gauge is located near the grease pump on top of the grease supply reservoir.
17.7.13 lnspect Deck Wrenches
1. Inspect the pawls, bodies, and housings for cracks, wear, corrosion, and distortion.
2. Check for broken or weak springs.
3. Check for worn, broken, or missing hardware items.
4. Check the hydraulic and lubrication hoses and fittings for wear and leaks.
5. Check for free rotation around the hinge pins.
6. Refer to the Pipe Handling Section for repair procedures.
17.7.14 Inspect Pipe Racks
To ensure safe and satisfactory pipe rack operation, and correct positioning of the drill pipes, inspect the condition
of each pipe rack weekly.
1. Before shutting down the drill, move the pipe racks in and out to confirm correct operation.
2. Lower the mast and shut down operation of the drill.
17.7.15 Inspect Crawler
1. Check for cracked or broken shoes
2. Check for excessively worn upper or lower rollers
3. Check both axles for wear, cracks, and loose or damaged mounting hardware
4. Check for smooth mesh between shoe and tumbler lugs
17.7.16 lnspect Jack Shoes And Retaining Pins
The leveling capability and stability of the drill depends on the integrity of the jack shoe assemblies. Inspect these
assemblies weekly for cracked gussets, loose or broken retainer pin, and missing retainer pin capscrew and lock-
washer.
17.8 B Maintenance Checks
The B Maintenance Checks should be performed every week, or after 100 hours of operation, whichever occurs
first. If an item is checked and found to be incorrect, the problem must be corrected prior to machine start-up to
ensure satisfactory operation of the drill. Refer to the maintenance check sheets and complete all A Maintenance
Checks before proceeding with the B Maintenance Checks.
17.8.1 lnspect Hydraulic System Components
Visually inspect each hydraulic component for damage and leaks. Operate each control valve and solenoid and
check for correct component operation. Repair or replace any damaged or malfunctioning hydraulic component.
Inspect, but do not limit the inspection to the following components:
All hydraulic control valves and connections.
All hydraulic hoses and fittings.
Drive-to-pump couplings.
Hydraulic pumps.
Suction filter/return filters.
Cylinders, pins, and bushings.
Hydraulic motors.
17.8.2 Check Cable Reel Drive Reducer Oil Levels
The trail cable reel (optional equipment) is mounted across the front of the drill and stores the trail cable. The cable
reel is driven through the use of gear reducers, driven by a hydraulic motor, and provides the rotary motion to rotate
the cable drum and the level-wind assembly.
WARNING
!
Working on or near the cable reel while the drill is operating is hazardous and can result
in injury or death. Shut down operation of the drill, and lock out and tag the operator
controls prior to working on or near the cable reel. Follow the lockout and tagout proce-
dures outlined in this manual.
1. Lock out and tag the operator controls to prevent inadvertent movement during maintenance activities.
2. Remove the oil level plug, and check the oil level. The oil should reach up to the lower edge of the level plug
opening. The oil level plug on the planetary gear reducer is located on the hydraulic motor end of the gear
reducer. There are plugs located at the three o'clock and nine o'clock positions. The breather/filler cap is
mounted on the same end of the reducer at the twelve o'clock position.
CAUTION
Operating the cable reel when the gear reducer has been overfilled with oil will cause
overheating of the gear reducer components resulting in component damage. Never
operate the cable reel when the oil level is below or above the lower edge of the level
plug opening.
3. If the oil is below the lower edge of the level plug opening, add oil, of the type specified in the Lubrication Sec-
tion, through the reducer breather opening.
WARNING
!
Inadvertent operation of the drill while working on or near the mast structure can result
in injury or death. Lower the rotary carriage to the bottom of the mast, shut down drill
operation, lock out and tag the operator controls prior to working on or near the mast
structure. Follow the lockout and tagout procedures outlined at the front of this manual.
5. Inspect for the following:
Breakout dogs on each pipe location, for wear.
Figure 17-9: Right Angle Gear Reducer
LEGEND
01. Right Angle Gear Reducer
Hydraulic cylinders for oil leaks, wear, or damage.
Pipe rack structure for damage.
Pipe rack for correct operation.
Linkages for looseness, wear, or damage.
Repair or replace worn or damaged pipe rack components. Refer to the applicable topic in this manual for repair
instructions regarding the pipe rack.
17.8.3 lnspect Breakout Wrench
1. Inspect for cracked, broken, or distorted arm or hinge pins.
2. Inspect for missing die teeth, die retainers, shims, and pins.
3. Confirm that the arms move freely on the hinge pins.
17.8.4 lnspect Mast Racks and Pinions
Inspect the condition of the mast racks and pinions once weekly. Proceed as follows:
1. Lower the rotary carriage to the bottom of the mast, lower the mast to the stored position, and shut down oper-
ation of the drill.
WARNING
!
Working on or near the mast structure while the drill is operating is hazardous and can
result in the injury or death of personnel. Lower the rotary carriage to the bottom of the
mast, lower the mast to the stored position, shut down drill operation, lock out and tag
the operator controls prior to working on or near the mast structure. Follow the lockout
and tagout procedures outlined at the front of this manual.
3. Inspect the gear racks and pinions for excessive wear, fractured or missing gear teeth, and other signs of dam-
age which could effect the operation of the rotary carriage or pulldown system. Repair or replace any damaged
rack segments or pinions. Refer to the applicable topic in this manual for repair instructions or procedures.
17.8.5 lnspect Rotary Machinery
Visually inspect the condition of the rotary machinery. Check for cracks, wear, or damage. Repair or replace any
worn or damaged components.
1. Lower the rotary carriage to the bottom of the mast.
WARNING
!
Inadvertent machine operation while working on or near the mast structure can result in
the injury or death. Lower the rotary carriage to the bottom of the mast, shut down drill
operation, lock out and tag the operator controls prior to working on or near the mast
structure. Follow the lockout and tagout procedures outlined at the front of this manual.
2. Lock out and tag the operator controls to prevent inadvertent movement during maintenance activities.
3. Inspect for the following:
Pulldown motor bolts for correct torque.
Pulldown motor coupling for correct torque.
Pulldown gearcase for secure mounting.
Pulldown gearcase for oil leaks.
Resolver for secure mounting.
Hoist brake for assembly for secure mounting.
Main rotary gearcase shaft for end play.
Swivel for leaks.
Rotary motor bolts for correct torque.
Rotary gearcase for oil leaks.
Rotary head side frames for cracks.
Motor blowers for operation and cleanliness.
Drill pipe coupling damper for correct clearances.
Drill pipe coupling for thread wear or damage.
Condition of hoses and cables.
Refer to the applicable sections of this manual for detailed instructions on inspection and adjustment of the rotary
machinery.
17.8.6 Inspect Bailing Air System Components
Visually inspect the condition of the bailing air system components. Check for cracks, wear, or damage. Repair or
replace any damaged components. Inspection should include but not be limited to the following bailing air system
components:
Check the GUI to confirm functioning of the main air pressure transducer (MAPT), the bailing air pressure
transducer (BAPT), the main air temperature transducer (MATT), and the compressor oil temperature trans-
ducer (COTT).
Confirm functioning of the bailing air pressure gauge.
Check all oil hoses and connections for leaks, wear, cracks, or damage.
Check the thermostatic valve for leaks.
Oil cooler for dirt and leaks.
Cooling fan and motor.
T-Tank for air/oil leaks.
Scavenger line oil filter for leaks.
17.8.7 Check Crawler Belt Tension
Refer to Figure 17-10 and check crawler belt tension as follows:
1. Raise the drill until the crawler belt is free of the ground.
2. Measure the distance from the bottom of the side frame nearest the mid-point of the crawler to the top of the
crawler pad where the roller normally contacts the pad.
3. Normally this distance will be from 12 to 14 inches (300 to 360 mm). If the distance exceeds 14 inches, adjust-
ment is required.
Figure 17-10: Check Crawler Belt Tension
17.8.8 Check Hydraulic Charge Filter
Each main hydraulic system is equipped with a pressure filter which is inserted between the output of the control
pressure charging pump and the input to the system control valves. The charge filters are located on a support
bracket above the pump drive transmission. Check the filters as follows:
Figure 17-11: Charge Filter
4. Inspect the filter unit for visible damage, leaking seals, or leaking fittings. If the GUI filter indicator shows that
the element has become fouled (or, alternatively, after 6 months or 1000 hours of operation has passed), the
element should be replaced. Refer to and replace the charge filter elements as follows:
WARNING
!
WARNING
!
6. Turn off the Handwell valve and be sure that no pressure exists in any of the main hydraulic system circuits.
7. Remove the bleed plug located on bottom of the filter.
Figure 17-12: Charge Filter
BD0573a01
01
02
LEGEND
01. Pressure Test Port
02. Bleed Port
NOTICE
Clean dirt from the filter assembly before loosening the bleed plug.
8. Loosen and remove the cap from the filter body.
9. Remove and discard the old filter element.
10. Check the cap seal O-ring and back-up ring for nicks or damage. Replace these components as necessary.
11. Install a new filter element into the body of the filter. Be sure the element is correctly located on the bottom
seat.
12. Apply a coating of hydraulic oil to the O-ring and back-up ring, and install with the filter cap. Torque the cap
securely.
13. Install the bleed plug securely in the bottom of the filter.
14. Open the Handwell valve, start the hydraulic pumps, and check for leaks.
17.8.9 Check Hydraulic Return Line Filters
The hydraulic system is equipped with two return line filters. These filters are located in the top of the hydraulic res-
ervoir (see Figure 17-9):
Figure 17-13: Return Filters
15. Check the filters for visible damage, leaking seals, and leaking connections.
16. If the filter indicators are in the red zone, or after six months or 1000 hours of operation the filter elements must
be replaced. Replace the hydraulic return line filter elements as follows:
17.8.9.1 Disassembly.
Disassemble the return line filters for replacement of filter elements as follows (see Figure 17-1 1):
WARNING
!
tenance work on a machine without first disabling the operator controls. Lockout and
17.8.10 Check Main Compressor Oil Filter Indicator
To ensure unrestricted flow of oil to the main compressor, the oil filter assembly must be serviced at regular inter-
vals.
The main compressor oil filter is flange mounted to the oil return port on the main compressor. The compressor
must be running and the oil at operating temperature for the indicator to read accurately. Check the indicator with a
bright light to be certain of the indicator position. Some lubricants will obscure the indicator.The element must be
replaced when one of the following conditions exists:
Figure 17-14: Main Compressor Oil Filter
BD0559c01

