MD5075 Hydraulic Track Drill Service Manual

May 2012
BI006823-00
Service
Manual
MD5075 Hydraulic Track Drill
435119
SAFETY.CAT.COM
BI006823-00
Product and Dealer Information

Note: For product identification plate locations, see “Product Identification Information” in the Operation and
Maintenance Manual.
Delivery Date
Product Information
Model
Product Identification Number
Engine Model/Serial Number
Compressor Model/Serial Number
Undercarriage Model/Serial Number
Rotary Drive Model/Serial Number
Pump Drive Model/Serial Number
Rock Drill Model/Serial Number
Customer Equipment Number
Dealer Equipment Number
Dealer Information
Name Branch
Address
Dealer Contact Phone Number Hours
Sales
Parts
Service
Caterpillar Global Mining LLC

Mining Products Division
3501 S. FM Hwy 1417
Denison, TX 75020
For Factory Spare Parts Ordering, Contact Your Local Cat Dealer
Technical Parts Support + 1.903.415.4021

Technical Service Support + 1.903.786.6455
Machine Breakdown Emergency + 1.903.814.3744
BI006823-00
Contents
INTRODUCTION
MACHINE SPECIFICATIONS
COMPONENT LOCATIONS
SAFETY .....................................................................................................................SECTION 1
MAINFRAME AND TRACKS .....................................................................................SECTION 2
POWER TRAIN ..........................................................................................................SECTION 3
HYDRAULIC AND ELECTRICAL SYSTEMS ............................................................SECTION 4
AIR SYSTEM .............................................................................................................SECTION 5
BOOM AND FEED ASSEMBLIES .............................................................................SECTION 6
PRESSURE SETTINGS AND ADJUSTMENTS ........................................................SECTION 7
VENDOR SERVICE INFORMATION .........................................................................SECTION 8
HYDRAULIC ROCK DRILL REPAIR .........................................................................SECTION 9
LUBRICATION AND MAINTENANCE .....................................................................SECTION 10
Drill Serial No. :
Date Drill Delivered :
Dealer :
Customer :
Specifications are subject to change without notice.

Information contained in this manual was current at the time of printing.
10/19/2010
Introduction i
Introduction BI006823-00
Intended Use
This machine and its approved attachments are designed to drill blast holes for surface and underground
quarry, mining and construction applications. Use of this machine in any other way is prohibited and con-
trary to its intended use.
This safety alert symbol indicates important SAFETY MESSAGES in this manual. When you see
this symbol, carefully read the message that follows and be alert to the possibility of personal
injury or property damage.
DO NOT weld on any part of this machine without first disconnecting the negative battery cable
or place the battery disconnect switch in the open position. Disconnect the connections to the
Electronic Control Module (ECM) on the engine before welding.
Before Starting Engine, Study Operator's Manual

* Read and understand the warnings and cautions shown in Section 1
* Practice All Safety Precautions
* Make Pre-Operations Check
* Learn Controls Before Operating
It is Owner/Operator's responsibility to understand and follow manufacturer's instructions on ma-
chine operation and service, and to observe pertinent safety precautions, laws, and regulations.
California Proposition 65 Warnings
The following warning applies to equipment supplied with lead-acid batteries:
Battery posts, terminals and related accessories contain lead and lead compounds, chemicals
known to the State of California to cause cancer and reproductive harm. Wash hands after han-
dling.
The following warning applies to equipment supplied with diesel powered engines:
Diesel engine exhaust and some of its constituents are known to the State of California to cause
cancer, birth defects, and other reproductive harm.
ii Introduction
BI006823-00
Machine Specifications
Track Undercarriage
Two (2) hydraulic motor-driven compact planetary gear drives with manual disconnect for towing.
Complete with hydraulic released, spring applied automatic disc brakes, 15 in. (38 cm) wide, overlap-
ping, triple grouser tracks with mud/snow relief. Tram speed is 2.4 mph (4 km/hr.)
Engine
Caterpillar C9 300 hp (224 kW) diesel engine, 6-cylinder, water cooled, air-to-air aftercooled turbo-
charger. The engine speed is automatically controlled by power demand.
Cab
Certified ROPS/FOPS pressurized fixed cab complete with heater, air conditioner, wiper, drilling lights,
electronic two axis angle indicator and all necessary drilling controls. AM/FM stereo with CD player.
Hydraulic System
The system consists of two (2) direct driven pressure-compensated variable displacement, axial pis-
ton pumps, two (2) two-speed variable displacement traction drive motors. SmartDrill drilling control
system.
Air System
350 cfm @ 150 PSI (8.2 m3/min @ 10.2 bar) Gardner-Denver Rota-Screw Compressor driven by a
fixed displacement axial piston hydraulic motor.
Feed System
Model UHF16 Chain Feed, powered by a hydraulic piston motor complete with a power centralizer.
The feed will accept a 20 ft. (6.1 m) drill steel for single pass without a hose reel.
Rock Drill
Model HPR45 hydraulic percussion drill, 25 hp (19 kW), standard on R30C. For drilling holes up to 5
in. (127 mm) diameter. .
Boom
A 12.5 ft. (3.81 m) swing boom with 5 ft. (1.5 m) telescopic system complete with a drill positioner, a
3 ft. (0.9 m) feed extension and a feed table with retaining device. Boom swing angle capability of 70
L, 33 R deg.
Rod Changer
Linear rod changer for 5 (45 mm) or 4 (51 mm) 12 or 14 ft. (3.7 or 4.3 m) round rods for up to 72 ft.
(21.9 m) drill steel capability.
Additional Standard Features
• Fully Enclosed canopy
• Power Pickup Pot
• Angle Inclinator
• Dust Collector
Options
• Detergent System
• HPR51 Hydraulic Percussion Drill, 30 hp (23 kW)
Introduction iii
Component Locations BI006823-00
Fig. i-1 Right Side View of R30C

1. Detergent Tank 9. Feed Table Assembly
2. Engine Air Filter 10. Dust Collector Precleaner
3. Hydraulic Tank Filters 11. Feed Swing Cylinder
4. Cab Air Filter 12. Boom Lift Cylinder
5. Dust Collector 13. Air Receiver Tank
6. Boom Swing Cylinder 14. Hydraulic Tank
7. Feed Dump Cylinder 15. Hydraulic Pumps (2)
8. Feed Extend Cylinder 16. Pump Drive
Fig. i-2 Left Side View of R30C

17. Drill Slide Assembly 24. Track Oscillation Cylinder (2)
18. Feed Assembly 25. Outer Boom Tube
19. Upper Rod Rack 26. Inner Boom Tube
20. Cab 27. Positioner
21. Electrical Enclosure 28. Hydraulic Rock Drill
22. Engine Radiator Shunt Tank 29. Rod Wrench
23. Radiator/Cooler
iv Introduction
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Component Locations
Fig. i-3 Top View of R30C

30. Feed Drive Assembly 34. Fuel Tank
31. Breather, Hydraulic Tank 35. Air Receiver Tank
32. Batteries 36. Air Compressor
33. Caterpillar C9 Diesel Engine
Fig. i-5 Boom Mounted Angle Indicator
Fig. i-4 Lower Boom/Feed

1. Lower Rod Rack 4. Pendulum
2. Rope Pull Shutdown Switch 5. Centralizer
3. Pickup Pot
Introduction v
Component Locations BI006823-00
Fig. i-6 Valve Locations

1. Tram Valve
2. Boom/Feed Valve
Fig. i-7 Manifold Locations

1. Rod Changer Manifold
2. Auxiliary Manifold
vi Introduction
BI006823-00
Component Locations
Fig. i-9
Fig. i-8 Dust Collector Regulator and Blow Air Valve 1. Electronic Control Module (ECM)
1. Regulator (set at 80 PSI (5.5 bar)) 2. Plug-Ins–Disconnect from ECM before welding
2. Ball Valve
Fig. i-10 Hose Reel
Introduction vii
Notes BI006823-00
viii Introduction
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Section 1
Safety
Safety 1-1
Notes BI006823-00
1-2 Safety
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Hazard Classification
The hydraulic track drill is a heavy moving machine with a boom capable of extending its reach verti-
cally and horizontally. Like all moving objects and reach extending devices, there are potential hazards
associated with its use. These hazards will be minimized if the machine is properly operated, inspected,
and maintained. The operator's must read this manual and have been trained to use the machine in an
appropriate and safe manner. Non-English speaking persons must have an interpreter explain all safety
and operating procedures in this manual. Should any questions arise concerning the maintenance or
operation of the machine contact the manufacturer.
Safety Alert Symbol

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

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

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

minor or moderate injury.

property or equipment damage.
Safety 1-3
Safety Sign Symbols BI006823-00
Potential Hazard Prevention

Safety Alert Symbol. Used to alert See Operator's Manual for instruc-
you to potential personal injury haz- tions. If you do not understand the
ards. Obey all safety messages that information the manuals, consult
follow this symbol to avoid possible your supervisor, the owner, or the
injury or death. manufacturer.
Entanglement Hazard. Death Keep clear of rotating drill steel and

or serious injury can result from drivelines. Switch off engine before
contact with rotating drill steel and performing service.
drivelines.
Entanglement Hazard. Rotating Keep away from fan and belt when
parts can cause personal injury. engine is running. Stop engine be-
fore servicing.
Explosion / Burn Hazard. Will Keep all open flames and sparks
cause death, burns or blindness away. Wear personal protective
due to ignition of explosive gases or equipment, including face shield,
contact with corrosive acid. gloves and long sleeve shirt.
READ MANUALS
Read all manuals prior to opera-
tion.
Explosion Hazard. Death or seri- Do not use ether or other high en-
ous injury can result from the use of ergy starting aids. Engine equipped
ether or other high energy starting with grid heating system.
aids.
ous injury can result from the use ergy starting aids in compressor.
of ether or other high energy start-
ing aids.
Burn Hazard. Death or serious

injury can result from release of hot Keep away from flames.
pressurized liquids.
Relieve all pressure.
Allow to cool before performing ser-

vice on compressor.
1-4 Safety
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Safety Sign Symbols
Flying Object & Spray Hazard. Shut off live air at source, and re-
Death or serious injury can result lieve all pressure before removing
from release of pressurized liq- filler plug.
uids.
Flying Object Hazard. Serious Use guards.

injury or death can occur if drill is Keep in place.
operated without guards in place.
Flying Object Hazard. Serious Read and understand the proce-

injury or death can occur if track dures in the Operation and Main-
tension is adjusted improperly. tenance Manual before adjusting
track tension
Electrocution Hazard. Death or Maintain required clearance.

injury can result from contacting
electric power lines. See Table 1-1 in this manual.
Burn Hazard. Hot fluid under pres- Allow to cool before opening.
sure can scald.
Trip & Fall Hazard. Death or seri-

Keep off top of machine.
ous injury can result from tripping
and falling.
Fall Hazard. Death or serious injury Use the access system provided
can result from falling. when servicing the machine.
Safety 1-5
Safety Sign Symbols BI006823-00
Inhalation Hazard. Compressor Keep clear of compressor air dis-

discharge air is hazardous if inhaled. charge area.
Death or serious injury may result.
Injection Hazard. Escaping fluid Relieve pressure before disconnect-

under pressure can penetrate skin, ing hydraulic lines. Keep away from
causing serious injury. leaks and pin holes. Use a piece of
cardboard or paper to search for
leaks. Do not use hand.
Crush Hazard. Death or serious Keep clear of moving centralizer. Do

injury can result from contact with not actuate centralizer until person-
moving centralizer. nel are clear.
Crush Hazard. Death or serious Keep clear of moving machine.