C
H
A
N
G
E
F
I L
T
E
R

C
H
A
N
G
E
F
I L
T
E
R
Normal Operation Change Filter
the top of the indicator on the filter is in the red Change Filter half of the window (refer to Figure 17-14).
the GUI issues a main compressor oil filter fault.
More than 6 months / 2000 hours has elapsed since the filter was last changed.
When the pressure differential on the air control panel (refer to Figure 17-15) exceeds 8 psi.
Replace the main air compressor oil filter as follows:
Figure 17-15: Main Air Control Panel
CIPS MAPS
SUB PILOT
VALVE OPENS
AT 58 PSI
TANK FILTER
COMP. FILTER
COPS
BAPT
BACS
01
02
03
04
05
06 07
08
09
10 11 12
A
B
C
E
D
G
F
H
MAPT
BD0509a01
LEGEND
01. Bit Air Pressure Transducer
02. directional flow control Valve
03. Bit Air Control Solenoid
04. Main Air Pressure Transducer
05. Electrical Panel
07. Main Air Pressure Switch
09. T-Tank Oil Separator Pressure
Differential Manual Switch
10. Scavenger Oil Filter
11. Compressor Oil Filter Differential
Manual Switch
(COPS)
PIPING LEGEND
A. From Bit Air
B. To Air Pilot Valve
C. From Compressor Filter (inlet side)
D. From Compressor Filter (outlet side)
E. From Separator (outlet side)
F. From Separator (inlet side)
G. From T Tank
H. To Compressor
WARNING
!
CAUTION
!
tank before loosening the filter canister. Wear appropriate face, ear, and body protective
2. Vent any residual air pressure from the T-tank. The T-tank will vent through the main air system muffler when
the main air compressor is not running.
3. Remove the head assembly by rotating tee handle counter-clockwise until head assembly is free of housing.
4. Holding baffle down, push down on indicator assembly to ensure that it moves up and down freely within the
baffle. Remove baffle, and check the bore for burrs or deep scratches. Carefully smooth out the bore, if
required. Check seal for cuts or excess wear.
5. Remove element from housing assembly. Remove the indicator assembly from element by inserting a screw-
driver between the indicator assembly and the element cap, and carefully prying downward. Inspect indicator
O-ring for cuts or excessive wear and discard element.
6. Remove O-ring from head assembly, and inspect it for cuts or excessive wear. Wipe the O-ring area of head
with a clean cloth, and, after covering the O-ring with oil, reinstall it in the head assembly.
7. Reinstall indicator assembly into new element. Place the element into canister, being sure the large diameter of
spring contacts the new element. Install baffle.
8. Place head assembly onto housing assembly and rotate tee handle clockwise until it is hand tight; do not
exceed 20 ft-lbs (26 N.m).
9. Start the compressor. If leakage appears at the top of the canister, replace O-ring (02). If this does not stop the
leakage, the canister may be nicked or distorted by over-torquing, and the canister should be repaired or
replaced.
10. If leakage appears around tee handle (08), remove snap ring (lo), and, then, remove the tee handle from head
assembly (01). Remove and discard O-ring (09). Wipe the tee handle and the 0 - ring groove. Oil and install a
new O-ring, then insert the tee handle into the head assembly, and replace the snap ring.
17.8.11 Check Main Compressor Oil Separator Element
11. The main compressor oil separator is equipped with inner and outer filter elements. The separator includes a
system for measuring the pressure differential between the inlet and outlet ports of the oil separator. When the
differential pressure exceeds 8 psi (0.5 bar), the oil separator element needs to be replaced.
Refer to Figure 17-16 and replace the filter elements inside the oil separator as follows:
WARNING
!
work.
Figure 17-16: T-Tank (on Left Hand Platform)
01
02
03
04
07
08
11 10
09
BD0501b01
05
06
05
LEGEND
01. Sight Tube
02. Fill Plug
03. Oil Separators
04. Main Air Pipe
05. Sling Lift Point
06. Union
07. Safety Relief Valve
08. Air Pilot Valve
09. Air/Oil Reservoir
11. Shutoff (Drain) Valve
CAUTION
!
3. Thoroughly clean the air-oil separator flange and fittings to remove any dirt that could fall into the T-Tank when
the separator cover and other fittings are opened.
4. Tag and remove the hose assembly on top of the oil separator cover that connects to the scavenger tubes.
Technician Tip
It is not necessary to remove the fittings or interconnecting tubing from the oil separator cover.
5. Tag and remove the upstream pressure tap hose assembly on top of the oil separator cover.
6. Remove hose from the safety relief valve.
CAUTION
!
heavy objects.
7. Attach suitable hoisting equipment to the main air pipe assembly, and carefully take up the slack.
8. Remove nuts, lockwashers, and capscrews that attach main air pipe flange to the oil separator cover, and lift
the main air pipe assembly from the T-Tank.
9. Remove and discard gasket.
10. Attach a suitable hoist to oil separator cover, remove capscrews and lockwashers from the separator cover,
then lift the separator cover and attached inner separator element from the T-Tank. Lift the cover straight up
when removing it from the T-Tank to avoid damaging the separator element.
11. Remove outer separator element from the T-Tank. Discard the element in a suitable container, and cover the T-
Tank opening to prevent entry of dirt.
12. Remove capscrews, lockwashers, retainer, and inner separator element from oil separator cover. Discard the
element in a suitable container.
13. Clean away any deposits from inside the T-Tank and from the mounting surfaces of oil separator cover.
14. Inspect scavenger tubes for signs of deterioration or plugging. Replace as necessary.
15. Inspect the insert (Item 10, Figure 6-45) to be sure it is positioned correctly. The cut-out at the bottom must
face the front of the drill away from the 6" inlet pipe.
CAUTION
!
Staples on the filter elements are required to eliminate static electricity, which could
cause the oil to flash, resulting in personal injury and/or property damage. Do not
remove staples from the gaskets.
16. Install a new gasket between the inner separator element and the T-Tank tower.
17. Install new inner separator element to oil separator cover assembly with retainer, capscrews, and lockwashers.
Position inner scavenger tube so that it rests on the bottom plate of the inner element.
18. Install a new outer separator element into the top of the T-Tank. Align the holes in the element cover with those
of the T-Tank flange.
CAUTION
!
heavy objects.
19. Attach suitable lifting equipment to separator cover assembly, and position on top of outer element flange on
the T-Tank. Be sure outer scavenger tube is correctly positioned at the bottom of the outer element. Position
the holes in the separator cover to align with the holes in the outer element flange.
20. Install oil separator cover to the T-Tank flange with capscrews and lockwashers. Torque the capscrews evenly
in a crisscross pattern to uniformly compress the outer element flange.
21. Attach suitable lifting equipment to air inlet nozzle, and position the flange above the mating flange on top of
separator cover assembly.
22. Install main air pipe to separator cover assembly with capscrews, lockwashers, nuts, and a new gasket. Do not
tighten the nuts at this time.
23. Align the opposite end of air pipe with manifold and couple with union. Tighten the union securely, then uni-
formly tighten the nuts at the flange end of the air inlet nozzle.
24. Install the hose assembly to the scavenger tube fitting on top of oil separator cover.
25. Install the upstream pressure tap hose assembly on top of oil separator cover.
26. Check the level of compressor oil in the T-Tank, and fill as necessary.
17.8.12 Check Main Compressor Air Intake Filters
The main compressor is equipped with two filter systems, one at each intake. Each filter system has two filters in
series (see Figure 17-14); a primary filter element, and a safety filter element. The air drawn into the main com-
pressor passes through both filters. To ensure that the compressor retains its maximum output capacity, the air
intake filters must be periodically cleaned.
Inspect the filter assembly weekly. Visually inspect the main compressor intake filter(s) for dirt and contamination.
The filters are fitted with restriction indicator fittings. Check the GUI fault log to determine the need for cleaning.
Refer to the Main Air Section of this manual for removal and replacement procedures.
NOTICE
The safety element is not designed to be cleaned. For maximum compressor protection, install
a new safety filter every third primary element cleaning (or replacement). Replace the main air
compressor air intake filter elements as follows:
WARNING
!
2. Loosen the band clamp which secures air cleaner cover, and remove the cover.
Figure 17-17: Main Compressor Air Cleaner Assembly
3. Remove wing nut and washer, and pull primary element from the air cleaner assembly.
4. Remove wing nut, and pull safety element from the air cleaner assembly.
5. If the filter body requires cleaning, loosen the band clamps which secure housing and cup to primary body, and
separate the air cleaner assembly.
6. Clean or replace the primary element, and replace the safety element as required.
7. Refer to Figure 17-17 and assemble the air cleaner with clean or new elements.
17.8.13 Check Auto Lube Grease Reservoir Level
Weekly or every 40 hours of operation, check the level of the grease lubricant in the automatic lubrication system
grease reservoir. Remove the cover of the grease reservoir and visually check the lubricant level. Refill the reser-
voir as necessary to maintain adequate lubrication.
Continued drill use will provide a history of grease consumption, which may dictate varied grease reservoir level
checks. If unsure of the lubricant level, shut down operation of the drill and check the reservoir level.
17.8.14 lnspect Trail Cable
Proceed as follows.
WARNING
!
Hazardous voltage can cause injury or death. Disconnect electric power to the tail cable
at the power substation and use lockout and tagout procedures prior to visual inspec-
tion or handling of the tail cable. Use qualified inspection personnel equipped with
appropriate devices for testing, handling, and personal protection.
Power is fed to the blast hole drill via the trail cable power conductor cable. It is imperative that this cable not
be damaged, or cut. Visually inspect the tail cable to ensure that it is not damaged, crushed, or cut. Replace
the trail cable if it is damaged.
17.9 C Maintenance Checks
The C Maintenance Checks should be performed monthly, or every 160 -250 hours. If an item is found to be
incorrect, the problem must be corrected prior to start-up to ensure satisfactory operation of the drill.
Refer to the maintenance check sheets and complete A and B Maintenance Checks before proceeding with the
C Maintenance Checks.
17.9.1 lnspect Mast Back Braces And Slides
Proceed as follows:
WARNING
!
Cracks in the back brace pivot anchors will result in the pivot anchors separating from
the drill frame, or from the mast chords, resulting in the collapse of the mast. Collapse of
the mast may result in injury or death. Visually inspect the pivot points of the back
braces, and make repairs immediately if cracks are found.
The back braces restrain movement of the mast during drilling operations. These tubular braces absorb a large
amount of the vibration from the drilling operation and as a result are common points for the development of struc-
tural cracks. Visually inspect the pivot points of the back braces for cracks.
SAFETY FIRST
Although cracks are most commonly found at the upper mast anchor point, each pivot should
be carefully checked. If any doubt exists as to the presence of a crack, test the crack using
chemical or magnetic crack detection methods.
If cracks are found, refer to the Mast Section of this manual, and repair the back braces. Inspect the slide surfaces
of the back brace locking sleeves for wear or damage. If the slides are excessively worn or damaged, repair the
slides and/or sleeves as described in Mast Section of this manual.
17.9.2 lnspect Mast
Visually inspect the structural condition of the mast. Check for cracks, wear, or damage. Repair or replace the com-
ponents of the mast, mast bracing, or lacing as revealed through this inspection.
WARNING
!
result in injury or death. Lower the rotary carriage to the bottom of the mast, shut down
drill operation, lock out and tag the operator controls prior to working on or near the
mast structure.
Follow the lockout and tagout procedures outlined at the front of this manual. Inspect for the following:
Mast chords, for cracks or kinks.
Lacings, for cracks or kinks.
Mast hoist cylinder pins and retainers for wear or looseness.
Ladders, platforms, and handrails for looseness.
Hoist cylinder rods, pins, and seals for damage or wear.
Hydraulic connections and cylinders for leakage.
Pivot pins, anchors, and retainers for wear and looseness.
Refer to the Mast Section of this manual for detailed instructions on inspection of the mast.
17.9.3 lnspect Auxiliary Winch Sheaves
Proceed as follows.
WARNING
!
result in injury or death. Lower the rotary carriage to the bottom of the mast, shut down
drill operation, lock out and tag the operator controls prior to working on or near the
mast structure. Follow the lockout and tagout procedures outlined at the front of this
manual.
As wire rope passes over sheaves, the sheaves become worn. Inspect the condition of the winch sheaves monthly
to ensure that the sheaves are not excessively worn. Measure the sheave groove wear pattern using a sheave
gauge. Replace the sheaves as revealed through this inspection. Refer to the Mast Section of this manual for
repair instructions regarding the winch sheaves. The mast must be lowered to facilitate inspection of the sheaves.
17.9.4 Clean Main Compressor and Hydraulic Oil Cooler
To ensure satisfactory cooling of the main compressor oil, the main compressor oil cooler must be periodically
cleaned. At least monthly, or every 160 hours of operation, clean the oil cooler radiators as follows:
1. Shut down operation of the main air compressor and cooler.
WARNING
!
injury or death. Shut down operation of the drill, and use lockout/tagout procedures
prior to working on or near rotating machinery.
2. Lock out and tag the electrical controls to the main air compressor pressor and cooler to prevent inadvertent
start-up during service activities.
3. Remove the machinery house access covers to access to the main compressor oil cooler radiator.
CAUTION
!
Pressurized steam used for cleaning can cause injury. Exercise care and caution when
using pressurized steam to clean machinery components. Wear protective clothing,
gloves, and face shield when operating a pressurized steam cleaner.
4. Use a pressurized steam cleaner to flush dirt and contaminants from the fins of the main compressor oil cooler
radiator. Ensure thorough cleaning of the entire radiator.
5. After the radiator has been thoroughly cleaned, use compressed air to blow the remaining dirt, contaminants,
and water from the oil cooler fins.
6. Clean any dirt, contaminants, and water from the floor of the machinery house.
7. Reinstall any access covers which were removed to permit cleaning of the oil cooler.
17.9.5 Inspect Main Frame
Visually inspect the structural condition of the drill framework. Check for cracks, wear, or damage. Repair or
replace the components of the frame as revealed through this inspection.
Inadvertent machine operation during maintenance activities can cause injury or death. Shut down the drill before
performing inspections, service, or maintenance. Establish a procedure to guard against inadvertent equipment
operation or movement while conducting inspections. Use lockout and tagout procedures prior to conducting main-
tenance or service.
1. Lock out and tag the operator controls to prevent inadvertent movement of the machine during maintenance
activities.
2. Inspect the following:
Entire structural frame.
Jack flanges and flange bolts.
Stairways, ladders, and platforms.
Machinery house framing.
Jack assemblies/jack shoes.
Machinery house panels.
Machinery house doors.
Water tank (optional equipment).
Dust collector chutes (optional equipment).
17.9.6 Inspect Crawler Frames
Visually inspect the structural condition of each crawler side frame. Check for cracks, wear, or damage. Repair or
replace the components of the crawler frames as revealed through this inspection.
WARNING
!
the injury or death of personnel. Shut down operation of the drill, and use lockout/tagout
procedures prior to working on or near rotating machinery.
Inspect the following components:
Entire structural crawler side frame.
Track shoes.
Crawler links.
Idler rollers.
Top guide rollers.
Bottom guide rollers
Main axle mounting bolts.
Equalizer axle mounting pins.
Track pins and retainers.
Take-up adjustment assemblies.
Drive tumblers.
17.9.7 Check Auxiliary Winch Oil Level
Monthly, check the auxiliary winch gearcase oil level as follows:
1. Shut down operation of the drill.
WARNING
!
Working on or near rotating machinery while in operation is hazardous and can result in the
injury or death of personnel. Shut down operation of the drill, and use lockout/tagout procedures
2. Use lockout and tagout procedures to prevent inadvertent start-up during service activities.
3. Remove the oil level plug from the end opposite the hydraulic motor, and check the winch gearcase oil level.
The oil should reach up to the lower edge of the level plug opening.
CAUTION
Operating the winch when the gearcase has been overfilled will cause overheating of the
gearcase components resulting in component damage. Never operate the winch when
the oil level is below or above the lower edge of the level plug opening.
4. The oil level must be even with the lower edge of the level plug opening. If the oil is below the lower edge of the
level plug opening, add oil, of the type specified in the Lubrication Section through the gearcase breather open-
ing.
5. Clean and securely reinstall the breather.
6. Apply pipe thread sealant to the level plug, and install securely.
17.9.8 Inspect Cable Reel Components
Visually inspect the condition of the optional cable reel components. Check for cracks, wear, or damage. Repair or
replace the components of the cable reel as revealed through this inspection.
WARNING
!
the injury or death of personnel. Shut down operation of the drill, and use lockout/tagout
procedures prior to working on or near rotating machinery.
1. Lock out and tag the operator controls to prevent inadvertent movement of the machine during maintenance
activities.
2. Inspect the following:
Hydraulic motor. for leaks
Drive chain for wear and tension.
Chain sprockets for wear.
Right angle gear reducer for leaks.
Cable reel structure, for cracks
Refer to the applicable section of this manual specific to this drill for detailed instructions on correct inspection of
and/or adjustment of the cable reel machinery.
17.9.9 Clean/Flush Water Tank
Flush and clean the optional water tank periodically to remove dirt, sediment, and contaminants accumulated over
time. Monthly, drain, clean, and flush the water tank. Refill the tank with fresh water.
17.9.10 Check Pump Drive Transmission Oil Level
The pump drive transmission mounted on the front end of the main power unit, drives the two main hydraulic
pumps and one auxiliary hydraulic pump. Monthly, check the oil level in the pump drive transmission using the fol-
lowing procedure:
1. 1. Shut down operation of the main power unit.
WARNING
!
2. 2. Shut down, lock out, and tag the electrical controls to the drill to prevent inadvertent start-up during service
activities.
3. 3. Check the pump drive transmission oil level using the dip stick.
4. 4. If the oil level is low, add oil to bring the level even with the full mark on the dip stick. (See the Lubrication
Section, for lubricant specifications). Add oil through the oil filler plug located on top of the reducer housing.
CAUTION
Operating the pump drive transmission when it has been overfilled will cause overheat-
ing of the pump drive transmission components resulting in component damage. Never
operate the pump drive transmission when the oil level is either too full or too low.
17.9.11 Change Main Compressor Bearing Oil Filter
A spin-on type oil filter (located on the motor-end face of the compressor) is used to filter the bearing oil as it
passes through the main air compressor. This filter removes dirt and abrasives from the circulated oil before it
reaches the bearings.
The filter is disposable, and is equipped with a relief valve that opens in the event the element becomes dirty
enough to block the flow of oil. Replace this filter each time the main oil filter element is replaced. Use only the
replacement filter shown in the parts list; others may not have sufficient burst pressure strength.
Replace the main compressor bearing oil filter as follows:
WARNING
!
Working on the main air system while the compressor is in operation is hazardous and
can result in injury or death. Shut down the main air compressor, and use lockout/tagout
procedures prior to starting any service on the machinery.
1. Lock out and tag the high-voltage main circuit breaker switch to prevent operation of the main air compressor
drive motor during system service.
WARNING
!
Pressurized oil will spray with extreme force from the compressor bearing oil filter when
tank before loosening the filter canister. Wear appropriate face, ear, and body protective
devices while removing the filter from the compressor housing.
2. Vent any residual air pressure from the T-tank. The T-tank will vent through the main air system muffler when
the main air compressor is not running.
3. Spin off the old filter and discard. Apply a film of oil to the filter gasket, then spin on the new filter. Tighten the fil-
ter firmly by hand to prevent oil leaks. Be sure the filter sealing surfaces are clean before installing the new fil-
ter.
NOTICE
When changing this filter between oil changes, add one quart of compressor oil to the system to
replace that retained in the old filter (see the Lubrication Section for specifications of the com-
pressor oil to use).
17.9.12 Check Propel Transmission Oil Level
The propel transmissions are mounted at the front of each crawler assembly. Each propel transmission is driven by
a hydraulic motor and together with the transmission. serves as the drive mechanism to propel the drill. Monthly,
check the oil level in the propel transmissions using the following procedure:
1. Rotate the transmission until the level/fill plug and drain plug are positioned as shown in Figure 17-15.
2. Shut down operation of the main power unit.
Figure 17-18: Propel Transmission Plugs
WARNING
!
3. Shut down, lock out, and tag the electrical controls to the drill to prevent inadvertent start-up during service
activities.
4. Remove the propel transmission oil level/fill plug.
5. Check that the oil level is up to the bottom of the oil level plug hole.
6. If the oil level is low, add oil to bring the level even with the bottom of the oil level plug hole (see the Lubrication
Section for lubricant specifications). Add oil through the oil level/fill plug.
7. Apply pipe thread sealant to the oil level/fill plug, and install the plug securely.
CAUTION
Operating the propel transmission when it has been overfilled will cause overheating of
the propel transmission components resulting in component damage. Never operate the
propel transmission when the oil level is either too full or too low.
17.9.13 Clean/inspect Machinery House Blowers And Filters
The following paragraphs describe the inspection and maintenance procedures that should be followed when ser-
vicing the machinery house blowers and impingement filters that provide pressurized air to the machinery house.
An electric-motor-driven blower provides air under slight positive pressure to the machinery house. The fan is
located in the upper section of the mast. Air is drawn from atmosphere and blown through filter assemblies into the