injury can result from contact with
moving machine.
Crush Hazard. Death or serious Read and understand operator's

injury can result from contact with manual and all safety signs before
moving feed mast. attempting to remove feed mast
swing pin.
Drill Feed And Table Can Fall Always raise the drill feed and feed
causing serious injuries or death. table clear of all obstacles before
moving the machine. Raise them
high enough to allow for rough
ground or small hills.
Do Not allow anyone under the drill
feed or feed table unless machine
parts are not moving and are sup-
Caution. Do not use high pressure ported.
spray by electrical connections. Do Not attempt to repair a pivot
pin that has failed or has been
sheared.
1-6 Safety
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Safety Information
Before Operation
• Do study this manual and fully understand the controls.
• Do be sure all safety guards are securely in place. Replace any damaged or missing guards.
• Do be sure all nameplates and decals pertaining to safety, operation, and maintenance are in place
and not damaged. Replace any damaged or missing nameplates or decals. Refer to decal locator
drawings in this section.
• Do be sure all personnel are clear of the machine and work area before starting the engine or operat-
ing the machine.
• Do be sure drill area is clear of all obstructions before operating machine.
• Do attach safety chain when using towbar.
• Do wear safety helmet, glasses and hearing protection when operating or working on machine.
• Do Not operate machine with:
• Hydraulic or air leaks.
• Damaged hydraulic hoses or fittings.
• Broken or damaged electrical wiring.
• Damaged or missing guards and shields.
• Damaged structural members.
• Worn or damaged mechanical parts.
• Damaged or missing fasteners.
• Broken, damaged, or malfunctioning controls.
Operation
• Do examine the surface before drilling to determine the possible presence of unfired explosives.
• Do provide sufficient ventilation when running the engine in an enclosed area. Exhaust gases contain
carbon monoxide, a deadly poison, which is colorless and odorless.
• Do keep work area clean and clear of mud, snow, ice, fluids, hand tools and other objects.
• Do raise the drill feed before moving the machine. Raise it high enough to allow for rough ground or
small hills. Drill feed can fall causing serious injury or death.
• Do wear seat belt and operate machine with door closed on cab machines.
• Do use PPE (personal protection equipment) appropriate for the conditions you are working in; e.g.
safety helmet, safety glasses, hearing protection, gloves, respirator.
• Do maintain minimum clearance from high voltage wires (see Table 1-1). Check with power
company and local regulations for specific guidelines and safety information.
• Do Not use the machine for any other purpose than what it was designed for.
• Do Not wear loose clothing or jewelry; keep clothing and hands clear of moving parts.
• Do Not travel on steep inclines, soft or unstable ground, or close to unsupported excavations.
• Do Not move boom or machine if it is in a potentially unstable position.
• Do Not stand directly under a boom or feed.
• Do Not drill into or near a "bootleg" hole or any hole that may contain explosives.
Safety 1-7
Safety Information BI006823-00
After Operation
• Follow Shutdown Procedures given in Section 4 of this manual.
Maintenance
• Two people shall be present when performing service work, both being fully trained on safety issues.
One person shall supervise from the operator's position and have immediate access to an emergency
stop in all situations. Visual, audible or verbal communication signals shall be established and under-
stood by both persons.
• Do relieve pressure in the hydraulic or pneumatic systems before loosening connections or parts.
• Do use only proper tools to make repairs or adjustments.
• Do be sure of adequate lighting when performing service work at night.
• Do maintain a metal-to-metal contact between the fill nozzle and fuel tank when filling the fuel tank.
This will prevent sparks and the possibility of explosion.
• Do be sure each person is adequately trained to perform service and maintenance procedures.
• Do place a warning tag on starting controls to alert personnel that someone is working on the machine
and disconnect battery before making repairs or adjustments to machine.
• Do be sure machine and components are well supported before servicing or replacing parts.
• Do Not service, or perform maintenance, while machine is running, or capable of being started.
• Do Not hammer bit or drill steel. Use only proper tools to make repair or adjustments.
• Do Not weld or grind near oil, air, fuel lines, or batteries.
• Do Not smoke or use an open flame near batteries. Batteries can give off hydrogen which is a highly
explosive gas.
• Do Not direct high pressure cleaning agents or water on electrical connections.
Equipment Transfer
If all or part of the equipment is shipped to a new destination, always include a complete Operator's
Manual or a copy of the following topics:
• Safety Section
• Operation Instructions including:
Pre-Start Checks
Start-up Clearances from High Voltage Lines
After Start Checks Line Voltage Minimum Clearance
Shutdown Procedure 0 to 50 kv 10 ft (3 m)
Tramming Machine 50 to 200 kv 15 ft (4.6 m)
200 to 350 kv 20 ft (6.1 m)
350 to 500 kv 25 ft (7.6 m)
500 to 750 kv 35 ft (10.7 m)
750 to 1000 kv 45 ft (13.7 m)
Table 1-1 Minimum safe distances from high voltage lines.
1-8 Safety
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Safety Sign List
Machines Without Enclosures
Refer to Figures 1-1 to 1-4 for locations

Item Description Part No. Qty.
1 DANGER - Electrocution Hazard 429116 1
2 WARNING - Flying Object Hazard 429082 2
3 WARNING - Operation/Maintenance, Read Manual 428892 3
4 WARNING - Flying Object & Spray Hazard 429141 2
5 DANGER - Entanglement Hazard, Rotating Drill Steel 429115 2
6 NOTICE - Hydraulic Oil Requirements 429106 1
7 DANGER - Explosion Hazard 428896 1
8 NOTICE - Fueling 429471 1
9 WARNING - Burn Hazard, Hot Fluid 428897 1
10 DANGER - Inhalation Hazard 429491 1
11 WARNING - Burn Hazard 429405 1
12 DANGER - Flying Object Hazard 429119 2
13 WARNING - Fall Hazard, Operator's Seat 429087 1
14 WARNING - Drill Feed and Table Can Fall 409485 1
15 WARNING - Crush Hazard, Centralizer 429438 1
16 WARNING - Crush Hazard, Feed Mast 429084 1
17 NOTICE - Do Not Weld 429489 1
18 NOTICE - Grease Instructions 427967 1
19 WARNING - Explosion Hazard, Engine 429494 1
20 WARNING - Explosion Hazard, Compressor 429493 1
21 WARNING - Entanglement Hazard, Fan and Belt 428893 1
23 CAUTION - High Pressure Spray on Elect. Connections 429468 2
24 DANGER - Crush Hazard 428884 4
26 WARNING - Injection Hazard 428898 2
27 WARNING - Crush Hazard, Centralizer (Clear) 429938 1
28 DECAL - R30 Maintenance Summary 435214 1
(Ref. 431329 rev. C)
Safety Sign Maintenance

Replace any missing or damaged safety signs. Keep operator safety in mind at all times. Use mild
soap and water to clean safety signs. Do not use solvent-based cleaners as they may damage the
safety sign material.
Safety 1-9
Safety Sign Location BI006823-00
Without Enclosures
Fig. 1-1 Right Side of Machine
Fig. 1-2 Left Side of Machine
1-10 Safety
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Safety Sign Location
Without Enclosures
Fig. 1-3 Top View of Machine
Fig. 1-4 Front and Rear of Machine
Safety 1-11
Notes BI006823-00
1-12 Safety
BI006823-00
Safety Sign List
Machines With Enclosures

Refer to Figures 1-5 to 1-9 for locations
Item Description Part No. Qty.
1 DANGER - Electrocution Hazard 429116 1
2 WARNING - Flying Object Hazard 429082 2
3 WARNING - Operation/Maintenance, Read Manual 428892 3
4 WARNING - Flying Object & Spray Hazard 429141 2
5 DANGER - Entanglement Hazard, Rotating Drill Steel 429115 2
6 NOTICE - Hydraulic Oil Requirements 429106 1
7 DANGER - Explosion Hazard 428896 1
8 NOTICE - Fueling 429471 1
9 WARNING - Burn Hazard, Hot Fluid 428897 1
10 DANGER - Inhalation Hazard 429491 1
11 WARNING - Burn Hazard 429405 1
12 DANGER - Flying Object Hazard 429119 2
13 WARNING - Fall Hazard, Operator's Seat 429087 1
14 WARNING - Drill Feed and Table Can Fall 409485 1
15 WARNING - Crush Hazard, Centralizer 429438 1
16 WARNING - Crush Hazard, Feed Mast 429084 1
17 NOTICE - Do Not Weld 429489 1
18 NOTICE - Grease Instructions 427967 1
19 WARNING - Explosion Hazard, Engine 429494 1
20 WARNING - Explosion Hazard, Compressor 429493 1
21 WARNING - Entanglement Hazard, Fan and Belt 428893 1
22 WARNING - Fall Hazard 428885 1
23 CAUTION - High Pressure Spray on Elect. Connections 429468 2
24 DANGER - Crush Hazard 428884 4
25 WARNING - Trip & Fall Hazard 429548 4
26 WARNING - Injection Hazard 428898 2
27 WARNING - Crush Hazard, Centralizer (Clear) 429938 1
28 DECAL - R30 Maintenance Summary 435214 1
(Ref. 431331 rev. B)
Safety 1-13
Safety Sign Location BI006823-00
With Enclosures
Fig. 1-5 Right Side of Machine
Fig. 1-6 Left Side of Machine
1-14 Safety
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Safety Sign Location
With Enclosures
Fig. 1-7 Top View of Machine
Fig. 1-8 Front and Rear of Machine
Safety 1-15
Safety Signs BI006823-00
429119
428884
429491
429115
428896
429116
1-16 Safety
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Safety Signs
428892
429494
429082
429493
428893
429405
Safety 1-17
BI006823-00
Safety Signs
429548–Enclosure Machines Only

428885–Enclosure Machines Only
428897
429438
429938–Clear Background
429141
428898
1-18 Safety
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Safety Signs
429084
429468
409485
429087
Safety 1-19
Safety Signs BI006823-00
429471
429489
427967
429106
435214
1-20 Safety
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Section 2
Mainframe/Tracks
Mainframe/Tracks 2-1
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Notes
2-2 Mainframe/Tracks
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Track Oscillation Cylinders
DO NOT work on track system or undercarriage unless engine is off and controls are
locked out and machine is on level ground.
MAKE SURE machine and components are well supported before servicing or re-
placing parts.
RELIEVE PRESSURE on hydraulic or pneumatic systems before loosening connec-

tions or parts.
Fig. 2-1 Right Side View of R30C Fig. 2-2 Track Oscillation Cylinder Lower Pin (outside)
1. Track Oscillation Cylinder 2. Bolt, Pin Retaining
3. Pin
Track Oscillation Cylinders BI006823-00
Fig. 2-3 Lower Pin (inside) Fig. 2-4 Upper Pin (inside)
4. Bolt and Washer 5. Bolt, Pin Retaining
6. Upper Pin
Removal and Repair

For removal of track oscillation cylinder, the rear of the frame must be supported with substantial mate-
rial to handle the weight of machine. Place feed in a vertical position in the machine centerline, and stinger
planted firmly on the ground to support the front of the machine. If both oscillation cylinders are removed
at the same time, the machine can tip, if not supported adequately.
1. Remove the lower pin retaining bolt (item 2, fig. 2-2) from pin (item 3, fig. 2-2). Remove the bolt
and washer (item 4, fig. 2-3) from the pin that faces the inside of the machine.
2. Drive the pin out of the bore.
3. Start machine and retract cylinder rod all the way. Shutdown machine and relieve pressure. Tag
and remove the two hoses connected to the cylinder. Cap or plug all ports and hose ends.
4. Support the weight of the cylinder with a suitable lifting device. Cylinder weighs about 100 lbs.
(45.4 Kg.). Remove the upper pin retaining bolt (item 5, fig. 2-4) and drive out the upper pin (item
6, fig. 2-4). Lower cylinder slightly to clear the top support, tilt outward and remove from frame.
5. Refer to Section 8 of this manual for repair procedures. Refer to parts manual for your specific
machine for repair parts information.
Installation
Install cylinder in machine frame, rod end down. Hold cylinder in a supported manner (see instruction
above), install cylinder top pin first. Attach hoses to proper ports. With caution, operate control for oscilla-
tion until the cylinder rod end lines up to frame clevis. Install pin and bolt retainer.
BI006823-00
Track Maintenance
Idler, Track Rollers, Support Rollers

• There is no maintenance required on these units. These units are filled with oil and have metal to
metal seals that prevent the entering of dirt and the loss of oil.
Final Drive
• Every day, check that the parking brake is functioning properly.
• Check oil level every 200 hours of operation.
• Initial oil change is to be done after 200 hours of operation. Refer to final drive maintenance for
proper oil change procedure.
• Routine oil change is to be done at least once per year.
After a Long Period of Standstill

• Check oil level in final drive gearbox, refill as necessary. Refer to "Recommendation for Lubricating
Oil" in the final drive maintenance section.
After a Short Period of Operation

• Check the track chain tension, adjust as necessary according to procedure in this section.
• Check the idler and rollers for any signs of leakage.
• Check the oil level in the final drive, because oil is now distributed within the gearbox. Refill as nec-
essary.
After a Long Period of Operation

• Check the track chain tension regularly.
Track Tension Adjustment BI006823-00
Fig. 2-5 Track Tension Adjustment
BI006823-00
Track Tension Adjustment
Grease in the track adjusting cylinder is under high pressure. Grease coming out
of the relief valve of the track adjuster is under high pressure and can penetrate the
body causing personal injury or death.
When loosening the tension on the track, loosen the relief valve only one turn.
DO NOT visually inspect the relief valve to see if grease is being released from the
track adjuster. Instead, watch the track to see if it loosens. If the track does not loosen
after opening the relief valve, move the machine forward and backward to release the
tension.
The tracks are adjusted manually by applying grease to the tensioning cylinder through the grease fit-
ting. When properly adjusted, there should be a 1/2 to 3/4 in. (13 to 19 mm) space between a straight edge
laid across track directly above the center pivot and the top of the track grouser.
Adjust track tension as follows (see fig. 2-5):

If Track is Too Tight
1. Loosen grease relief valve one turn maximum. If track does not loosen after opening
the grease relief valve, move the machine forward and backward until tension is
released, then tighten grease relief and adjust as required.
If Track is Too Loose
1. Attach a grease gun to the grease fitting located inside the hole on the side of the
track.
2. Pump grease in until the track chain is properly adjusted. Do not overtighten the
track. See next page for torque specifications.
Proper Track Tension
If chain is too tight, it will cause increased wear of the bearings at the front idler and drive sprocket.
Also, wear will be increased at the bushings and pins of the track chain.
If chain is too loose, it will not fit properly on the idler and the chain will slide when tramming the ma-
chine. This sliding will cause rapid wear of the chain links.
Always check for correct sag in track chain per fig. 2-5.
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Metric Bolt Torque Specifications
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Track Assembly
Grease in the track adjusting cylinder is under high pressure. Grease coming out of
the relief valve of the track adjuster is under high pressure and can penetrate the body
causing personal injury or death.
tension.
Separate Track Chain Assembly

1. Put the machine on a flat level surface.
2. Release the tension on the track assembly (fig. 2-5). Access the track tensioner through the open-
ing in the track side frame. Loosen relief valve for the track adjuster only one turn. If the track
assembly does not loosen after opening the relief valve, move the machine forward and backward
until the tension is released.
To prevent possible injury during removal of master pin, keep away from the area out-
side the track assembly near the master pin. The master pin may come out of the track
links with force during the removal procedure.
3. Locate the master pin and position pin between the sprocket and support roller. It is easier to ac-
cess the pin by removing the track shoes directly above the pin. Drive the pin out with a hammer
and driving pin.
4. Remove the track chain in the direction of the sprocket.
Fig. 2-6 Master Pin –removal Fig. 2-7 Track Chain–removal
BI006823-00
Track Assembly
Track Link–Repair and Replace

1. Remove track shoe from damaged link.
2. Cut damaged link as shown in fig. 2-8 with a oxy/acetylene torch. Cut the chain completely through
the damaged area and lay the chain on the ground.
3. Now, cut the bushings and pins of the damaged link as shown in fig. 2-9.
Fig. 2-8 Cut out damaged link Fig. 2-9 Cut out links, bushings & pins as shown
4. Burn a hole into the center of the pin stumps and drive them out (fig. 2-10).
5. Cut off the ends of the bushing and grind smooth (fig. 2-11).
Fig. 2-10 Remove pin stumps Fig. 2-11 Grind bushings smooth
6. Before assembling the track link, be sure you have on hand the following new parts:
(1) Track Link, R.H.
(1) Track Link, L.H.
(1) Master Bushing
(2) Master Pins
(4) Master Collars
(4) Bolts and Nuts (for attaching Track Shoe)
BI006823-00
Track Assembly
7. Assemble the new parts using the following procedure (see fig. 2-12):
Be sure the links are facing the proper direction (see fig. 2-14).
A. Connect the track link by putting two

master collars in place as shown.
B. Attach the two ends by driving in the
master pin.
C. Place track chain onto track frame and
join the two ends by putting two master
collars in place as shown and driving in
the master pin.
D. Assemble track shoe to track chain with
the four bolts and nuts. Torque bolts
according to specifications listed in Bolt
Torque Chart in this section.
Fig. 2-12 Track Chain Assembly
8. Tension track chain according to procedure outlined previously.
Track Link–Description
Each track link is made up of the components shown in fig. 2-13. The links are pressed together to form
a compound unit, called the track chain.
Fig. 2-13 Track Link Assembly

1. Track Link–R.H., L.H. 2. Pin 3. Bushing 4. Master Collar
BI006823-00
Track Assembly
Track Link Position

Be sure, when assembling the track link, that the pin boss of the link always faces forward and the front
nose of the track shoe faces forward (toward the idler end).
Fig. 2-14 Track Link Position

1. "Nose" of track shoe
2. Pin boss of track link
Track Shoe (grouser)–Mounting to Track Chain

The purpose of this instruction is to describe the correct fastening procedure of the track shoe to the
track chain. Improper mounting procedure is the most common cause for track shoe failure.
1. Mounting surface of track chain must be clean and free of paint. Any damaged areas must be
ground smooth, so as not to protrude above the mounting surface. The same applies to the track
shoes.
BI006823-00
Track Assembly
Track Shoe (grouser)–Mounting to Track Chain (cont.)

2. Bolts and nuts must be free of nicks and burrs in the thread area. Threads must be lightly oiled to
maintain a proper and equal friction factor.
3. Before assembly, verify that the track chain and shoe will accept the same bolt size. Align the track
chain before starting.
4. Place track shoes on the track chain and insert bolts. Align the track shoes parallel with each other.
Hand start the nuts, making sure the rounded corners of the nuts are showing towards the track
link and the nuts are parallel to the securing edge of the nut seat.
NOTE When assembling in a workshop, the "straight torque" or "torque turn" methods can
be used as an option.
When assembling in the field, only the "torque turn" method can be used.
For either method, make sure the track shoes are not misaligned when torquing.
Use a criss-cross pattern when torquing the bolts.
After torquing all bolts, there is a possibility of contact between the track shoes on
certain profiles, which by design have a small gap. The same applies to extremely
wide shoes. The contact area is only permissible at the end of the shoes, in an area
not exceeding 10% of the total width.
Direct Torque Method

With an air wrench or a torque wrench, tighten the bolts to 11 ft. lbs. (15 Nm). When starting, make
sure to secure the nuts in the nut seat to keep from twisting. Next, proceed to torque the bolts with a torque
wrench or computer controlled torque system to the specified torque value as listed in the Grouser Bolt
Torque Chart (KN111) - Direct Method, in this section.
Torque Turn Method

With an air wrench or a torque wrench, tighten the bolts to 11 ft. lbs. (15 Nm). When starting, make
sure to secure the nuts in the nut seat to keep from twisting. Next, proceed to torque the bolts with a torque
wrench or computer controlled torque system to the specified torque value as listed in the Grouser Bolt
Torque Chart (KN111) - Torque Turn Method, in this section.
Now tighten the bolts by 1/3 of a turn (120 degrees).
When assembling the track shoes in the field, this method must be used because the final torque is not
done with a calibrated torque wrench and although the deviation may be small, the tightening of a third of
a turn more, gives the necessary clamping force independent for the required friction factor.
Track Shoe–Retightening
DO NOT merely retorque the bolts in the field. This would lead to failure of the joint due to the altered
friction factor and a reduced preload of the bolts.
The CORRECT METHOD of retightening the bolts, is to loosen the bolts until they turn freely. Now
torque the bolts using the "torque turn" method described above.
NOTE This can only be done once and only after a short time of machine operation (approxi-
mately 50 hours). After extended operation, loose bolts and nuts must be replaced
with new ones for safety reasons.
BI006823-00
Grouser Bolt Torque (Direct Torque Method)
Grouser Bolt Torque (Torque Turn Method)
BI006823-00
Track Assembly BI006823-00
Track Chain with Shoes
Fig. 2-15 Track Chain with Shoes

1. Track Link, R.H. (44) 5. Bushing (43) 9. Triple Grouser Shoe (44) 15 in. (380 mm)
2. Track Link, L.H. (44) 6. Master Collar (2) 10. Bolt, 5/8-18 NF X 2 (176)
3. Master Bushing (1) 7. Grease Seal (86) 11. Nut, 5/8-18 NF (176)
4. Pin (43) 8. Master Pin (1)
Track Chain and Shoe–Assembly and Installation

1. Align both links to each other (fig. 2-16).
2. Set pin in place and drive in until knurled end caught. Place a guiding pipe over the pin and using a
driving pin, drive in until both ends protrude the same amount (fig. 2-17).
3. Place the grousers on the track chain and be sure they are facing the right direction (see fig. 2-14).
Install grouser bolts (fig. 2-15) and tighten according to mounting procedure outlined previously.
Fig. 2-16 Align Links Fig. 2-17 Install Pin Fig. 2-18 Install Grousers
BI006823-00
Track Assembly
Track Chain and Shoe–Assembly and Installation (cont.)

4. Lay track chain with grousers attached, flat on ground. Place crawler assembly over track chain
(fig. 2-19) so that the idler is near the end of the track chain.
5. Pull the track chain over the crawler assembly from the sprocket end (fig. 2-20).
6. The end position should be the top of the idler (fig. 2-21).
Fig. 2-19 Crawler to track chain Fig. 2-20 Pull track chain over sprocket Fig. 2-21 End position of track
chain.
7. Grease two master collars and place in link pin boss (fig. 2-22).
8. Align the pin bores of the track links and insert pin (fig. 2-23).
9. Drive pin in all the way (fig. 2-24).
Fig. 2-22 Master collars–grease Fig. 2-23 Align pin bores and Fig. 2-24 Drive in pin
and install. insert pin.
10. This completes the track chain installation.
Crawler Carriage BI006823-00
Fig. 2-25 Crawler Carriage Assembly

2. Side Frame (1) 9. Bolt, M16 x 85 (32) 15. Support Roller (2)
3. Final Drive (1) 10. Idler Unit (1) 16. Bolt, M20 x 80 (4)
4. Bolt, M16 x 60 (18) 11. Bolt, M12 x 50 (2) 17. Washer, 21mm (4)
5. Washer, 17mm (72) 12. Washer, 13mm (2) 18. Chain Guide (1)
6. Sprocket (1) 13. Cover (1) 19. Bolt, M16 x 45 (4)
7. Bolt, M16 x 55 (18) 14. Bolt, M8 x 16 (2) 20. Track chain with shoes (1)
8. Track Roller (8)
Final Drive–General Description

The final drive is a 3-stage planetary gear drive which is totally enclosed. The bearings are protected
by special slide ring packings.
It has an internal multi-disc brake which is spring applied and released by hydraulic pressure. The brake
is therefore, maintenance free and no repair work should be done on the brake except by factory authorized
specialists. The brake unit should be exchanged for a complete unit.
BI006823-00
Final Drive Unit
Removal from Track Frame

1. Release track chain tension and separate track according to instructions at the front of this section.
2. Clean all dirt from parts and loosen the sprocket mounting bolts in a criss-cross pattern (fig. 2-26).
3. Place three puller screws in the corresponding holes (fig. 2-27) and tighten equally to loosen
sprocket. Remove sprocket with a proper lifting device.
Fig. 2-26 Sprocket Bolts–remove Fig. 2-27 Puller Screws (3)–install & tighten
4. Remove all but two of the final drive mounting bolts (fig. 2-28).
5. Attach a suitable hoist to the final drive (approximate weight is 185 lbs. [84 kg.]), remove the two
remaining bolts and lift the final drive free of the track frame (fig. 2-29).
6. Drain the oil from the final drive into a suitable container (fig. 2-30). The final drive holds 4.8 quarts
(4.5 liters)
Fig. 2-28 Final drive bolts–remove Fig. 2-29 Final drive–remove Fig. 2-30 Drain oil
BI006823-00
Final Drive
Installation into Track Frame

1. Clean all mounting surfaces thoroughly. Lift final drive into place with an adequate lifting device (fig.
2-31). Approximate weight is 185 lbs. (84 kg.).
2. Install M16 x 60 bolts and 17 mm washers, tighten hand tight only. Check to make sure the final
drive flange is seated properly. Now torque the bolts to 148 ft. lbs. (200 Nm), fig. 2-32. Tighten bolts
in the sequence shown in fig. 2-33. Final torque to be according to "Metric Bolt Torque Specifica-
tion" in this section.
Fig. 2-31 Install Final Drive Fig. 2-32 Tighten Mounting Bolts Fig. 2-33 Bolt tightening sequence
3. Fill final drive gearbox with clean oil of the specified type (see oil recommendations in this section).
The capacity is 4.8 quarts (4.5 liters). Position fill plug as shown in fig. 2-34 with drain plug at bot-
tom. Fill to bottom of filler hole. Check sealing condition of fill plug, replace if damaged.
4. Clean mounting surfaces for sprocket and lift into position with an adequate lifting device. Install
M16 x 55 bolts and 17 mm washers (fig. 2-35).
5. Tighten bolts (fig. 2-36) to specified torque according to "Metric Bolt Torque Specification" in this
section.
Fig. 2-34 Oil Filler Plug Fig. 2-35 Install Sprocket Fig. 2-36 Torque sprocket bolts
BI006823-00
Final Drive Maintenance
HOT OIL will burn. Always wear work gloves and let final drive cool down after a long
period of operation, before draining oil.
Place an "Out of Service" tag on the ignition switch before doing any service or main-
tenance work on the machine.
Drain oil into an approved container and dispose of according to local environmental
regulations.
Operation of final drive with low or incorrect oil may cause irreparable damage to the
gearbox. Follow recommended oil check and change intervals.
Oil Check/Change
1. Machine must be on level surface. Position final drive so drain plug is at bottom and fill plug is at
position shown in fig. 2-37.
Fig. 2-37 Final Drive Position

1. Fill Plug
2. Drain Plug
2. Remove fill plug and check oil. Oil should be at bottom edge of fill plug hole. Check to see that
sealing surface of fill plug is not damaged, and install plug.
3. Initial oil change is at 200 hours of operation.
4. Regular oil change interval is 300–2000 hours of operation, but not more than one year.
5. When changing oil, machine must be on level surface and final drive in position as shown in fig. 2-
37. Place an "Out of Service" tag on the ignition switch. Place a suitable container under the drain
plug (oil capacity is 4.8 quarts [4.5 liters]). Remove drain plug and fill plug.
6. Check sealing surface of drain and fill plug and replace if necessary. Install drain plug and fill with
correct oil type to bottom of fill plug hole. Install fill plug. Refer to recommended oil list on following
page.
Final Drive Oil BI006823-00
Specifications
• Use only the lubricants listed below or oil that meets the specifications in the chart on the next
page.
• Oil must meet the specification listed on the final drive label.
• For ambient temperatures of 50 to 86oF (10 to 30oC) use oil with a viscosity of
ISO-VG 150 or ISO-VG 220.
• If ambient temperature is 14 to 50oF (-10 to 10oC) use oil that is one viscosity class lower.
• If ambient temperature is 86 to 122oF (30 to 50oC) use oil that is one viscosity class higher.
Recommended Oils
ARAL Degol BG 150