machinery house. Air flows through the house and is exhausted to atmosphere through openings in the house.
This ensures that cooling air within the house is clean and fresh.
The blowers maintain a slight positive pressure within the machinery house, causing air to flow outward through
any house openings, thus helping to keep dirt out.
The blowers and motors are installed in-line within sheet metal housings that attached to impingement type filters.
These filters separate dust and entrained particles from the input air stream and allow the resulting clean air to
enter the machinery house while dropping the separated particulate out of the machine through tubes at the bottom
of the air cleaners, as shown in Figure 17-17.
Inspect the ventilation system as follows:
1. Check for large debris in air inlet passages and remove when found.
2. Check blower motor mounting for security.
3. Check that the blower blades are tight and set at the same angle.
4. Check the filters for accumulated dirt and debris. A light coating of dust on the cells is normal and will not
impair operation or efficiency of the filters. However, the cell blades may accumulate a thicker deposit of sur-
face dirt due to the sticky character of some types of dust, or the presence of oil mist or similar vapor in the out-
side air. When the accumulated deposit reaches a thickness of 118 inch (3.2 mm), the cell blades should be
cleaned. In addition to the 160-hour inspection, a more detailed inspection should be made twice annually.
Check that the blower blades are clean and set at the proper pitch
Use the following procedure to clean the filter elements:
1. Gain access to the filters by removing the sheet metal which encloses them.
2. Refer to Figure 17-22 and loosen the nuts which hold the blade pack clamp bars in place. Then rotate the
clamp bars 90 degrees and remove the bullnose strips.
3. Refer to Figure 17-22 and pull each of the blade packs out of the cell.
4. Thoroughly clean the blade packs in a detergent or other similar non-oily solution.
NOTICE
If the cleaning process removes paint from the blades, they should be repainted prior to installa-
tion.
5. After cleaning and drying the filter blade packs, coat the outside surfaces of the channels to which the blades
are welded and the inside surfaces of the channels into which each blade pack slides with grease. This grease
lubricates the edge of the blade pack for easier installation and serves as a seal to prevent air and dirt bypass.
6. Check bleed ducts for dirt buildup and clean if necessary. The only maintenance possible on the motor/blower
assemblies is blower replacement, motor replacement, or replacement of the blower and motor unit as an
assembly.
NOTICE
When ordering replacement parts for the blower/motor assembly always give all information on
the blower data plate.
Figure 17-19: Filter Packs
Figure 17-20: Blade Pack
17.9.14 Inspect Rotary Carriage Rollers
Check the clearance of the carriage rollers monthly, or more often if there is extended use of the drill on a daily
basis. The carriage rollers are mounted on eccentric shafts to permit adjustment of roller position, and to maintain
proper pulldown pinion engagement due to roller wear. The 16 mounting holes in the shaft flanges permit adjust-
ment in increments equivalent to the 22.5" difference in the location of the mounting holes.
WARNING
!
Inadvertent machine movement or operation can cause injury or death. When necessary
to operate the blasthole drill while making an adjustment or performing a check, obtain
the assistance of a second person who is thoroughly familiar with the machine. Have the
assistant at the control panel to be sure that nothing is actuated that may be hazardous
to you or the machine.
17.9.14.1 Roller Adjustment
The mast should be positioned in the down, or lowered, position. Refer to Figure 17-21 and proceed as follows:
1. Lower the mast so that the pinion shrouds are resting on the rack shrouds.
2. Remove the four socket head capscrews from the eccentric bushing.
3. Turn the eccentric bushing until a gap of 1/8" (.125"; 3mm) is obtained between all of the rollers and the back of
the mast chord.
Follow steps 1 through 3 for all three remaining roller carriers.
Figure 17-21: Roller Adjustment
BD0552a01
17.9.15 Check And Adjust Water Pump Drive Belt
The water pump (see Figure 17-21) is mounted on a bracket at one end of the water supply tank. It is protected
from the environment by a louvered enclosure. The pump is V-belt driven by an independently-mounted electric
motor. The tension of the V-belt should be checked at least once monthly, and adjusted as needed. Adjust the drive
belt tension as follows:
WARNING
!
2. Remove the pump enclosure.
3. Loosen, but do not remove, the motor mounting hardware.
4. Loosen the adjustment locknuts.
5. Turn the belt tensioning screws as required until there is 112 inch (13 mm) deflection of the belt at a point mid-
way between the sheaves. Adjust the screws evenly so the motor sheave remains parallel to the belt.
6. Tighten the adjustment locknuts.
7. Tighten the motor mounting hardware securely.
8. Install the pump enclosure.
17.10 D Maintenance Checks - 500 Hours (Quarterly)
The D Maintenance checks should be performed every 500 hours, or quarterly. If an item is checked and found to
be incorrect, the problem must be corrected prior to start-up to ensure satisfactory operation of the drill.
Repeat A, B and C Maintenance Checks before proceeding with the D Maintenance Checks, refer to the
maintenance check sheets and complete all of the A, B, and C Maintenance Checks.
17.10.1 Replace Oil Line Scavenger Filter Element
The oil line scavenger filter is located on the main air control panel. This filter cleans oil scavenged from between
the two oil separator elements. Replace the filter as follows:
WARNING
!
operator controls to prevent inadvertent machine startup during maintenance.
WARNING
!
2. Be sure that no air or hydraulic pressure exists in the main air system.
3. Loosen and remove the filter housing from the body.
CAUTION
Small amounts of contaminants in the air compressor recirculation system can cause
significant equipment damage. Clean dirt from the filter assembly before loosening the
housing.
4. Remove and discard the used filter element.
5. Check the filter seal for nicks and cuts. Replace as necessary.
6. Install a new filter element in the housing.
7. Lubricate the seal with hydraulic oil, and install the housing securely in the filter body.
17.10.2 Check Bolts, Mounting And Attachment Torques
It is recommended that all mounting and attachment bolts and capscrews be checked periodically for correct torque
to ensure that all components remain securely mounted. This mounting bolt check should be made quarterly at first
and adjusted as experience dictates. Refer to the bolt and capscrew torque values provided in Table 17- 1 for appli-
cable bolt and capscrew torques.
17.11 E Maintenance Checks - Semi-annual/1000 Hours
The E Maintenance checks should be performed every 1000 hours, or semi-annually. If an item is checked and
found to be incorrect, the problem must be corrected prior to start-up to ensure satisfactory drill operation. Refer to
the maintenance check sheets and complete all of the A, B, C, and D Maintenance Checks.
17.11.1 Change Rotary Gearcase Oil
The rotary gearcase is mounted to the lower end of the rotary carriage. This double-reduction gear reducer drives
the rotary head coupling, the drill bit, and the pipe string. Change the rotary gearcase oil as follows (see Figure 17-
3):
1. Lower the rotary carriage to the bottom of the mast.
WARNING
!
injury or death. Lower the rotary carriage to the bottom of the mast; use lockout/tagout
procedures to shut down the drill before performing service procedures.
2. Use lockout/tagout procedures to prevent inadvertent start-up during service procedures.
3. Open the gearcase bearing drain valve and remove the drain plug from the bottom of the gearcase, and drain
the oil from the gearcase into a suitable container.
4. When the old oil is completely drained, close the gearcase bearing drain valve. Clean the drain plug, apply
pipe thread sealant, and install it in the back of the gearcase.
5. Remove the vent cap from the top of the gearcase.
6. Add oil, of the type and amount specified in the Lubrication Section, through the fill pipe until oil reaches the
FULL mark on the dipstick.
7. Clean and install the vent cap.
CAUTION
Operating the rotary machinery when the rotary gearcase has been overfilled will cause
overheating of the gearcase components resulting in damage to the gearcase compo-
nents. Never operate the rotary machinery with the rotary gearcase oil level above the
FULL mark on the dipstick.
17.11.2 Change Pump Drive Transmission Oil
The pump drive transmission provides the rotational power to drive the three main hydraulic pumps and one auxil-
iary hydraulic pump. Every six months, or each 1000 hours of operation, change the pump drive transmission oil as
follows (see Figure 17-22):
WARNING
!
injury or death. Lower the rotary carriage to the bottom of the mast; use lockout/tagout
procedures to shut down the drill before performing service procedures.
1. Use lockout/tagout procedures to prevent inadvertent start-up during service procedures.
2. Open the gearcase drain valve and drain the oil from the gearcase into a suitable container. The outlet for the pump drive
transmission drain is located below the machinery deck.
3. When the old oil is completely drained, close the crankcase drain valve.
4. Remove the vent/fill cap.
5. Add oil, of the type and amount specified in the Lubrication Section, until oil reaches the full mark on the dip stick.
6. Clean and install the fill/vent cap.
CAUTION
Operating the pump drive transmission when the transmission has been overfilled will
cause transmission components to overheat, resulting in damage to the transmission.
Never operate the pump drive transmission with the oil level above the level plug.
Figure 17-22: Pump Drive Transmission (typ)
17.11.3 Change Hoist/Pulldown Gear Reducer Oil
The hoist/pulldown gear reducer (see Figure 17-3) provides the torque required to power the rotary carriage
assembly along the vertical length of the mast. Every six months, or 1000 hours of gearcase operation, use the fol-
lowing procedure to change the oil in the reducer:
WARNING
!
2. Using a suitable container to catch the used oil, remove the drain plug from the bottom of the reducer housing,
and drain all of the oil.
3. Install the drain plug with pipe thread sealant.
4. 4. to the correct level, indicated on the sight gauge, with oil specified in the Lubrication Section of this manual.
5. Install the filler plug with pipe thread sealant.
17.11.4 Change Propel Transmission Oil
The propel transmission is equipped with a planetary drive gearcase, hydraulically driven, which functions to pro-
vide rotary motion to drive the crawler belt and propel the drill. Use following procedure to change the oil in the pro-
pel transmission once each year, or every 2000 hours of operation (see Figure 17- 15):
1. Rotate the transmission until the level/fill plug and drain plug are positioned as shown on Figure 17-15.
WARNING
!
Unexpected movement of the propel system could result in injury or death. Use lockout
tagout procedure to shut down the drill before starting propel transmission oil change
procedures.
2. Shut down the drilling operations. Use lockout/tagout procedures to prevent inadvertent drill movement.
3. Remove the propel transmission drain and level plugs, and drain the oil into a suitable container.
4. Clean the oil drain plug. Apply a coating of pipe thread sealant, and install the drain plugs.
17.11.5 Change Hoist/Pulldown Gear Reducer Oil
The hoist/pulldown gear reducer (see Figure 17-3) provides the torque required to power the rotary carriage
assembly along the vertical length of the mast. Every six months, or 1000 hours of operation, use the following pro-
cedure to change the oil in the reducer:
WARNING
!
2. Using a suitable container to catch the used oil, remove the drain plug from the bottom of the reducer housing,
and drain all of the oil.
3. Install the drain plug with pipe thread sealant.
4. Remove the filler plug from the top of the reducer housing, and fill the reducer to the correct level, indicated on
the sight gauge, with oil specified in the Lubrication Section of this manual.
5. Install the filler plug with pipe thread sealant.
17.11.6 Change Propel Transmission Oil
The propel transmission is equipped with a planetary drive gearcase, hydraulically driven, which functions to pro-
vide rotary motion to drive the crawler belt and propel the drill. Use following procedure to change the oil in the pro-
pel transmission once each year, or every 2000 hours of operation (see Figure 17- 15):
1. Rotate the transmission until the level/fill plug and drain plug are positioned as shown on Figure 17-15.
WARNING
!
Unexpected movement of the propel system could result in injury or death. Use lockout
tagout procedure to shut down the drill before starting propel transmission oil change
procedures.
2. Shut down the drilling operations. Use lockout/tagout procedures to prevent inadvertent drill movement.
3. Remove the propel transmission drain and level plugs, and drain the oil into a suitable container.
4. Clean the oil drain plug. Apply a coating of pipe thread sealant, and install the drain plugs.
5. Add oil, of the type specified in Lubrication Section, through the level/fill plug opening until the level reaches
the bottom of the fill/level plug hole.
6. Apply pipe thread sealant to the vent plug, and install the plugs.
17.12 F Maintenance Checks - Annual/2000Hours
The F Maintenance checks should be performed 2000 hours or annually. If an item is checked and found to be
incorrect, the problem must be corrected prior to start-up to ensure satisfactory operation of the drill.
Repeat A, B, C, D, and E Maintenance Checks before proceeding with the F Maintenance Checks
17.12.1 Change Hydraulic System Oil
It is recommended that the hydraulic system oil be changed once each year, or every 2000 hours of operation.
Drain, flush, and refill the hydraulic system. Refill the hydraulic system with the type and amount of oil specified in
the Lubrication Section.
NOTICE
It is recommended that a sample of oil be drawn from the hydraulic tank annually. This sample
should be about two quarts and should be taken when the oil is warmed through normal opera-
tion. If possible, the sample should be analyzed by a qualified lubrication specialist to determine
whether it is suitable for continued use. The interval between oil changes depends upon the
operating conditions and on the care used in the handling oils and keeping the clean during the
handling process.
17.12.2 Change Auxiliary Winch Gearcase Oil
The auxiliary winch gearcase contains a planetary-type transmission inside the winch assembly. Annually, or
every 2000 hours of operation, the oil in the auxiliary winch gearcase needs to be changed. Use the following pro-
cedure to change the oil in the gearcase:
WARNING
!
Working on or near the mast and/or winch during drilling operation is hazardous and can
result in injury or death. Lower the rotary carriage to the bottom of the mast and shut
down the drill using lockout/tagout procedures.
1. Lower the rotary carriage to the bottom of the mast, and shutdown the drill using lockout/tagout procedures to
prevent inadvertent start-up of the drill.
2. Remove the oil drain plug from the end opposite the hydraulic motor, and drain the oil into a suitable container,
3. Clean the oil drain plug, apply a coating of pipe thread sealant, and install the drain plug.
4. Remove the oil fill and level plugs.
5. Add oil of the type specified in the Lubrication Section, through the gearcase fill plug opening until the level
reaches the bottom of the level plug hole.
6. Apply pipe thread sealant to the fill and level plugs, and reinstall the plugs.
17.12.3 Change Cable Reel Gear Reducer Oil
The tail cable reel (optional equipment) is mounted across the front of the machinery house and serves to store the
tail cable. The gear reducer, driven by a hydraulic motor, provides rotary motion to rotate the cable drum.
Annually, or every 2000 hours of operation, the oil in the cable reel gear reducer needs to be changed. Use the fol-
lowing procedure to change the oil in the reducer:
1. Shut down the drilling operations, and power down the drill.
WARNING
!
Working on or near the cable reel during drill operation is hazardous and can result in
prior to working on or near the cable reel.
2. Lock out and tag the electrical controls to the auxiliary hydraulic system to prevent inadvertent start-up of the
cable reel during service activities,
3. Remove the oil drain plug, and drain the oil into a suitable container.
4. Clean the oil drain plug. Apply a coating of pipe thread sealant, and install the drain plug.
5. Remove the oil level plug and the oil breather cap.
CAUTION
Operating the cable reel when the gear reducer has been overfilled will cause overheat-
ing of the reducer components resulting in component damage. Never operate the cable
reel when the oil level is either below or above the lower edge of the level plug opening.
6. Add oil of the type specified in the Lubrication Section, through the gearcase breather opening until the level
reaches the bottom of the filler plug hole.
7. Apply pipe thread sealant to the fill level plug, and install the plug securely.
8. Install the oil breather cap.
BD120149 Mechanical Systems Manual General Maintenance
AppendixA.fm -A.1- Appendix A, Version 00 - 03/06
Appendix A
General Maintenance
A.1 Removal General
The following general rules apply to removal of most major components.
1. Always make sure that all controls are in the OFF position. Main and emergency power switches must be
opened and locked in the open (OFF) positions. Place warning signs on these switches so that others do not
turn on the power while you are working on the machine.
WARNING
!
Unexpected machine operation could result in death or severe personal injury. Warning
signs must always be removed by the person who placed them - never by anyone else.
2. Lifting heavy components with inadequate hoisting apparatus can injure personnel and/or damage equipment.
Use suitable rigging and hoisting equipment to stabilize and lift heavy objects.
3. Before performing any work on any system, consider the effect that the work may have on the system. Be sure
that the machinery will not move as a result of the work being performed. Be sure the system is not under pres-
sure. Be sure electrical power is disconnected.
A.2 Disassembly General
1. Disassemble only what is required for specific repairs.
2. Never use a torch to assist in removing parts unless the parts to be heated are already damaged beyond
repair, or the instructions recommend the use of heat for disassembly. Excessive heat may damage the part
beyond repair.
3. Never use more force than necessary to dismantle an assembly. In most cases, a great deal of force is not
required.
4. Handle parts carefully to prevent nicks or other damage while the parts are removed from the machine.
5. Tag all electrical leads and hydraulic lines before disconnecting them to ensure proper reconnections.
A.3 Inspection, Cleaning And Repair General
The following general recommendations should be followed during routine cleaning, inspection and repair of most
machine components.
General Maintenance BD120149 Mechanical Systems Manual
Appendix A, Version 00 - 03/06 -A.2- AppendixA.fm
WARNING
!
Gasoline, naphtha, and other highly flammable fluids will burn if ignited, and may
explode if the fumes are ignited in a confined space, resulting in burns, severe bodily
injury and/or death. Do not use these materials to clean, or for any other maintenance
procedure. If necessary, use Toluol, Perchloroethylene, or other approved solvent.
1. Clean all parts thoroughly using kerosene, diesel oil, or a suitable commercial solvent. Never use a hot alkaline
solution on finished parts or bearings.
2. Dry metal parts (except bearings) using low-pressure compressed air. Do not spin-dry bearings.
3. Inspect all gears as described under Subtopic A.5.7.
4. Inspect all bushings for wear, scoring or galling and replace when required.
5. If possible, replace all oil seals and O-rings, regardless of the reason for removal, even if no damage is appar-
ent.
6. If possible, replace all gaskets. Be sure the new gasket is of the same material and thickness as the discarded
gasket.
7. Inspect all anti-friction bearings as described under Subtopic A.5.1.
A.4 Assembly
The following general rules apply to assembly of any component.
1. When torque values are specified, be sure to use a torque wrench and tighten to the specified torque value. If
a tightening sequence is specified, follow the sequence. If none is given, tighten evenly and alternately around
the bolt circle.
2. Always pre-pack anti-friction bearings with suitable bearing grease before installation.
3. Install all bearings as instructed under Subtopic A.5.1.
4. Inspect all grease passages to be sure they are open and clean.
5. Smooth all nicks, burrs, or galled spots on shafts, bores, pins, gears and bushings. Pay particular attention to
oil seal seating areas to ensure that shaft irregularities do not lead to seal wear and lubrication leaks.
6. Check the fit of keys in keyways. Shaft keyways have an interference fit which should not be altered.
A.5 Maintenance Of Specific Components
A.5.1 Bearings
A.5.1.1 Removal
Most bearings are removed by means of a bearing puller or driver. In either case, the puller or driver should contact
only the inner bearing race to prevent damage to the bearing. Inspection and repair. Inspect all bearings for wear,
binding, excessive play, distorted races and roller wear or damage. Always replace worn or damaged bearings.
NOTICE
Some organizations make it a practice to replace all bearings in crucial applications whether or
not damage is apparent. The cost of the part is often minor in comparison with the cost of redo-
ing the job should the part fail.
A.5.1.2 Installation
Prepack all anti-friction bearings with a good grade of bearing grease before installation. Many bearings require an
interference fit between the inner race and the shaft on which the inner race is mounted. To obtain the required
interference fit, the bearing must be heated, the shaft must be cooled, or a combination of both methods may be
necessary. It is usually easiest to heat the bearing, and this is the method most commonly used. Use an oven, a
bearing heater, or an oil bath for heating a bearing; do not use a torch. Once the bearing has been properly heated,
it must be pressed into position on the shaft in one smooth and continuous operation. Do not allow the bearing to
stop short of it's final position, since it will quickly freeze on the shaft and will then have to be removed and
reheated before it can be properly installed.
CAUTION
Never use hot alkaline solutions on bearings (or other finished parts) because the alka-
line solutions will score or damage finished surfaces.
CAUTION
Never spin dry bearings with compressed air since this will damage the bearings.
A.5.2 Couplings
Power transmission couplings are the usual means of connecting coaxial shafts so that one shaft can drive the
other. For example, they may be used to connect an electric motor to a pump shaft or to connect two pieces of
shafting together to obtain a longer shaft extension.
Couplings are manufactured in many types, styles and sizes. However, they can be classified into two groups:
Rigid couplings (sometimes called solid couplings) and flexible couplings. Each is discussed below.
A.5.2.1 Rigid (Solid) Couplings
These couplings connect shaft ends together rigidly, making the shafts so connected into a single continuous