Degol BG 220
AVIAAvilub RSX 150
BP Energol GR-XP 150
Energol GR-XP 220
CASTROL Alpha SP 150
Alpha SP 220
CHEVRON NL Gear Compound 150
NL Gear Compound 220
DEUTSCHE SHELL Omala EP 150
Omala EP 220
ESSO Spartan EP 150
Spartan EP 220
FINA Giran 150
Giran 220
FUCHS Renep Compound 104
GULF EP Lubricant Oil HP 150
EP Lubricant Oil HP 220
MOBIL GF 629 (Mobilgear 629)
GF 630 (Mobilgear 630)
TEXACO Meropa 150
TOTAL Carter EP 150
Carter EP 220
BI006823-00
Final Drive Oil
Final Drive Assembly BI006823-00
Fig. 2-38 Final Drive Assembly
BI006823-00
Final Drive Assembly
ITEM QTY. DESCRIPTION ITEM QTY. DESCRIPTION

1 1 Final Drive without motor 34 1 Roller Bearing
2 1 O-Ring 35 1 Hub
3 1 Housing 36 1 Roller Bearing
4 2 Capscrew 37 1 Duo-Cone Seal
5 1 Planetary Carrier (complete) 38 1 Beam
6 1 Washer 40 1 Brake (complete)
7 5 Spur Gear 41 1 Circlip
9 1 Pinion Gear 42 1 Sleeve
10 1 Planetary Carrier (complete) 43 11 Outer Disc
11 1 Washer 44 10 Inner Disc
12 3 Spur Gear 45 1 Circlip
14 1 Pinion Gear 46 1 Hub
15 1 Pinion Gear Shaft 47 1 Support Ring
17 1 Planetary Carrier (complete) 48 1 Support Ring
18 1 Washer 49 1 O-Ring
19 1 Spur Gear 50 1 O-Ring
22 1 O-Ring 51 1 Support Ring
23 1 Cover 52 1 Gasket
24 1 O-Ring 53 1 Gasket
25 1 Cover 54 1 Piston
26 1 Circlip 55 14 Spring
27 12 Capscrew 56 14 Spring
28 2 Screw Plug 57 1 Cover
30 1 Nut 58 1 Snap Ring
31 3 Shim Ring 59 1 Snap Ring
32 2 Shim Ring 61 1 O-Ring
33 1 Shim Ring 62 1 Hydraulic Motor
63 2 Capscrew
1 The circled item number represents a module that can be ordered as a complete unit.
2 The item number represents the spare part.
5-7 Those parts following the first item number are supplied with that part, but may also be ordered
separately.
Parking Brake–Description
• The multiple-disc parking brake is integrated as a complete unit into the gearbox. It must be re-
moved and installed as a complete unit. After any repair work on the brake, the brake line must be
bled.
• Minimum brake release pressure: 232 PSI (16 bar)
• Maximum brake release pressure: 4350 PSI (300 bar)
Final Drive Assembly BI006823-00
Fig. 2-38 Final Drive Assembly
BI006823-00
Final Drive Assembly
DO NOT service, perform maintenance or make adjustments while machine is running.

The parking brake is nonfunctional when the gear drive is disengaged for towing.
BE SURE machine is on level ground and secured from movement, i.e. via tow bar to
pulling vehicle prior to disengaging the gear drive and while re-engaging the gear drive.
Parking Brake–Removal and Installation

Refer to fig. 2-38
1. Be sure machine is on level ground and tracks are blocked to prevent movement of machine.
2. Drain oil from final drive into a suitable container. Oil capacity is 4.8 quarts (4.5 liters). Dispose of
old oil according to local regulations.
3. Remove capscrews (63) and hydraulic motor (62) from final drive. Remove snap ring (59).
4. Remove snap ring (26) and cover (25). To remove cover, remove one capscrew (27) and screw into
tapped hole in cover (25). Pull out cover.
5. Using same capscrew in step 4, screw into tapped hole in pinion gear shaft (15) and remove pinion
gear shaft.
6. Insert a brass drift through the opening in the front cover and drive the parking brake assembly (40)
out the back.
7. Installation is basically the reverse of removal.
8. Fill final drive with correct type of oil. See "Oil Check/Change" procedure in this section.
Towing Procedure–Gear Drive Disconnect

Refer to fig. 2-38.
1. Be sure machine is secured from movement before gear drive is disconnected, via tow bar at-
tached to towing vehicle or by blocking tracks. When drive is disconnected the brakes are non-
functional.
2. Place a drain pan or other suitable container under final drive cover, as some oil will be lost during
this procedure.
3. Remove snap ring (26) and cover (25). To remove cover, remove one capscrew (27) and screw into
tapped hole in cover (25). Pull out cover.
4. Using same capscrew as in step 3, screw into tapped hole in pinion gear shaft (15) and remove
pinion gear shaft.
5. Replace cover, snap ring and screw that was removed.
6. Repeat procedure for opposite side. DO NOT tow vehicle faster than normal machine tram speed.
7. Install pinion gear shaft (15) before disconnecting machine from towing vehicle or block tracks.
8. Top off final drive with correct oil type. See "Oil Check/Change" procedure in this section.
BI006823-00
Idler Unit
DO NOT attempt to replace the recoil spring.

Replacement of the recoil spring must be done by an authorized Intertractor dealer.
The recoil spring assembly is assembled with a force of several tons.
DO NOT put the recoil spring assembly under compression or release the tension with
the nut that holds the unit together.
Damaged threads on the spring carrier rod or nut can cause the assembly to come
apart with force, resulting in personal injury or death.
General Description
The idler unit consists of four sub-groups:
1. Idler Wheel
2. Sliding Block
3. Spring
4. Hydraulic Tensioner
Fig. 2-39 Idler Unit
1. The idler wheel is filled with oil and the running surface is induction hardened for reduction in wear.
2. The sliding block is designed so no dirt can enter the idler.
3. The spring is fixed to a cross bulkhead at the crawler sides. The function is to absorb the extreme
loading of the track chain. The spring is pre-tensioned
4. The hydraulic tensioner serves to tighten the track chain. When grease is pressed into the hydrau-
lic tensioner, the idler will be pushed against the track chain.
BI006823-00
Idler Unit
Fig. 2-40 Idler Assembly

2 1 Idler Wheel (complete) 14 1 Spring Carrier
3 1 Idler Wheel 15 1 Spring
4 2 Bushing 16 1 Plate
5 1 Plug 17 1 Nut
6 2 Seal (set of 2) 18 1 Hydraulic Tensioner (complete)
7 2 Sliding Rail 19 1 Cylinder
8 2 Clamping Sleeve (Roll Pin) 20 1 Grooved Ring
9 1 Shaft 21 1 Piston
10 2 O-Ring 22 2 Capscrew, M16 x 50
11 1 Spring Unit (complete) 23 2 Spring Washer
12 1 Fork 24 1 Grease Nipple
13 1 Disk 25 1 Usit Washer
BI006823-00
Idler Unit
DO NOT work on track system or undercarriage unless engine is off and controls are
locked out and machine is on level ground.
MAKE SURE machine and components are well supported before servicing or replac-
ing parts.
RELIEVE PRESSURE on hydraulic or pneumatic systems before loosening connec-

tions or parts.
DO NOT attempt to replace the recoil spring.

Replacement of the recoil spring must be done by an authorized Intertractor dealer.
The recoil spring assembly is assembled with a force of several tons.
DO NOT put the recoil spring assembly under compression or release the tension with
the nut that holds the unit together.
Damaged threads on the spring carrier rod or nut can cause the assembly to come
apart with force, resulting in personal injury or death.
Removal and Disassembly

1. Separate track chain. Follow instructions outlined previously.
2. Clean dirt from all parts. Using an adequate lifting device, pull out the complete idler unit (fig. 2-41).
3. Remove the bolts that hold the hydraulic tensioner to the track frame bulkhead and remove ten-
sioner from underneath track frame (fig. 2-42).
Fig. 2-41 Idler Unit–removal Fig. 2-42 Hydraulic Tensioner–removal
BI006823-00
Idler Unit
Removal and Disassembly (cont.)

4. If the recoil spring unit is defective, remove it from the sliding block (fig. 2-43) and exchange it for a
new or repaired unit.
DO NOT ATTEMPT TO REPAIR THE RECOIL SPRING UNIT. Any repair to the recoil spring unit
must be done by an authorized Intertractor dealer. Repairs must be carried out in a shop, equipped
with a fixture for this purpose and must be done by qualified personnel.
5. To make further repairs to the idler, remove the sliding block (fig. 2-44).
6. To disassemble the idler components, refer to "Idler Assembly" instructions and carry out procedure
in reverse order.
Fig. 2-43 Recoil Spring–removal Fig. 2-44 Sliding Block–removal
Idler Unit BI006823-00
Assembly and Installation

(Refer to fig. 2-40 for complete assembly and reference to item numbers.)
1. Clean all parts thoroughly and be sure all mounting surfaces are free of nicks or burrs. Press bush-
ings (4) into idler wheel (3). Fig. 2-45.
2. Place seals (6) into bores of idler wheel (3) and sliding rails (7). Fig. 2-46. Be sure the lip of the
seal faces the direction shown in fig. 2-40.
NOTE If reusing the old seals, be sure to mark them, so they go back into the same bore
they came out of. Otherwise they may not seal properly.
3. Place the two o-rings (10) in the grooves on the shaft (9). Connect shaft with one sliding rail (7).
NOTE The oil groove (A) must face towards the rear.
Fig. 2-45 Fig. 2-46 Fig. 2-47

3. Idler Wheel 3. Idler Wheel 7. Sliding Rail
4. Bushing 6. Seal 9. Shaft
7. Sliding Rail 10. O-Ring
4. Align hole in shaft with hole in sliding rail and install clamping sleeve (8). Fig. 2-48.
NOTE Some units may have the hole drilled through the side of the rail and some may have
the hole drilled through the front of the rail.
5. Install the idler wheel onto the shaft (fig. 2-49).
Fig. 2-48 Shaft - install into sliding rail Fig. 2-49 Idler Wheel–install onto shaft
7. Sliding Rail 8. Clamping Sleeve
BI006823-00
Idler Unit
Assembly and Installation (cont.)

6. With the seals (6) installed and facing the correct way according to fig. 2-40, install the other sliding
rail (7) and install the clamping sleeve (8) as in step 4. Fig's. 2-50 and 2-51.
Fig. 2-50 Install other sliding rail Fig. 2-51 Install clamping sleeve (8)
7. Position idler wheel so fill plug (5) is about 45 degrees from vertical. Remove plug with a 6 mm al-
len wrench and fill idler with SAE-90 oil until oil runs out of hole. Install plug and tighten (fig's. 2-52
and 2-53).
8. Install sliding block to sliding rails with capscrews and tighten (fig. 2-54).
Fig. 2-52 Idler wheel–fill with oil Fig. 2-53 Filler plug–install Fig. 2-54 Sliding block–install
BI006823-00
Idler Unit
Assembly and Installation (cont.)

9. Install spring unit (11) to sliding block with capscrews (22) and spring washers (23). Fig. 2-55.
Torque capscrews according to "Metric Bolt Torque Specifications" in this section.
10. Install washer (25) and screw the grease nipple (24) into the hydraulic tensioner (18) and tighten
(fig. 2-56).
11. Install hydraulic tensioner (18) from under track frame and attach to frame bulkhead with cap-
screws (fig. 2-57). Torque capscrews according to "Metric Bolt Torque Specifications" in this sec-
tion.
Fig. 2-55 Spring Unit–install Fig. 2-56 Grease Nipple–install Fig. 2-57 Hydraulic tensioner–
18. Hydraulic Tensioner install in track frame
24. Grease Nipple
12. Install complete idler assembly into track frame using a suitable lifting device (fig. 2-58). Push idler
assembly back until the spring unit touches the hydraulic tensioner (fig. 2-59).
Fig. 2-58 Idler assembly–install Fig. 2-59 Spring unit–touches hydraulic tensioner
13. Install track chain by following instructions given previously under "Track Chain & Shoe–Assembly
and Installation".
BI006823-00
Track Rollers
General Description
The track roller unit serves two purposes:
1. To guide the track chain and therefore lead the dynamic forces of the track chain to the ground.
2. To absorb the loads coming from the machine itself.
The roller is specially designed and surface hardened.
The roller also has special metal to metal seals which prevent dirt from entering the roller body.
Fig. 2-60 Track Roller Unit

1. Roller Body
2. Metal to Metal Seals
BI006823-00
Track Rollers
tension.

1. Release track chain tension, by loosening the grease nipple on the track tensioner. Refer to "Track
Tension Adjustment" at the front part of this section.
2. Using an adequate lifting device, lift crawler frame off of track chain high enough to gain access to
the track rollers for removal (fig. 2-61). Support track frame with an adequate support so it can not
fall.
3. Clean all dirt and debris from track rollers.
4. Remove attaching bolts and remove track roller from frame (fig. 2-62). If track frame is fitted with a
chain guide, it will have to be removed first.
Fig. 2-61 Track frame–lift Fig. 2-62 Track roller–remove
5. To disassemble track roller, refer to "Track Roller–Assembly" instructions and carry out procedure
in reverse order.
BI006823-00
Track Rollers
Track Roller Assembly
Fig. 2-63 Track Roller Assembly

1 8 Track Roller (complete) 6 1 Shaft
2 2 Bracket 7 1 Roller Body (complete)
3 2 Clamping Sleeve (Roll Pin) 8 1 Roller Body
4 2 Seal (set of 2) 9 1 Plug
5 2 O-Ring 10 2 Bushing
BI006823-00
Track Rollers
Track Roller–Assembly
1. Clean all parts thoroughly and press the bushings (10) into the roller body so that the oil grooves in
the bushing are aligned with the oil fill plug (9).
2. Place the seals (4) in position in the roller body (8) and brackets (2), fig. 2-65. Be sure the seal lips
face the proper direction as shown in fig. 2-63.
NOTE If reusing the old seals, be sure to mark them, so they go back into the same bore they
came out of. Otherwise they may not seal properly.
3. Install o-rings (5) onto shaft (6). Install shaft into one bracket (2) making sure the oil groove (A)
faces the same direction as the mounting surface (B) of the bracket (2), fig. 2-66.
Fig. 2-64 Bushing–install Fig. 2-65 Seals–install Fig. 2-66 Shaft–install

8. Roller Body 8. Roller Body 2. Bracket
10. Bushing 4. Seals (2 per side) 5. O-Ring (2)
8. Roller Body 6. Shaft
4. Align hole in shaft (6) with hole in bracket (2) and install clamping sleeve (3).
NOTE Place a block of wood under the bracket when driving in clamping sleeve to avoid
damage to the seal retainer.
5. Push assembled shaft into roller body (fig. 2-67).