entity. They are generally used when true alignment and a solid coupling are required, as with line shafting. Solid
couplings are self-supporting and automatically align the shafts to which they are attached when the coupling
halves on the shaft ends are connected. Solid couplings require the following for good service:
1. Coupling halves must be interference fits on shafts
2. After installation, all surfaces of the coupling must be checked for runout and surfaces found to be running out
must be machined true. Checking of surfaces for runout is especially necessary if the coupling halves are
assembled by driving or bumping rather than pressing.
Rigid couplings should not be used to connect shafts of independent units which must be aligned at assembly.
A.5.2.2 Flexible Couplings
Flexible couplings are used to connect two independently supported coaxial shafts so one can drive the other. For
example, prime movers such as internal combustion engines and electric motors are usually connected to gear
reducers and pumps by means of flexible couplings.
For this type of application, the flexible coupling is used because it is practically impossible to obtain perfect align-
ment of the adjacent shafts. Also, there is usually wear occurring in the connected components and their shaft
bearings, as well as movement from temperature changes and external forces such as vibration.
Therefore, to enable coaxial shafts to operate satisfactorily with slight misalignment, flexible couplings, depending
on the design, may allow one or more of the following misalignments:
Angular Misalignment
Parallel Misalignment
Axial Movement (End Float)
Torsional Movement (Twisting)
Most flexible couplings are made up of three basic parts: two hubs mounted on the shaft ends to be connected,
and a flexing element that transmits power from one hub to the other. Most flexible couplings fall into one of the fol-
lowing categories:
Chain Couplings
A chain coupling is one having two sprockets with hubs for attachment to the shafts, connected by a length of dou-
ble chain having links which mesh with the sprocket teeth. This type of coupling normally requires lubrication.
Gear Couplings
Gear couplings are made up of meshing internal and external gears or splines. Flexibility results from both the fit of
the teeth and the special shaping of the teeth that permits them to pivot in relation to each other. This type of cou-
pling normally requires lubrication.
Jaw and Slider Couplings
These couplings usually have two hubs which attach to the shafts. The hubs are connected by a sliding member
which provides flexibility. The slider is connected to the hubs by jaws, keys, or splines. These couplings usually
require lubrication.
Resilient Element Couplings
This is a very common type of coupling. The most commonly used resilient flexible materials are metal and rubber
(or synthetic substitute). These couplings allow angular and parallel misalignment and end float. Those using rub-
ber elements have more torsional flexibility than most other types of couplings. Most of these couplings do not
need lubrication, except the ones using flexible metal elements.
A.5.3 Alignment
In preparing to align a coupling, it must be determined which unit is to be adjusted - the driving or the driven unit.
Common practice is to position, level and secure the driven unit as required and then adjust the driver to align
with it. The driven unit must be set with its shaft centerline slightly higher than the driver to allow for alignment
shims.
Coupling alignment consists of bringing the centerlines of two coaxial shafts into alignment, rather than aligning the
surfaces of the coupling. For example: If the coupling hub surfaces do not run true with the shaft centerline, align-
ment of the untrue surfaces will result in misalignment of the shaft centerlines. True running surfaces are therefore
a vital requirement if the alignment procedures that follow are to be successful.
There are two kinds of shaft misalignment: Angular Misalignment and Parallel Misalignment.
Note that misalignment of the shaft centerlines may occur in any plane within a full circle. Angular misalignment
may be a tilt up, down, or to the side of one shaft in respect to the other. Parallel misalignment may be one shaft
high, low, or to the side of the other. The usual method of correcting alignment is to check and adjust in the vertical
and horizontal planes as illustrated in Figure A-4.
To align centerlines of coaxial shafts in both the vertical and horizontal planes requires four distinct operations: An
angular and parallel alignment in the vertical plane and the same in the horizontal plane.
To do an alignment properly requires an organized procedure. Since adjustments are usually made by inserting
shims at low support points, an important first step is to check the foundation of the unit to ensure that no rocking
motion exists. If rocking does exist, eliminate it by shimming before proceeding. Tools best suited for coupling
alignment are the straight edge, feeler gauge, and taper gauge. The taper gauge is just what it implies, a tapered
piece of straight metal which allows direct reading instead of the trial and error type of reading obtained by a
feeler gauge.
Two methods of coupling alignment are commonly used: the straightedge-feeler gauge method and the dial indica-
tor method. Each method will be illustrated using specific measurements as examples after the following general
explanation. In both methods, four alignments are performed in a specific order, although the final two steps are
combined into one in the numbered procedure below.
NOTICE
Only when adjustments are performed in the correct order can a succeeding adjustment be per-
formed without disturbing prior settings.
A.5.3.1 Vertical Face Alignment
To adjust vertical face alignment, it is necessary to tip the unit as required. First, measure the gap at the top and
bottom of the coupling; then, shim as required to align these faces.
The easiest way to determine the amount of shims required is as follows:
The tilt required at the coupling face is the same as the angle of change at the base of the unit. Therefore the shim
thickness required is proportional to the misalignment.
As an example, the misalignment at the coupling faces is 0.006" in 5 inches. Therefore, each five inches of base
must be tilted 0.006" to correct misalignment. Since the base length is 10 inches, the shim thickness required is
twice 0.006" or 0.012".
NOTICE
A rule for shim thickness selection is: Shim thickness is as many times greater than the mis-
alignment as the base length is greater than the coupling diameter.
A.5.3.2 Vertical Height Alignment
Measure the height difference from the coupling hub base to the shaft centerline. Then raise the lower unit as
required without changing its angular position. This adjustment corrects parallel misalignment in the vertical plane.
A.5.3.3 Horizontal Face and OD Alignment
When the units are properly aligned vertically, shimming is complete. Then move the unit as required to align the
coupling hub faces and O.D's at the sides of the coupling.
A.5.4 Coupling Alignment - Straightedge-Feeler Gauge Method
Align the coupling as follows:
1. Using feeler gauges, measure the width of the gap at top and bottom between the coupling faces.
2. Assume the gap at the top is 0.160 and at the bottom is 0.152. This equals 0.008" misalignment in 5 inches
(the diameter of the coupling). Base length is 12 inches. Therefore, shim thickness required is about 2-112
times 0.008" or about 0.020". A shim placed under the low end of the driver will tilt it into approximate angular
alignment with the driven unit.
3. Using a straightedge and feeler gauges, measure the height difference between driver and driven unit height at
the OD of Figure A-8. Straight Edge Feeler Gauge Alignment the coupling halves. Then, place shims at all
driver support points equal in thickness to the measured height difference.
4. Finally, use a straightedge to check alignment of O.D's at the sides of the coupling. Using a feeler gauge,
check the gap between coupling hub faces at the sides of the coupling. Adjust the driver as necessary to align
the O.D's and to set the gap equal at the sides.
A.5.5 Coupling Alignment - Dial Indicator Method
A dial indicator can be used in two ways to check coupling alignment. They are:
1. Attached to one shaft or coupling half while contacting the second hub or shaft while both shafts are rotating,
or
2. Attached to one shaft or coupling half while contacting the second hub or shaft while one shaft is rotating.
The ideal method is the first, dial indicating while both shafts are rotating. In this method, when the indicator is
rotated its tip will proceed in a circle which is concentric with the shaft bearings. The mating unit shaft should also
be rotated, since the point contacted by the indicator tip will also describe a true circle. When these two circles
coincide (zero runout on the indicator) the shafts will be in alignment in the plane being measured. The reason this
method is ideal is that coupling surface runout does not affect the accuracy of shaft alignment. In other words, it is
possible by this method to accurately align shafts in spite of coupling surfaces that are not running true to each
other. However, in some cases, the above method is not possible. In such cases, it becomes necessary to use the
method of attaching the dial indicator to one shaft or coupling half while contacting the second hub or shaft while
one shaft is rotating. Refer to Figure A-9 and proceed as follows:
A.5.5.1 Vertical Face Alignment
Attach the indicator to the shaft or coupling half of the driver. Place the indicator tip in contact with the face of the
coupling half on the driven unit. Rotate the shafts of both units together and note the total indicator readings (T.I.R.)
at top and bottom. T.I.R. is a measure of vertical angular misalignment. Place shims (calculate the amount as pre-
viously described) under the driver at the low end to bring it into vertical alignment with the driven unit.
A.5.5.2 Vertical Height Alignment
Place the indicator tip in contact with the outside surface of the driven unit coupling half. Rotate shafts of both units.
Note the indicator readings at top and bottom. The height difference between the units is one-half of the T.I.R.
Place shims at all driver support points equal to one-half total indicator runout.
A.5.5.3 Horizontal Face Alignment
Place the indicator tip in contact with the face of the driven unit coupling half. Move the driver as necessary to
obtain zero reading on the indicator.
A.5.5.4 OD Alignment
Place the indicator in contact with the OD surface of the driven unit coupling half. Move the driver as necessary to
obtain zero reading on the indicator. Repeat steps 3 and 4 as necessary to obtain zero readings on both face and
OD surfaces at the sides of the coupling. Do not disturb shims during horizontal alignment adjustments.
A.5.6 Sheaves
1. Inspect sheaves to see that belts or wire rope have not worn grooves into the sheaves. Replace sheaves when
wear grooves appear since grooves will cause rapid and dangerous belt or rope damage.
2. Make sure the belt or wire rope is correctly sized for the sheave on which it is being used. If there is any doubt,
check your operating and/or maintenance manual to determine the proper size for the application.
A.5.7 Gears
Some of the basic terms associated with gears are defined under the topic Terminology. Some of the defects for
which gears should be inspected are defined under Inspection.
TERMINOLOGY.
ADDENDUM. The addendum is the distance a gear tooth extends above the pitch circle (or circular pitch).
BACKLASH. Backlash is the difference between the thickness of a tooth and the width of the gap between the two
gear teeth on it's mating gear. Backlash is necessary to compensate for variations in spacing and form of the gear