6. Install other bracket (2) onto shaft, align holes as in step 4 and drive in clamping sleeve (3) with
wood block under bracket (fig. 2-68).
Fig. 2-67 Shaft–install into roller body Fig. 2-68 Clamping Sleeve–install
2. Bracket 3. Clamping sleeve
BI006823-00
Track Rollers
Track Roller–Test and Install

7. Check the end play. Check for air tightness by inserting air pressure through the oil fill hole. Test
pressure should be not more than 87 PSI (6 bar). Fig. 2-69.
8. If the air test is satisfactory, with no air leakage around the seals, fill roller with SAE 90 oil through
the oil fill hole (fig. 2-70).
9. Hold the roller in such a way so the oil groove is at the bottom and the oil fill hole is at the top. Now
inset air pressure into the roller as in step 7 so the oil is pressed into the seal retaining spaces (9).
Fig. 2-71.
Fig. 2-69 Track roller–air leakage Fig. 2-70 Track roller–oil fill Fig. 2-71 Track roller–air/oil
test 1. Oil 1. Oil 9. Seal retaining spaces
10. After filling with oil, check for correct level (fig. 2-72).
• MAX Oil Level -
Turn the roller so the oil fill hole is 40o from a horizontal line through the center. Oil should not
spill out of the oil fill hole in this position.
• MIN Oil Level -
Turn the roller so the oil fill hole is 10o from a horizontal line through the center. Oil MUST spill
out of the oil fill hole in this position.
11. Apply loctite on the threads of the oil fill plug and install with a 6 mm allen wrench (fig. 2-73).
12. Install track roller assembly on track frame (fig. 2-74). Torque capscrews according to "Metric Bolt
Torque Specifications" in this section.
13. Remove supports and lower track frame onto track chain. Adjust track tension according to "Track
Fig. 2-72 Track roller–oil level Fig. 2-73 Track roller–fill plug Fig. 2-74 Track roller–install
Support Rollers BI006823-00
General Description
The purpose of the support roller is to guide the track chain.
The roller is specially designed and surface hardened.
The roller has special metal to metal seals which prevent dirt from entering into the roller shell.
Fig. 2-75 Support Roller Unit

1. Roller Shell
2. Metal to Metal Seals
BI006823-00
Support Rollers
tension.

1. Release track chain tension, by loosening the grease nipple on the track tensioner. Refer to "Track
2. Using an adequate lifting device, lift the track chain up off the support roller. Support track chain so
it cannot fall.
3. Clean all dirt and debris from support rollers.
4. Remove attaching bolts and with an adequate lifting device, remove support roller from frame (fig's.
2-76 & 2-77).
Fig. 2-76 Support roller–remove mounting bolts Fig. 2-77 Support roller–remove
5. To disassemble support roller, refer to "Support Roller–Assembly" instructions and carry out proce-
dure in reverse order.
BI006823-00
Support Rollers
Support Roller–Assembly
Fig. 2-78 Support Roller–Assembly

1 2 Support Roller (complete) 9 1 Seal
2 1 Roller Body (complete) 10 1 Gasket
3 1 Shaft (complete) 11 1 Thrust Washer
4 1 Seal (set of 2) 12 1 Roller Body
5 1 Retainer 13 1 Collar Bushing
6 1 Spacer 14 1 Bushing
7 1 Cover 15 1 Shaft
8 5 Capscrew M10 x 22
BI006823-00
Support Rollers
Support Roller–Assembly
1. Clean all parts thoroughly and press in the collar bushing (13) from the front side of the roller body
(2). Press in the bushing (14) from the rear of the roller body (fig. 2-79).
2. Place the seals (4) into the retaining seats of the roller body (12) and retainer (5). Be sure the seals
face the proper direction as shown in fig. 2-79.
NOTE If reusing the old seals, be sure to mark them, so they go back into the same bore they
came out of. Otherwise they may not seal properly.
3. Put retainer (5) onto back of shaft (15) and push the shaft into the roller body (fig. 2-80).
4. Place thrust washer (11) on shaft end and secure with two capscrews (8). Fig. 2-81. Torque cap-
screws according to "Metric Bolt Torque Specifications" in this section.
Fig. 2-79 Support roller–bushings Fig. 2-80 Support roller–install on shaft

and seals installation 5. Retainer
2. Roller Body
4. Seals
5. Retainer
13. Collar Bushing
14. Bushing
Fig. 2-81 Thrust washer–install

11. Thrust Washer
Support Rollers BI006823-00
Support Roller–Assembly (cont.)

(Refer to fig. 2-78 for item number reference.)
5. Place gasket (10) on front of roller body (2) and align with the three cover screw holes, then install
cover (7) and two capscrews (8). Leave out one capscrew (8) and seal (9) to allow for oil filling (fig.
2-82). Torque capscrews according to "Metric Bolt Torque Specifications" in this section.
6. Fill roller body with SAE 90 oil through the cover capscrew hole until oil runs out (fig. 2-83). Install
the third capscrew (8) and seal (9) and tighten. Place spacer (6) on the shaft at the rear side of the
roller (fig. 2-84).
Fig. 2-82 Support roller–cover & gasket installation Fig. 2-83 Support roller–oil fill
7. Cover 10. Gasket
Fig. 2-84 Support roller–oil fill screw & spacer Fig. 2-85 Support roller–install
6. Spacer 8. Capscrew 9. Seal
7. Install support roller on track frame (fig. 2-85). Torque capscrews according to "Metric Bolt Torque
Specifications" in this section.
8. Remove supports and lower track chain down on top of rollers. Adjust track tension according to
"Track Tension Adjustment" at the front part of this section.
BI006823-00
Section 3
Power Train
Power Train 3-1

BI006823-00
Fuel System
Fig. 3-1 Caterpillar Engine Model C9

1. Fuel Filter 3. Fuel/Water Separator
2. Fuel Priming Pump
Fig. 3-2 Fuel Tank Assembly (ref. 428263 rev. B)

1. Fuel Supply 7. Thermostatic Valve for Compressor Oil
2. Breather 8. Compressor Oil Filter
3. Fuel Return 9. Thermostatic Valve for Hydraulic oil
4. Filler Cap 10. Fuel Level Sender
5. Transducer Manifold 11. Hydraulic Oil Return Manifold
6. Fuel Level/Temp. Gauge
3-2 Power Train
BI006823-00
Fuel System
Fuel Filter–Installation
FIRE HAZARD–Fuel leaked or spilled onto hot surfaces or electrical components can
cause a fire.
Turn the battery disconnect switch OFF or remove battery cables when changing fuel
filters.
Every 250 hours: Change fuel filter, see fig. 3-1.
NOTE It is highly recommended that only Caterpillar filters be used for replacement.
Other brands may fit, but are not made to Caterpillar specifications, and shortened
injector and engine life will result.
Never pre-fill a new filter when installing as this allows some fuel to bypass the filter
altogether.
1. Stop engine.
2. Turn battery disconnect switch OFF or remove battery cables.
3. Remove old filter element and discard.
4. Clean the gasket sealing surface of the filter base. Make sure old gasket is not stuck to the sur-
face.
5. Apply clean diesel fuel or oil to new fuel filter gasket.
6. DO NOT fill fuel filter with fuel before installing. Install filter until gasket contacts the base, then
tighten 3/4 turn more by hand. Do not overtighten.
7. Wipe up any fuel or oil spills.
8. Turn battery disconnect switch ON or connect battery cables.
9. Machines with electrical priming system, it will automatically prime.
10. Start engine and check for leaks.
NOTE There should be enough residual fuel in the head for the engine to start. If the engine
runs then stops, crank the engine for 30 seconds, then allow starter to cool for 2 min-
utes. Repeat until engine runs smoothly and continuously.
Fuel Tank
The fuel tank has a capacity of 136 gallons (515 L). A fuel level indicator (sight tube) is mounted on the
left side of the tank and a fuel sender and fuel gauge is provided. The engine is equipped with a fuel/water
separator (3, fig. 3-1) to remove water from fuel. Drain daily.
Power Train 3-3

Fuel System–Maintenance BI006823-00
Fuel Contamination Control

Dirty Fuel
Dirty fuel can rob the engine of power, accelerate wear on fuel system components and reduce fuel ef-
ficiency. As little as one spoonful of dirt in a tank of fuel can ruin an injector in eight hours.
The two most critical areas affected by dirty fuel are:
1. Injector Plunger and Barrel
2. Control Valves
Sources of Fuel Contamination

1. Fuel–Make sure to use a reliable fuel supplier. Demand periodic fuel sampling and testing to as-
sure consistent quality for top performance. Use No. 2D diesel fuel with low sulfur (0.05% maxi-
mum) or regular sulfur (0.5% maximum). No. 1 grades are acceptable.
2. During Operation–In dusty applications, airborne contaminants can be drawn into your fuel tank
through the vent tube. Contaminants can also develop during storage or through improper fuel
transfer.
3. During Service–Any time the fuel system is open, whether to make repairs or changing filters, con-
taminants can enter the system.
How to Minimize Fuel System Contamination

During Storage and Transfer
Proper storage and handling procedures are essential to keep contaminants out of the fuel system.
Steps to take to help keep fuel clean:
1. Periodically drain and flush all fuel storage containers, including tanker trucks and stationary tanks.
This will remove sediments that can easily enter the fuel system.
2. Keep all fuel nozzles, hoses and other equipment clean. Clean around fuel fill cap before removing.
3. Maintain all hoses, gaskets and seals in the fuel storage and transfer equipment.
4. Use and maintain line filters on all fuel transfer equipment.
5. Never transfer fuel with buckets, funnels or other open containers.
6. Only purchase fuel from a reliable, reputable source. Demand periodic testing to assure a consis-
tently high quality product.
3-4 Power Train

BI006823-00
Fuel System–Maintenance
How to Minimize Fuel System Contamination (cont.)

During Operation
It is the responsibility of everyone from the machine operator to the maintenance technician to keep fuel
contamination to a minimum.
Daily Checklist
1. Repair any fuel line leaks immediately. If fuel is leaking out, contaminants can get in.
2. Never operate machine without the properly installed fuel cap. Replace any defective gaskets or
replace damaged cap.
3. Make sure fuel tank vent tube is open and breather is clean and installed properly.
4. Do not run machine out of fuel; this can draw sediment from the bottom of the tank into the fuel
system.
5. Be aware of any unexplained power loss, excessive smoke or hard starting, especially when the
engine is warm. Have engine checked out by qualified service personnel immediately.
When Changing Filters

1. Maximize filtration by using only OEM (Original Equipment Manufacturer) high efficiency fuel filters.
2. Follow the recommended change interval. If premature filter plugging occurs, consider fuel quality
or other contamination sources.
3. Remove filters carefully, making sure not to knock dirt and debris from the engine compartment into
openings.
4. Keep filters packed in their original box until they are installed.
During Service and Maintenance

Many fuel system failures occur immediately after the engine has been serviced. Planning and prepara-
tion are the keys to keeping contaminants out of the engine when it is "open" for service.
Steps to help minimize contamination entering the fuel system:

1. Clean dirt, dust and other debris from the engine compartment before performing service. Use high
pressure wash to blast away mud, dust, dirt and other built-up grime off the engine before "open-
ing" the engine for repairs.
2. Tightly cap or plug all openings during repairs, even if only for a few minutes.
3. Clean reusable parts with solvents, using proper cleaning and drying methods.
4. Never place components directly on the ground.
5. Keep new parts in their original package until ready to use.
6. Do not reuse seals, always replace them.
7. Perform routine inspection of fuel line and connections and make repairs immediately.
8. Maintain a regular schedule for draining and cleaning machine fuel tank. Do this weekly for severe-
ly dusty conditions, every 3 months for normal conditions.
Power Train 3-5

Engine Oil–Caterpillar C9 BI006823-00
HOT OIL can burn, avoid direct contact.

Avoid prolonged and repeated skin contact with used engine oil. Skin disorders can result
from repeated and prolonged contact. Wash thoroughly after skin contact.
Some state and federal agencies have determined that used engine oil can be carcinogenic
and cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged
contact with used engine oil.
Fig. 3-3 Caterpillar C9 Engine (injector side)

1. Oil Filter 2. Oil Fill Tube 3. Oil dipstick
Change Oil and Filter–Every 250 Hours

1. Be sure machine is on level ground. Operate engine until warm. Shut off engine and place a con-
tainer under drain plug. Oil capacity for C9 engine is 32 qts. (30 L).
2. Remove drain plug or open drain valve (if equipped). Drain all oil into container and dispose of
according to local regulations. Install drain plug. Do not overtighten. Torque to 22 ft. lbs. max. (30
Nm).
3. Clean area around the filter and remove oil filter (1, fig. 3-3). Check to be sure old filter gasket is
not stuck to filter head.
4. Apply a light film of oil to the gasket where it will contact the filter head. Do not fill filter with oil be-
fore installing. Tighten by hand according to instructions on the filter.
5. Fill engine with high quality multi-viscosity lubricating oil. Use correct oil for your operating environ-
ment. See engine manual or Lubrication section in this manual for correct oil.
6. Crank engine to fill oil filter(s), but do not start. Do not crank engine for more than 30 seconds. Start
engine and operate at low idle. Check for leaks. Stop engine and wait 10 minutes to let oil drain
back down into crankcase. Check oil level, and add if required.
3-6 Power Train

BI006823-00
Engine Radiator–Caterpillar C9
Engine Radiator–Capacity and Service

MAKE SURE machine and components are well supported before servicing or replacing
parts.
DO NOT perform service work on radiator or oil coolers when system is hot. Allow time
for system to cool before any service procedures are performed.
Cooling system capacity is 12 gallons (45.4 liters).

• Radiator 2.1 gal. (8 L)
• Shunt Tank 5 gal. (19 L)
• Engine 4.9 gal. (18.5 L)
Machine is factory filled with a 50/50 mixture of ethyl-

ene glycol anti-freeze and water. This brings the engine
cooling system down to -34oF (-37oC). Check and adjust
mixture as required for ambient conditions.
Add 2 qts. engine conditioner (P/N 1405131) or

equivalent per Caterpillar Engine Manual.
Fig. 3-6 Left Rear View of Machine

1. Radiator/Oil Coolers
2. Radiator Shunt Tank
Fig. 3-7 Radiator Shunt Tank

1. Shunt Tank
2. Coolant Sight Glass
3. Radiator Cap/Coolant Fill Neck
Power Train 3-7

BI006823-00
Coolers
Coolant Specifications
Propylene Glycol
Protection
Concentration Anti-Freeze Anti-Boil
o
% Glycol/% Water F (oC) o
F (oC)
30/70 5 (-15) 216 (102)
40/60 -9 (-23) 219 (104)
50/50 -34 (-37) 222 (106)
Ethylene Glycol
Protection
Concentration Anti-Freeze Anti-Boil
o
% Glycol/% Water F (oC) o
F (oC)
30/70 5 (-15) 219 (104)
40/60 -12 (-24) 222 (106)
50/50 -34 (-37) 226 (108)
60/40 -62 (-57) 231 (111)
Freezing point curve for typical ethylene glycol solution.
Cooler Maintenance
• Check coolers every week for debris build up that will block cooler air flow.
• Clean cooler assemblies as required or at least every 200 hours. Steam clean from both directions
to be sure all dirt and debris is removed.
3-8 Power Train

BI006823-00
Cooler Service
Cooler Assembly
Fig. 3-8 Cooler Installation (ref. 432768 rev. A)

1. Cooler Assembly 17. Stabilizing Bracket
2. Hexhead Capscrew 18. Guard Mounting Bracket
7. Locknut 23. Top Cooler Mount
14. Water Hose 27. Belt Guard
Fig. 3-9 Radiator/Oil Cooler Assembly (ref. 420437)
Power Train 3-9

BI006823-00
Cooler Service
Removal and Installation

MAKE SURE machine and components are well supported before servicing or replac-
ing parts.
BE SURE the hydraulic and pneumatic systems are not pressurized before loosening
any connections or parts.
DO NOT perform service work on radiator or oil coolers when system is hot. Allow time
for system to cool before any service procedures are performed.
1. Allow time for system to cool down, drain coolant from radiator into a suitable container. Capacity
of radiator is 2.1 gal (8 L). Capacity of shunt tank is 5 gal (19 L).
2. Tag and remove all lines to radiator and coolers. Cap or plug all openings in hydraulic lines. Re-
move hose (14) from shunt tank.
3. Remove belt guard (27). Remove finger guard from fan shroud.
4. Remove cooler cover if equipped (fig. 3-10).
5. Remove stabilizer brackets (17) and cooler cover bracket (18).
6. Attach lifting straps to top cooler mounting brackets (23) and support cooler assembly (1) with a
suitable lifting device.
7. Remove the four capscrews (2) and locknuts (7) that secure the cooler to the frame. Carefully lift
the cooler from the frame.
8. The cooler can now be separated for repair work.
9. Installation is basically the reverse of removal.
Fig. 3-10 Cooler Cover–on machines without removable enclosures (ref. 422028)
3-10 Power Train

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Hydraulic Pumps
MAKE SURE machine and components are well supported before servicing or replacing
parts.
Fig. 3-11 Hydraulic Pumps and Lines

1. Dust Collector Pump
2. Pump Discharge to Pressure Manifold Lines
3. Pump Case Drain Lines
4. Tandem Hydraulic Pumps
5. Gauge Ports to Pressure Gauges above Pumps.
6. Pump Compensators (set to 3200 PSI (220 bar))
7. Supply Lines from Hydraulic Tank
8. Supply Line from Hydraulic Tank
9. Pump Discharge Line to Dust Collector Manifold
Power Train 3-11

BI006823-00
Hydraulic Pumps
Fig. 3-12 Cat C9 Power Pack Assy (ref. 428261)

1. Tandem Pumps
3. Suction Lines from Hydraulic Tank Fig. 3-13 Top of Hydraulic Tank
4. Pump Drive 1. Filter with Pressure/Vacuum Valve
Hydraulic Pumps–Removal and Installation

1. Clean all fittings and flange surfaces before removal.
NOTE If the hydraulic tank is not going to be drained, apply a vacuum source to the tank
before removing the lines to the pumps. Have all necessary parts on hand to complete
the job as quickly as possible.
2. Remove the hydraulic tank filter with pressure/vacuum valve (1, fig. 3-13). Attach vacuum pump
where filter was removed and apply vacuum.
3. Tag and remove all lines to pump(s). Cap and plug all hose and fitting connections.
4. With suitable lifting device in place, remove the two bolts that hold the pumps to the pump drive.
Remove pump from pump drive. Repair or replace pump(s) quickly while maintaining vacuum on
hydraulic tank. If it will be some time before repairs are completed; make a plate and gasket to
seal off the suction flange fitting to the pumps. This should prevent leakage after vacuum pump is
removed.
6. Installation is reverse of removal. Be sure pump case(s) is filled with new hydraulic oil upon instal-
lation. Prime pumps after installing by turning engine over for 5 seconds, pause for 5 seconds and
turn over for additional 5 seconds. Be sure to install hydraulic tank filter and add hydraulic fluid to
tank if required.
7. Start machine and let warm up a few minutes. Switch the Control System Switch in the cab ON.
Plug one pump compensator line and with the other line open, adjust that compensator (6, fig. 3-
11) to 3200 (220 bar). Adjust the other compensator in the same manner.
NOTE Be sure o-rings are present in the tank suction lines and properly installed.
3-12 Power Train

BI006823-00
Hydraulic System Service
Fig. 3-14 Hydraulic Oil Lines and Components

1. Pump Pressure Lines 6. Drain Manifold
2. Return Filters 7. Return Manifold
3. Return Lines 8. Pressure Manifold
4. Line to Oil Cooler 9. Hydraulic Oil Tank–110 Gal. (416 L)
5. Thermostatic Valve
Hydraulic Oil Change Procedure

This procedure is used to change hydraulic oil from one type to another, or to remove contaminated
hydraulic oil. This procedure uses a calculated timing sequence for some steps. It is important to move
control valves to FULL ON position and leave on for the prescribed minimum time.
NOTE Clean all areas around hoses and fittings before removing them.
1. Drain oil from the hydraulic tank into a suitable container. Hydraulic tank holds 110 gallons (416 L).
Inspect or clean tank if necessary. Fill with new hydraulic oil.
2. Remove a 3/4 in. SAE plug from the return manifold (7) and install a fitting and a 3/4 in. hose.
Route the hose down and through the tracks.
NOTE It is important to route the hose as low as possible as draining the oil requires grav-
ity flow from some areas. Direct the hose into a clean 5 gal (19 L) container. Be sure
container is clean if oil is to be reused.
3. Position suitable containers under the tandem hydraulic pumps and remove the two oil supply lines
coming from the tank and allow pump cases to empty. Install the lines and tighten securely.
Power Train 3-13

BI006823-00
Hydraulic Oil Change Procedure–cont.

4. Remove the hose from the top of the hydraulic oil cooler (4); this allows air to enter to drain the
hydraulic oil cooler.
NOTE Air will be heard entering and oil will flow into the container installed in Step 3.
5. Position a thin pan under the hoses to the return filters on top of the hydraulic tank and remove the
two inlet hoses (3) from the return filters (2) and lay as low as possible to drain these hoses into the
container. Install hoses to filters and tighten securely.
6. Install the top hose to the hydraulic oil cooler that was removed in Step 4.
7. Fill the pump case with new hydraulic oil of the same type used in the machine.
8. Mark all connections and connect the feed motor hoses together at the feed motor. Connect drill
pressure and return hoses together at drill, connect drill rotation forward and reverse hoses togeth-
er at the drill. Connect dust collector motor hoses together at motor. Connect compressor motor
hoses together at motor. This will allow oil to flow through these functions and to return manifold.
9. Position the hose installed in Step 2 into a 55 gallon (208 L) drum or other suitable container. Be
sure container is clean if the oil is to be reused.
10. Start machine and select DRILL function. Turn dust collector and detergent system (if used) to full
ON position.
11. Turn air ON position to cause engine to switch to high idle. Turn on the drill, rotation and feed func-
tions to maximum position and allow to run for a minimum of 15 seconds. Reverse direction of rota-
tion and feed for an additional 10 seconds.
NOTE This process allows oil to flow from the tank through the hydraulic pump to the drill,
rotation, feed and compressor control valves and back to the return line to the return
manifold and out the 3/4 line into the container.
12. Stop the machine and connect all the hoses that were
removed in Step 8. Remove the 3/4 in. hose from the
drain manifold and plug with the 3/4 in. SAE plug (from
Step 2).
13. Remove the brake release hose from one final drive
motor (4, fig. 3-15), this causes the brake to be locked
at all times.
14. Place a low container under the final drive motor and
disconnect both supply hoses (1,2) from the final drive
motor and put both ends in the container. Start machine
and switch to TRAM mode and move tram lever for
that side only to cause oil to flow from one of the open
hoses for a minimum of 3 seconds, then the other hose
for a minimum of 3 seconds to clear oil from the tram Fig. 3-15 Final Drive Motor
valve and hoses. DO NOT move tram lever for other 1. Return Line
side or machine will move. 2. Pressure Line
3. Drain Line
4. Brake Release Line
3-14 Power Train

BI006823-00

15. Replace the supply hoses on the final drive motor and tighten securely. Move the tram lever for-
ward and reverse for a minimum of 5 seconds per direction to clear oil from the brake line and
valve. Connect the brake release line and tighten.
16. Repeat steps 13–15 for the opposite final drive motor.
17. The following procedure is to be performed for each cylinder to clear old oil from the cylinder valve,
hosing and cylinder barrel.
• Remove the hose from the rod end of the cylinder and install a short adapter hose and allow the
cylinder hose and valve hose to drain into a clean container.
• Start the machine and extend that cylinder to the maximum position. This will push the old oil from
the rod end of the cylinder. Then move the control handle for this cylinder to the retract position for
3 seconds minimum, this will clear the old oil from the cylinder valve and hose.
• Connect the rod end hose and tighten securely. Remove the piston end hose from that cylinder and
install the short adapter hose on the cylinder fitting and position both hoses in a clean container.
• Start the machine and retract that cylinder to the minimum position. This will push the old oil from
the piston end of the cylinder. Move the control handle for this cylinder to the extend position for 3
seconds minimum, this will clear the old oil from the cylinder valve and hose. Connect the cylinder
hose and tighten securely.
• Repeat this procedure for all cylinders, i.e.;
Boom Lift, Boom Swing, Boom Extend, Feed Swing, Feed Dump, Feed Extend,
Track Oscillation, Pickup Pot and Centralizer.
NOTE When all lines have been cleared of old oil, be sure to top off hydraulic tank with new
oil.
18. Remove the drain line (2, fig. 3-16) from the connection
at the case drain filter (1, fig. 3-16) and place end in a
clean container. Place hand fill pump hose in a contain-
er of clean oil (of the type you are refilling the system
with). Operate the fill pump until about 1 gal (3.8 L)
has passed out of the 1 in. drain line removed from the
filter. Connect drain line to return filter and tighten.
Fig. 3-16 Case Drain and Return

1. Case Drain Filter
2. Drain Line to Return Filter
3. Return Filter
Power Train 3-15

BI006823-00

19. Tag and remove all hoses from the drain manifold except for the 3/4 in. and 1 in. hoses. Remove
drain hose from each motor and blow compressed air through drain line to completely remove old
oil. Drain lines will have to be disconnected from the following motors:
Rotation Motor, Feed Motor, Dust Collector Motor, Compressor Motor, Final Drive Motors and Rod
Changer Motor.
Connect lines to all motor drain ports and drain manifold and tighten.
20. Install new hydraulic oil filter elements (shown in Section 10). This completes the process.
3-16 Power Train