teeth, to provide space for lubricant, and to allow expansion of the teeth when their temperature increases during
operation.
BOTTOM LAND. The bottom land is the surface at the bottom between adjacent gear teeth.
CIRCULAR PITCH. Circular pitch is the distance along the pitch circle or pitch line between the corresponding pro-
files of adjacent teeth.
CIRCULAR THICKNESS OF TOOTH. The circular thickness of a tooth is the length of the arc between the two
sides of a gear tooth as measured along the pitch circle unless otherwise specified.
CLEARANCE. Clearance is the radial distance between the working depth circle and the root circle.
DEDENDUM. The dedendum is the depth of the tooth space below the pitch circle or pitch line; the radial distance
between the pitch circle and the root circle.
FACE WIDTH. The face width is the length of a gear tooth in the plane parallel to the shaft centerline (the axial
plane).
FILLET CURVE. The fillet curve is the concave portion of the tooth profile where it joins the bottom land.
PITCH CIRCLE. Pitch circle is the curve of intersection of a pitch surface of revolution and a plane of rotation. It is
the imaginary circle that rolls without slipping with a pitch circle of a mating gear.
ROOT CIRCLE. The root circle is tangent to the bottom of the tooth space when viewed in a cross section.
TOOTH PROFILE. Tooth profile is one side of a gear tooth in a cross section between the outside circle and the
root circle.
WORKING DEPTH. The working depth is the depth of engagement of two gears; the sum of the operating adden-
dum.
TOP LAND. The top land is the surface of the top of the gear tooth.
WHOLE DEPTH. The whole depth is the distance from the top land to the bottom land.
A.6 Gear Tooth Wear
A.6.1 Inspection
All gearing should be inspected for signs of wear or damage. If any of the problems illustrated and discussed below
are found, the problem should be corrected and, if necessary, the gear or gear set should be replaced as soon as
possible.
A.6.2 Gear Wear
Gear wear is usually caused by abrasion, corrosion or lubrication failure. Each is discussed below:
NOTICE
If a damaged or worn pinion or gear must be replaced always replace the mating gear or pinion.
Do not run a new pinion or gear with a worn mating part as rapid failure of the parts will result.
1. Abrasion. Abrasive wear is typified by a lapped appearance, radial scratch markings or grooving of the tooth
contact surfaces and is generally caused by foreign material in the lubricating oil.
2. Corrosion. Corrosive wear is a deterioration of the tooth surface caused by chemical action. It often results
from active ingredients in the lubricating oil such as acid, moisture or extreme pressure additives. Lubricants
can also be contaminated by atmospheric chemicals, or chemicals or other materials (such as salt water)
which somehow leak into the lubricant supply.
3. Lubricant Failure. Lubricant failure results in allowing metal-to-metal contact of gear teeth. This causes over-
heating, which produces alternate welding and tearing of the metal, thus removing metal from the tooth sur-
faces. This is called scoring. The most common cause of this problem is localized overheating of the teeth at
the point at which they mesh, causing breakdown of the lubricant film. Another similar condition called frost-
ing is a form of scoring typified by micropitting under thin lubricant film conditions.
A.6.3 Surface Fatigue
Surface fatigue of gear teeth is divided into three primary categories. They are:
1. Pitting. Pitting occurs when the endurance limit of the tooth material is exceeded. The usual causes are over-
loading or excessive shock.
2. Spalling. Spalling is similar to pitting except that the pits are usually larger, very irregular in shape and quite
shallow. Spalling is usually caused by high contact stress levels. The edges of the initial spalled areas break
away rapidly and larger irregular voids are formed. These voids often join together and form still larger voids.
3. Case Crushing. Case crushing is a subsurface fatigue failure which occurs when the endurance level of the
tooth material is dramatically exceeded. Severe shock loading is the most likely cause of case crushing.
A.6.3.1 Plastic Flow
Plastic flow consists of deformation of tooth surfaces caused by high contact stresses as the gear teeth mesh.
There are two basic types of plastic flow. They are:
1. Cold Flow. Cold flow is the cold-working deformation of tooth surfaces caused by high contact stresses and the
rolling and sliding action of the meshing teeth. The dents and battered appearance of the surfaces are a result
of dynamic loading due to operation while the tooth profiles are being damaged by a combination of cold-work-
ing and wear.
2. Rippling. Rippling is generally caused by high contact stresses under cyclical operation. This has a tendency to
roll and knead the contact surfaces, resulting in the rippling of the immediate surface.
A.6.3.2 Gear Backlash
Gear backlash is the play between teeth which prevents the gears from binding while in motion. It is built into the
gearset during manufacture. In terms of tooth dimensions, it is the amount by which the width of the tooth spaces
exceeds the thickness of the mating gear teeth. Backlash can also be described as the distance, measured along
the pitch line, that a gear will move when engaged with another gear that remains motionless.
Normally, there must be some backlash present in gear drives to provide running clearance and room for lubricant.
Without backlash, gear binding will result in heat generation, noise, abnormal wear, and possible failure of the
gearset.
Backlash is built into standard gears by cutting the gear teeth thinner by 50% of the backlash desired in the set.
When two gears made in this manner are mated, at proper center-to-center distance, their two 50% allowances
combine to give 100% of the backlash desired by the designer.
On non-reversing drives, or where load is applied in only one direction, the increase in backlash that results from
tooth wear does not adversely affect operation. However, on reversing drives and drives where timing is critical,
excessive backlash cannot be tolerated.
The following illustration and chart can be used as a rule of thumb to obtain the approximate backlash for a pair of
gears operating at standard center distance. See Figure A-12. This chart should only be used when the manufac-
turer's recommendations can not be obtained. If any discrepancy between the chart and manufacturer's recom-
mendations exists, the manufacturer's instructions take precedence.
In general, check backlash as follows:
1. Hold one gear motionless.
2. Turn the mating gear until it contacts the motionless gear.
3. Install a dial indicator touching the gear which can be moved on the side toward which it can be moved and
turn the gear as far as it will go.
4. Read the total backlash on the dial indicator. Note that feeler gauges can often be used in place of a dial indi-
cator. The space which constitutes backlash is illustrated in Figure A-12. Backlash must be held within the lim-
its specified by the manufacturer or rapid gear wear will result.
A.6.4 Shafts
All shafts should be inspected for nicks, burrs, and wear ridges prior to reinstallation. Smooth defective areas using
crocus cloth, India Stone or a very fine file. It is particularly important that shaft seal surfaces (surfaces on which
seal lips fit) be smooth to prevent seal lip wear, which will cause lubricant leaks. Keyways must be free of nicks and
burrs.
BD120149 Mechanical Systems Manual General Hydraulic System Maintenance
AppendixB.fm -B.1- Appendix B, Version 00 - 03/06
Appendix B
General Hydraulic
System Maintenance
B.1 General
Maintenance of individual hydraulic system components such as motors, pumps or valves is included in the system
of which the component is a part. For example, maintenance and repair of the propel motor is covered under Pro-
pel System. The purpose of this section is to discuss maintenance of hydraulic systems in general.
This section includes general procedures to be followed in the event of hydraulic component failure, preventive
maintenance, bleeding procedures, flushing procedures, and recognition of trouble symptoms.
B.2 General Maintenance Rules
The following points should be kept in mind when working on the hydraulic system or any components of the sys-
tem:
CAUTION
!
Pressurized fluid escaping from a hydraulic system can penetrate the skin causing seri-
ous injury. Always relieve pressure by connecting a microbore hose from the appropri-
ate test port to the tank test port before disconnecting hydraulic lines. Tighten all
connections before reapplying pressure. Keep hands and body away from pinholes and
nozzles which eject fluid under high pressure. Use a piece of paper to search for leaks.
Do not use your hands. If any fluid is injected into the skin, it must be surgically removed
within a few hours by a medical doctor or gangrene can result.
1. All systems are designed to operate within minimum and maximum pressure limits. A pressure relief (unload-
ing) valve is included in nearly all systems to limit maximum pressures to levels for which the system is
designed.
WARNING
!
The setting of a pressure relief or unloading valve must never be increased in an attempt
to get more out of the system. This could cause the system to operate at a pressure
level for which it was not designed and equipment damage and/or personnel injury or
death could result.
2. Because internal leaks waste the power of the system, working parts are designed for extremely close fits.
Because of the necessary close fits, even very small amounts of dirt or foreign material can cause wear or
damage to components, which will, in turn, cause faulty operation of the system. Every precaution must be
General Hydraulic System Maintenance BD120149 Mechanical Systems Manual
Appendix B, Version 00 - 03/06 -B.2- AppendixB.fm
taken to assure absolute cleanliness of hydraulic oil. This includes dirt, chips from failed parts of the system, as
well as contaminants such as water or other fluids which are incompatible with the fluid in the system.
3. To ensure cleanliness of the system oil, samples should be drawn from the reservoir every 6 month (more
often, if problems are experienced). Each sample should be taken by an approved sampling procedure (e.g.
IS0 Standard 4021) and analyzed by a qualified lubrication specialist to determine whether it is suitable for fur-
ther use. The interval between normal hydraulic fluid replacements depends on operating conditions and on
successfully keeping contaminants out of the system.
4. Whenever there is a hydraulic system component failure that gives reason to believe that there are metal parti-
cles or other foreign materials in the system, drain and flush the entire system, clean strainer baskets and
replace filter cartridges. A complete change of hydraulic oil must be made under these circumstances.
NOTICE
Flushing the hydraulic system is time consuming and expensive. Therefore, it should be done
only when necessary. However, avoiding a flush when there is clear evidence of a contami-
nated system will prove to be a false economy in the long run.
5. Whenever the hydraulic system is drained, check the magnetic drain plugs for metal particles. If metal particles
are present, flush the system and add a new charge of oil.
6. Never change the type of oil used in the system without first checking that the replacement oil is acceptable for
use in the system.
7. All containers and funnels used in handling hydraulic oil must be very clean. Use a funnel with a 200 mesh
screen for filling the hydraulic oil reservoir and fill the reservoir only through the filler opening. The use of cloth
to strain the oil is not acceptable because this will allow lint to enter the system.
8. When removing any hydraulic component, be sure to cap and tag all hydraulic lines involved. Always plug the
ports of the removed components.