BI006823-00
Section 4
DO NOT weld on any part of the machine without first disconnecting the negative bat-
tery cable or place the battery disconnect switch in the OFF position. On machines
equipped with electronic engine, disconnect the connections to the Electronic Control
Module (ECM) on the engine before welding.
DO NOT direct high pressure cleaning agents or water on electrical connections.
Hydraulic and Electrical Systems
Fig. 4-1 Caterpillar C9 Engine

1. Electronic Control Module (ECM)
2. Plug-Ins–Disconnect from ECM BEFORE welding
Fig. 4-2 Battery Disconnect Switch at Rear of Machine
Hydraulic and Electrical Systems 4-1

Valve Installation BI006823-00
Fig. 4-3 Valve Installation (ref. 428265 Rev. B)
4-2 Hydraulic and Electrical Systems

BI006823-00
Tram Valve Components
The tram valve is for Emergency Use Only. Owner/Operator must contact manufacturer
for proper operation and before use.
Stay clear of moving machine, death or serious injury can result
Fig. 4-4 Tram Valve

BI006823-00
Tram Valve Components
Fig. 4-5 Left Tram Counterbalance Valve (Under Cab)
Fig. 4-6 Right Tram Counterbalance Valve

BI006823-00
Auxiliary Manifold
OSCILLATION EXT PICK UP POT B

LEFT BRAKE
OSCILLATION EXT RIGHT BRAKE
OE
PPB LB RB 2S
OR
OSCILLATION RETRACT TWO SPEED
CASE
DRAIN
PPA CA
CB
CP
GAUGE
CENTRALIZER A PRESSURE
COMPENSATOR PORT
RETURN
CENTRALIZER B
PICK UP POT A
Fig. 4-7 Auxiliary Manifold Functions (ref. 432748 Rev. B)

BI006823-00
Drill/Boom Valve
The drill/boom valve is for Emergency Use Only. Owner/Operator must contact manu-
facturer for proper operation and before use.
Fig. 4-8 Drill/Boom Valve Functions

BI006823-00
Drill Control Circuit
Fig. 4-9 Drill Control Hosing

BI006823-00
Transducer Manifold
The transducer manifold is mounted on the fuel tank and receives pressure inputs and converts these
into an electrical signal which the operator reads on the cab display. The signals are shown in fig. 4-10.
Fig. 4-10 Transducer Manifold Functions (ref. 431749)

1. Air Pressure
2. Hammer Pressure
3. System Pressure
4. Rotation Pressure
5. Feed Pressure

BI006823-00
Electrical Components Installation
BATTERIES
AUDIBLE ALARM
BATTERY
VIEW A-A
VIEW ROTATED 90° FOR CLARITY
DISCONNECT
Fig. 4-11 Electrical Components Installation (ref. 434541 rev. A)

Electrical Enclosure BI006823-00
Fig. 4-12 Electrical Enclosure with Electronic Communication and Control Modules (ref. 436586 rev. A)
1. DVC80–J1939 Communication Bridge Module
2. DVC50 Universal Input/Output Module (3)
3. DVC22 Digital Input Expansion Module
4. DVC10 Valve Controller Module
5. DVC41 Sourcing Output Expansion Module (3)

BI006823-00
Electrical Enclosure
Fig. 4-13 Wiring Diagram (Ref. 436586 rev. A)

Notes BI006823-00

BI006823-00
Communication and Control Modules
DVC80–J1939 Communication Bridge

Refer to the HCT descriptive data sheet on the following pages for more information on the DVC80
module, followed by the module pinouts and LED indicators for troubleshooting and repair criteria.

BI006823-00
HCT - High Country Tek
DVC80 – J1939 COMMUNICATION BRIDGE DATA SHEET

The DVC80 (J1939 Bridge) is a unique CAN bus gateway. The DVC80 is designed for a range
of applications, including but not limited to agriculture, construction, forestry, mining, material
handling, refuse and transportation. This module was built to serve as a data link between DVC and
J1939 CAN Bus systems. It uses the DVC CAN Bus protocol and SAE J1939 standard protocol to
receive, filter, and retransmit messages. The data gathered by these messages can then be incorporated
into the DVC control system, allowing for a proactive system control approach as well as the typical
reactive system control approach.
An RS-232 interface allows for connection to on-board computers or laptops. This port is used
for setup, real-time diagnostics and data logging. A +5Vdc reference is available for supplying power to
external sensors.
Rugged Construction:
♦ Rugged encapsulated enclosure withstands harsh environments commonly found in mobile
applications.
♦ All connectors are sealed.
♦ Operating Temperature: -40 Celsius to +80 Celsius
♦ Storage Temperature: -40 Celsius to +80 Celsius
Setup and Installation:
♦ User programmable.
♦ Physical Size - 6.2L” x 4.75W” x 1.65H”
encapsulated module.
♦ Each module has two mounting holes 4.0” a
part. Mounting hole I.D. is 0.325”.
♦ An RS-232 port is used for setup, real- time
diagnostics, data logging and setting the
MAC ID (node) number.
Power Supply:
♦ Rugged power supply operates over the full
range 8.0Vdc to 32Vdc.
♦ Reverse polarity protection and transient
protection up to 1.5K watts peak pulse power
dissipation.
♦ +5 Vdc reference/sensor power output.
Supplies 150 mAmps and is fuse protected
against shorts and overvoltage.
Communications:
♦ DVC Can Bus 2.0B – This port is used to
interface to the DVC CAN Bus. A DeviceNet
protocol is used.
♦ J1939 CAN Bus 2.0B – This port is used to
interface to J1939 CAN Bus. Connecting a jumper wire between P12-C2 and P12-C3 will add a
120-ohm termination resistor between CAN_H and CAN_L.
♦ RS-232 serial port – This port is used for setting MAC ID, setting Baud Rate, monitoring,
diagnostics and data logging.

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Loader/Monitor Software Features:

♦ Local RS-232 Connection (connected directly to the DVC80).
Set the DVC CAN Bus baud rate.
Set the module MAC ID.
Monitor the J1939 messages passed to the DVC CAN Bus.
Select an additional ten J1939 messages to be monitored.
Take a data log of all J1939 messages being monitored.
♦ Remote RS-232 connection (connected to the DVC10 RS-232 port).
Monitor the J1939 messages passed to the DVC CAN Bus.
Indicators:
♦ Module Status (MS) (Qty 1) (R/G) –
Off – There is no power applied to the Module.
On green – The module is operating in a normal condition.
Flashing green – Device in standby state. May need commissioning.
Flashing red – Recoverable Fault.
On red – Module has an unrecoverable fault.
Flashing Red/Green – Device is in self- test.
♦ Network Status (NS) (Qty 1) (R/G) –
Off - Device in not on- line.
Flashing green – Device in on- line but has not established connection to other nodes.
On green – Device in on- line and has established connection to other nodes.
Flashing red – One or more connections are in a timed-out state.
On red – The device has detected an error that has rendered it incapable of communicating on
the network.
♦ J1939 Status (Qty 1) (R/G) –
Off – No message activity.
Randomly flashing green – message activity.
Flashing red – Loss of communication to the J1939 Bus.
Connectors:
♦ The DVC80 uses the Metri-Pack 150 series (or compatible) sealed electronic header designed for
severe underhood environments.
18-pin Header
♦ 5-pin CAN Bus (DeviceNet compliant) connector.
Pins are gold plated brass machined from solid stock.
Protection rating – Nema 1,3,4,6P, and IEC IP 68.

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DVC80 – J1939 Data Bridge Order Guide
8/15/02
DVC80 ORDERING GUIDE
ORDERING INFORMATION
D V C 8 0
DIGITAL VALVE CONTROLLER SERIES
MODULE IDENTIFICATION
J1939 BRIDGE 80 * CUSTOM OPTIONS *

- Consult factory for custom
- Leave blank if not custom
MOUNTING HOLES EXCEPT 1/4" BOLT (2PLS)
J1939
MS
NS P15
J1939
MS
3
2
DEVICENET COMPATIBLE
5-PIN CAN CONNECTOR
NS DIGITAL VALVE CONTROLLER
A
DVC80
4.00 in
B
C
J1939 BRIDGE
8
D E
MAC ID =
F
1.65 in 2.65 in 2.95 in
5 PIN CAN (P15)

18 PIN Metri-Pak (P14) 4 3
PIN FUNCTION PIN FUNCTION

5
A1 RXD D1 J1939 CAN_H
A2 TXD D2 J1939 CAN_L 1 2
A3 SIG COM D3 MALE (pins)

B1 SIG COM E1 +POWER IN
B2 +5Vdc E2 PIN FUNCTION
B3 +5Vdc E3 1 N/C
C1 F1 PWR COM 2 N/C
C2 TERM 1 F2 PWR COM 3 N/C
C3 TERM 2 F3 CAN_H
4
5 CAN_L

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High Country Tek, Inc.

208 Gold Flat Court
Nevada City, CA 95959
(530) 265-3236
www.highcountrytek.com
DVC80 LED Indicators
J1939 Status (R/G)

Module Status (MS) (R/G) Off – No message activity
Off – There is no power applied to the Module. Randomly flashing green – Message activity
On green – The module is operating in a Flashing red – Loss of communication to the J1939 Bus
normal condition.
Flashing green – Device in standby state. May
need commissioning.
Flashing Red/Green – Device is in self-test.
Module & Network Status (MS/NS)

Alternating Flashing Green – Device
is being programmed (BIOS or
Application Code).
Network Status (NS) (R/G)

Off – There is no J1939 device (or other DVC5)
in the project.
Flashing green – J1939 device in project but
communication has not been established.
On green – J1939 communication has been
established.
Flashing red – The J1939 communication is in
a timed-out state.
On red – The device has detected an error that
has rendered it incapable of communicating on
the network.

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DVC50 Universal Input/Output


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DVC50 (Universal I/O Module) Rev. P2.0
DESCRIPTION
The DVC50 Universal I/O Module is a slave expansion module that is designed to operate in
conjunction with a DVC10 Master Module. Its large number of inputs and outputs make it ideal for
applications that may need additional proportional outputs with local or remote closed loop
capabilities. A +5Vdc reference voltage is provided to supply power to external sensors. Four
analog (0 to 5Vdc) and two analog/pulse (0 to 5Vdc) inputs can interface to a number of different
types of sensors including joysticks, potentiometers, and pulse sensors. Eight digital inputs are
provided for a multitude of switch type inputs. The outputs are the same as the DVC10 Master
module including 6 High-side (sourcing, on/off) and 3 PWM outputs. The DVC50 communicates to
the Master Module through the CAN Bus (high-speed serial communication bus) and utilizes the
RS232 port for setting the MAC ID (node) and for device monitoring. The controller is packaged in
a small rugged enclosure and encapsulated to withstand extreme harsh environments.

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TECHNICAL DATA
Analog/Pulse Inputs – Qty (2)
These inputs can be configured as analog (0 to +5Vdc) or pulse (0 to +5Vdc) inputs. A
+5Vdc reference is supplied with each input for an external sensor. These inputs have 10-bit
resolution.
PROGRAMMABLE MODES
A. Input Modes
1. Analog (0 to +5Vdc)
2. Pulse (0 to +5Vdc)
a. Pulse Timeout – sets a flag if a pulse has not been detected for a
certain amount of time.
b. Pulses Per Rev – used for calculating RPM.
* Note - The maximum speed for per input is 7khz.
3. Counter Mode - For Counter pulse inputs, setup the Min and Max counts
under Count Limits. The output value will be a percent Min to Max count.
The counter value may be read or set by the application. The counter is
incremented on every falling edge of the pulse input.
B. Joystick Configuration
1. Enable Center - sets up upper and lower configuration for single axis
joystick.
2. Deadband – Sets the % of deadband at center.
C. Voltage Calibration – Setting for the actual voltage received at the input (Min,
Center and Max).
D. Voltage Limits – sets the Min a Max limits of the input. A flag is set when these
limits are met. This feature detects unwanted conditions so that the controller can be
safely programmed to a default condition.
* Note – The input will go high if the input is open (no connection).
E. Invert Output – Simply inverts the output control with respect to the input command.
F. Enable Ramps – applies ramping to the input.
G. Scaling – sets the offset and gain to the input which results to meaningful data
displayed in the Loader Monitor.