9. All hydraulic components must be disassembled and assembled in spotlessly clean surroundings. During dis-
assembly, pay particular attention to the identification of parts to ensure correct reassembly. Clean all metal
parts in a clean mineral oil solvent. Be sure to clean all internal passages. After the parts have dried, lay them
on a clean lint-free surface for inspection.
10. Replacement of all O-rings, back-up rings and seals is recommended when overhauling any component. Lubri-
cate all parts with hydraulic oil before reassembly. Use small amounts of petroleum jelly to hold O-rings in place
during reassembly.
11. Replace all lost hydraulic oil after completing installation of repaired components. Always maintain a sufficient
quantity of clean hydraulic fluid of the proper type and viscosity in the reservoir.
12. Bleed air from the system after components have been removed from the system or when it is suspected that
air has entered the system.
13. Keep all hydraulic connections tight. A loose connection in a hydraulic line will permit the oil to leak out or air to
be drawn into the system. Air in the system can cause damage to components as well as noisy or erratic sys-
tem operation.
14. Change filter elements and clean strainers when necessary.
B.2.1 Correct Tightening of Hydraulic Connections
The following procedures are recommended to ensure that system hydraulic connections are correctly made and
to minimize the probability of system leaks.
Figure B-1: Tightening SAE Flare Connections
B.2.2 Pipe Thread Connections
Pipe thread connections tend to leak more at high pressure than any other style of connection. National pipe threads (NPT)
leak much more than do the dry seal thread (NPTF) types. However, either will leak if under-tightened or over-tightened. Use
a good pipe thread sealant on NPT threads of the male connection, but do not use sealant on the first two threads. This will pre-
vent the sealant from entering the system. Always apply sealant on male threads - never apply sealant to female threads. The
most probable causes and remedies for pipe thread leaks are listed in Table B-1.
B.2.3 SAE Flare Connections
Most leaks from this type of connection are due to lack of tightening and human error. It is impossible to tell if the nut has been
tightened by simply looking at the connection. Figure B-1 shows one method of tightening this type of connection. If the joint
still leaks after it has been correctly tightened, refer to Table B-2 for possible remedies.
B.2.4 SAE Straight Thread Connection (O-ring Seal)
This type of connection leaks most often because the jam nut and washer are not properly installed before assem-
bly of the fitting. As a result, there is not enough room for the O-ring to seat when it is squeezed and the washer
cannot seat properly on the face of the O-ring boss (View A, Figure B-2). The compressed rubber between the
washer and the boss face will cold flow out of compression and the fitting will loosen and leak. Leakage from
straight thread connectors may be indicated by any of the following:
1. Fittings loosen after short service.
Table B-1: Pipe Thread Leaks
2. O-rings leak after short or long service.
3. Instant leakage upon start-up. To stop leakage from straight thread connectors, proceed as follows (see Figure
B-3):
A. Back the jam nut and washer (View A, Figure B-3) to the end of the smooth portion of the fitting.
B. Lubricate the O-ring.
C. Thread the fitting into the port, finger tight.
D. Back the fitting out (no more than one turn) to align the fitting for attachment of the mating hose or tube.
Figure B-2: Incorrect O Ring Installation
Table B-2: Flare Connection Leakage
E. Tighten the jam nut to achieve the O-ring seal as illustrated in View B, Figure B-33.
B.2.5 Split Flange Connections
Table B-3 lists probable causes and remedies for split-flange connection leaks. To install a split flange connection,
refer to Figure B-4 and proceed as follows:
1. Thoroughly clean the sealing surfaces and the flanges.
2. Lubricate and install the proper O-ring in the fitting groove.
3. Align the fitting with the port and assemble the flanges over the fitting.
Figure B-3: Correct O Ring Installation
Figure B-4: Split Flange Tightening Sequence
4. Snug the bolts in the sequence shown in Figure B-4 to 113 of the torque value obtained from Table B-4. Be
sure the flanges remain square with the fitting and bolt surface.
5. Torque the bolts diagonally to 213 of the final torque value from Table B-4.
6. Torque the bolts diagonally to the final torque value in Table B-4.
Table B-3: Split Flange Leakage
B.2.6 Flat Face O-ring Seal Connections
Flat face O-ring seal connections allow installation or replacement of connecting parts without mating piping. O-ring
failure is the primary cause of leaks in this type of fitting. Contamination, improper fluid, or improper installation of
the O-ring or fitting may cause premature failure of the O-ring. To install a flat face O-ring seal fitting, proceed as
follows:
1. Be sure the fitting sealing surfaces are clean and free of defects. See Figure B-5.
Table B-4: Split Flange Torque Values
2. Inspect the O-ring. It must be free of defects.
3. Lubricate the O-ring and install it in the groove. Use petroleum jelly to hold the O-ring in place.
4. Assemble the fitting and hand tighten while pressing the joint together. This will ensure that the O-ring remains
in proper position.
5. Tighten the connection to the torque value specified in Table B-5.
B.2.7 Troubleshooting Hydraulic Systems
Probably the greatest aid to troubleshooting is knowledge of the system. Every component has a purpose in the
system. The construction and operating characteristics of each component should be understood.
Figure B-5: Flat-face O Ring Seal Connection
B.2.8 Developing Systematic Procedures
To troubleshoot a system effectively, develop a logical sequence of looking for the cause of the problem, using
some or all of the following techniques:
1. Ask the operator how the machine performed when it started to fail or if there was anything unusual happening
prior to the machine failure.
2. If the machine is operative, check to see what gauge or other indications are normal and which are out of nor-
mal limits.
3. Visually inspect the machine for oil leaks and loose connections.
4. Examine filters and all lines, checking for heat, loose connections and collapsed hoses.
B.2.9 Recognizing Trouble Symptoms
The following symptoms are signs of trouble:
B.2.9.1 Excessive Heat
A misaligned pump places an excessive load on bearings and can be readily identified by the heat generated. A
warmer than normal return line may indicate that the system is operating at the unloading valve setting. Low vis-
cosity hydraulic oil will increase the internal leakage of components, resulting in a heat rise. Cavitation and slip-
page in a pump will also generate excessive heat.
B.2.9.2 Excessive Noise
Wear, misalignment, cavitation or air in the oil will cause noise. Contaminated oil can cause an unloading valve to
stick or chatter. Excessive noise may be the result of dirty filters or fluid, high fluid viscosity, excessive drive speed,
low reservoir level or loose intake lines, which would allow air to enter the system.
Table B-5: Flat-face Seal Torque Values
BD120149 Mechanical Systems Manual
BD120149-00-MS
To assist us in providing you with the most useful publications, we ask that you use this form to express your views
concerning this publication, its organization or subject matter, with the understanding that P&H Mining Equipment
may use or distribute whatever information you supply in any way it believes appropriate without any obligation to
you. All comments and suggestions are both welcome and appreciated.
To report machine problems or to request additional publications, do not use this form; rather, contact the nearest
P&H MinePro Services will forward your information or requests to the appropriate division at P&H Mining Equip-
ment.
Does the publication meet your needs? YES NO
Comment: _________________________________________________________________________________
__________________________________________________________________________________________
Is the information accurate and complete? YES NO Is it easy to read and understand? YES NO
Comment: _________________________________________________________________________________
__________________________________________________________________________________________
Is the information organized for convenient use? YES NO Is it well-illustrated? YES NO
Comment: _________________________________________________________________________________
__________________________________________________________________________________________
Is the information written to an appropriate technical level? YES NO
Comment: _________________________________________________________________________________
__________________________________________________________________________________________
Please use the space below to identify errors, suggest changes, or to provide additional comments. Include
drawings, photographs, or other graphics as appropriate. For comments regarding the manual, please refer to
page numbers and/or paragraph numbers. If necessary, use additional sheets and mail in an envelope.
Reader
Comment
Form
P.O. Box 310
Milwaukee, WI 53201-0310
Attn.: Knowledge and Development Department
Fold and Tape Please Do Not Staple Fold and Tape
PLACE
STAMP
HERE
BD120149 Mechanical Systems Manual
BD120149-00-MS
To assist us in providing you with the most useful publications, we ask that you use this form to express your views
concerning this publication, its organization or subject matter, with the understanding that P&H Mining Equipment
may use or distribute whatever information you supply in any way it believes appropriate without any obligation to
you. All comments and suggestions are both welcome and appreciated.
To report machine problems or to request additional publications, do not use this form; rather, contact the nearest
P&H MinePro Services office. They will forward your information or requests to the appropriate division at P&H
Mining Equipment.
Does the publication meet your needs? YES NO
Comment: _________________________________________________________________________________
__________________________________________________________________________________________
Is the information accurate and complete? YES NO Is it easy to read and understand? YES NO
Comment: _________________________________________________________________________________
__________________________________________________________________________________________
Is the information organized for convenient use? YES NO Is it well-illustrated? YES NO
Comment: _________________________________________________________________________________
__________________________________________________________________________________________
Is the information written to an appropriate technical level? YES NO
Comment: _________________________________________________________________________________
__________________________________________________________________________________________
Please use the space below to identify errors, suggest changes, or to provide additional comments. Include
drawings, photographs, or other graphics as appropriate. For comments regarding the manual, please refer to
page numbers and/or paragraph numbers. If necessary, use additional sheets and mail in an envelope.
Reader
Comment
Form
P.O. Box 310
Milwaukee, WI 53201-0310
Attn.: Knowledge and Development Department
PLACE
STAMP
HERE

120A

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

120A

Uploaded by

Copyright:

Available Formats

BD120149 Mechanical Systems Manual Preface

ITEMS TO BE VERIFIED REF COMMENTS

ITEMS TO BE VERIFIED REF COMMENTS

ITEMS TO BE VERIFIED REF COMMENTS

ITEMS TO BE VERIFIED REF COMMENTS

ITEMS TO BE VERIFIED REF COMMENTS

ITEMS TO BE VERIFIED REF COMMENTS

You might also like