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ANALOG INPUTS – Qty (4)

The Analog inputs have a range of 0 to +5Vdc. A Pot Reference output (+5Vdc reference) is
supplied with each Analog input. All Analog inputs have 10-bit resolution.
PROGRAMMABLE MODES
A. Joystick Configuration
1. Enable Center - sets up upper and lower configuration for single axis
joystick.
B. Voltage Calibration – Setting for the actual voltage received at the input (Min,
Center and Max).
C. Voltage Limits – sets the Min a Max limits of the input. A flag is set when these
D. Invert Output – Simply inverts the output control with respect to the input command.
E. Enable Ramps – applies ramping to the input.
F. Scaling – sets the offset and gain to the input which results to meaningful data
displayed in the Loader Monitor.
DIGITAL INPUTS – Qty (8)

All digital inputs are sinking inputs (connect to voltage to turn on). The voltage required to
turn on this input is between 3.0Vdc and 32Vdc (see Figure 1). All Digital inputs are connected
internally to PWR COM through a series resistor (> 10K ohm).
* This is a common example of a Digital Input connection.
+ PWR
( +3Vdc to +32Vdc)
to DIGITAL IN
FIGURE 1

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+5Vdc REFERENCE – Qty (6)

All Analog and Analog/Pulse inputs
POTENTIOMETER HOOK-UP
have a corresponding +5Vdc output. The
maximum current capability is 120ma (sum of to any POT REF
all six +5Vdc references). A 5 x 20mm 125ma
fuse is located at the back of the module for 10K ohm 0 to 4.5Vdc to Analog In
over-current protection.
to any SIG COM
FIGURE 2
Note: Connecting this output to greater than +5Vdc may cause permanent damage to the DVC50
module.
OUTPUTS – Qty (9)

The outputs are designed to give the user a great deal of flexibility. The software gives the
user the ability to control the sourcing voltage (HS OUT) to the positive side of the coil and control
the pwm sinking capability (PWM OUT) to the negative side of the coil.
HIGH-SIDE OUTPUTS (HS OUT) – Qty (6)

These outputs are designed to source (supply) power supply voltage when activated. Each
output is short protected and has open detection. The maximum current capability is 3Amps.
PWM OUTPUTS (PWM OUT) – Qty (3)

These outputs are designed to sink current to ground at a pwm frequency. Each output can
be configured for a specified current range for maximum current sensing resolution (10 bit). See
the DVC10 Ordering Guide for typical current ranges. All outputs are short circuit protected and
most current ranges have open circuit and short circuit detection (see Current Range Details for
more information).
A. Current Ranges – Each PWM output can be configured to a current range, which will
produce the maximum current sensing resolution (see ordering guide).
* Note - Current ranges “L”, “H”, and “D” are short circuit protected but do
not have short circuit detection.

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OUTPUT GROUPS (3)

The outputs are divided up into 3 output groups. Each output group has (2) High-Side
outputs and (1) PWM output.
OUTPUT GROUP CONFIGURATIONS

DUAL COIL HIGH-SIDE SINGLE COIL HIGH-SIDE
To HS OUT
To HS OUT To HS OUT To HS OUT
PWM BANG
PWM PWM BANG
To PWM OUT To PWM OUT To PWR COM
SINGLE COIL LOW-SIDE HIGH-SIDE ONLY

To +POWER IN To HS OUT
BANG BANG BANG BANG

BANG PWM BANG BANG BANG
To PWR COM To PWR COM To PWR COM

To PWM OUT
FIGURE 3
A. Programmable Features
1. Dither Amplitude
2. Dither Frequency
3. Ramp Up and Ramp Down
4. PID setting for current regulation and I/O functions.
5. Min and Max current
6. Output Group Selection
7. Process selection including: Current regulation, Enable process PI, Enable
current ramps, and PWM Duty cycle mode.
* Note – See the DVC10 Programming User Guide for more details on
programmable features.

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INPUT/OUTPUT FUNCTIONS – Qty (6)

There are six Input/Output Functions that can be programmed individually. The I/O
Function gives the user the ability to change the response of the output with the change of the input
(see sample screen below). The input and output being controlled must be both resident to the
DVC50. The input and output is based on 0 to 100% (Min. to Max.). Different adjustable points on
the response curve give the user full flexibility to control non-linear responses. These functions are
adjustable while the controller is running in order to adjust unknown output characteristics.
* Note – See the DVC10 Programming User Guide for more details.
LOCALIZED CLOSED LOOP FUNCTIONS

All inputs have the ability to be used in a closed loop configuration with the outputs locally.
Most closed loop configurations such as speed and rpm control require very fast response times.
Closing the loop locally, instead of over the CAN Bus, will result in the response needed for these
configurations.
COMMUNICATIONS
A. The DVC50 has two communication ports:
1. Can Bus 2.0B – This port is used to communicate to other DVC modules as
well as an ECM (engine control module).
2. RS-232 serial port is used for:
a. Downloading and uploading software.
b. Monitoring the functions of the DVC50.
c. Setting parameters on the fly (fine-tuning).

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POWER SUPPLY
A. The DVC50 Power Input has the following features:
1. Voltage Input Range - 8.0Vdc to 32Vdc
2. Reverse polarity protection and transient protection up to 1.5K Watts Peak
Pulse Power Dissipation
3. More than one power and ground pin must be used if driving over 8 amps (at
one time).
INDICATORS
A. Digital Input Status (Qty 8) (Green) – Turns on when the corresponding input is
activated. Inputs can be programmed as active high or low.
B. High-Side Output Driver Status (Qty 6)(Green) – Turns on when the corresponding
High-side output is activated. Blinks once per second for an open circuit. Blinks four
times per second for a short circuit.
C. PWM Output Driver Status (Qty 3) (R/G) – This LED displays duty-cycle status for
the corresponding PWM output. The LED will display from red to green as the duty-
cycle changes from 0% to 100% (50% displaying yellow).
D. Module Status (MS) (Qty 1) (R/G) –
1. Off – There is no power applied to the Module.
2. On green – The module is operating in a normal condition.
3. Flashing green – Device in standby state. May need commissioning.
4. Flashing red – Recoverable Fault.
5. On red – Module has an unrecoverable fault.
6. Flashing Red/Green – Device is in self-test.
G. Network Status (NS) (Qty 1) (R/G) –
1. Off - Device in not on-line.
2. Flashing green – Device in on-line but has not established connection to other
nodes.
3. On green – Device in on-line and has established connection to other nodes.
4. Flashing red – One or more connections are in a timed-out state.
5. On red – The device has detected an error that has rendered it incapable of
communicating on the network.
PACKAGING
BI006823-00
A. Physical Size - 6.2L” x 4.75W” x 1.65H” encapsulated module.

B. Each module has two mounting holes 4.0” a part. Each mounting hole has an I.D. of
0.325”.
C. Weight – 1 lb. 7 oz.
CONNECTORS
A. The DVC50 uses the Metri-Pack 150 series (or compatible) sealed electronic header
designed for severe underhood environments.
1. 30-pin Header (P16) – Used for sensor signal inputs.
2. 18-pin Header (P17) – Used for the power supply and output
connections.
B. 5-pin CAN Bus (DeviceNet compliant) connector
1. Pins are gold plated brass machined from solid stock.
2. Protection rating – Nema 1,3,4,6P, and IEC IP 68.
MATING CONNECTORS
A. Mating for 30-pin Header and 18-pin Header
1. Connector, 30-pin Female (P16) Delphi Packard P/N – 12034398
3. Terminals, Female Delphi Packard P/N – 12103881
4. Plugs Delphi Packard P/N – 12034413
6. DVC Series 48-pin Connector Kit HCT P/N - 999-10077
Includes the following:
1 - Connector, 30-pin Delphi Packard
1 - Connector, 18-pin Delphi Packard
60 - Terminals, Delphi Packard
25 – Plugs, Delphi Packard
B. Mating for CAN Bus connector (P18)
1. 5-pin Female Micro-style DeviceNet compliant connector.
C. Mating to the RS-232 Port – The RS-232 port is accessed through the 30-pin
connector at (P16). A DVC Slave Serial Port Adapter is available to connect to the
30-pin Female mating connector. A DVC RS-232 Cable can be used to interface
from the DVC Slave Serial Port Adapter to a PC. Drawings for these two cables are
supplied for user assembly; otherwise they are available from the HCT.
* Note – The DVC Slave Serial Port Adapter comes with a plug. The plug is
used to keep the cable weather-tight when not connected to
peripherals.
1. DVC Slave Serial Port Adapter HCT P/N - 999-10082
2. DVC RS-232 Cable Assembly HCT P/N - 999-10075
ENVIRONMENTAL
• Operating Temperature - -40 Celsius to 70 Celsius
• Storage Temperature - -40 Celsius to 85 Celsius

BI006823-00
g y y _ p
POLLED IO DATA
Vendor ID……………..62 Produced IO Data……..40 Product Type………….x68
Product Code………….50 Consumed IO Data……18
Produced IO Produced IO Produced IO Produced IO
Data Data Data Data
Word Byte 0 Byte 1 Byte 2 Byte 3
Byte Offset 0 2 4 6
Name Digital Inputs AI1 AI2 AI3
Bit 0 DI1
Bit 1 DI2
Bit 2 DI3
Bit 3 DI4
Bit 4 DI5
Bit 5 DI6
Bit 6 DI7
Bit 7 DI8
Bit 8
Bit 9
Bit 10
Bit 11
Bit 12
Bit 13
Bit 14
Bit 15

Data Data Data Data
Byte Offset 8 10 12 14
Name AI4 AI5 AI6 RPM1
Bit 0
Bit 1
Bit 2
Bit 3
Bit 4
Bit 5
Bit 6
Bit 7
Bit 8
Bit 9
Bit 10
Bit 11
Bit 12
Bit 13
Bit 14
Bit 15

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Data Data Data Data
Name RPM2 Analog Status Analog Status Output Status
Bit 0 A1.Dir A5.Dir 1.Enable
Bit 1 A1.MinF A5.MinF 1.Dir
Bit 2 A1.MaxF A5.MaxF Out1
Bit 3 A1.DB A5.DB Out2
Bit 4 A2.Dir A5.LOS 2.Enable
Bit 5 A2.MinF A6.Dir 2.Dir
Bit 6 A2.MaxF A6.MinF Out3
Bit 7 A2.DB A6.MaxF Out4
Bit 8 A3.Dir A6.DB 3.Enable
Bit 9 A3.MinF A6.LOS 3.Dir
Bit 10 A3.MaxF Out5
Bit 11 A3.DB Out6
Bit 12 A4.Dir
Bit 13 A4.MinF LS1Short
Bit 14 A4.MaxF LS2Short
Bit 15 A4.DB LS3Short

Data Data Data Data
Name Output Status Output1% Output3% Output3%
Bit 0 Short1
Bit 1 Short2
Bit 2 Short3
Bit 3 Short4
Bit 4 Short5
Bit 5 Short6
Bit 6 Open1
Bit 7 Open2
Bit 8 Open3
Bit 9 Open4
Bit 10 Open5
Bit 11 Open6
Bit 12
Bit 13 LS1Open
Bit 14 LS2Open
Bit 15 LS3Open

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Data Data Data Data
Name Mail Output 1 Mail Output 2 Mail Output 3 Mail Output 4
Bit 0
Bit 1
Bit 2
Bit 3
Bit 4
Bit 5
Bit 6
Bit 7
Bit 8
Bit 9
Bit 10
Bit 11
Bit 12
Bit 13
Bit 14
Bit 15
Consumed IO Consumed IO Consumed IO Consumed IO

Data Data Data Data
Byte Offset 0 2 4 6
Name Commands Mail Input 1 Mail Input 2 Mail Input 3
Bit 0 1.Enable
Bit 1 1.Dir
Bit 2 Out1
Bit 3 Out2
Bit 4 2.Enable
Bit 5 2.Dir
Bit 6 Out3
Bit 7 Out4
Bit 8 3.Enable
Bit 9 3.Dir
Bit 10 Out5
Bit 11 Out6
Bit 12
Bit 13 CLR Opens
Bit 14 CLR Shorts
Bit 15 CLR Min Max

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Consumed Consumed Consumed Consumed Consumed

IO Data IO Data IO Data IO Data IO Data
Word Byte 4 Byte 5 Byte 6 Byte 7 Byte 8
Byte Offset 8 10 12 14 16
Name Mail Input 4 Mail Input 5 Mail Input 6 Mail Input 7 Mail Input 8
Bit 0
Bit 1
Bit 2
Bit 3
Bit 4
Bit 5
Bit 6
Bit 7
Bit 8
Bit 9
Bit 10
Bit 11
Bit 12
Bit 13
Bit 14
Bit 15

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DVC50 CONNECTOR PINOUT

3
2
1
5-PIN CAN CONNECTOR
A B C D E
30 PIN Metri-Pak (P16)

P18
DIG 1
DIG 2
DIG 3
DIG 4
DIG 5
DIG 6
DIG 7
DIG 8
MS
NS
CAN BUS
F
G H J
PWM%A DIGITAL VALVE CONTROLLER
PWM%B
DVC50
K
PWM%C UNIVERSAL I/O MODULE
HSOUT1
HSOUT2
HSOUT3
HSOUT4
HSOUT5
HSOUT6
+5VDC
A B C
D E
F

PIN FUNCTION PIN FUNCTION PIN FUNCTION
A1 RXD D2 PULSE / ANALOG 2 G3 DIGITAL IN 2
A2 TXD D3 SIG COM H1 + 5V POT REF
A3 E1 + 5V POT REF H2 ANALOG IN 4
B1 SIG COM E2 ANALOG IN 1 H3 DIGITAL IN 3
B2 SIG COM E3 SIG COM J1 DIGITAL IN 4
B3 SIG COM F1 + 5V POT REF J2 DIGITAL IN 5
C1 + 5V POT REF F2 ANALOG IN 2 J3 DIGITAL IN 6
C2 PULSE / ANALOG 1 F3 DIGITAL IN 1 K1 +POWER IN
C3 SIG COM G1 + 5V POT REF K2 DIGITAL IN 7
D1 + 5V POT REF G2 ANALOG IN 3 K3 DIGITAL IN 8

5 PIN CAN (P18)
PIN
A1
FUNCTION
+POWER IN
PIN
D1
FUNCTION
HS OUT 5
PIN FUNCTION P18
4 3
A2 +POWER IN D2 HS OUT 6 1 DRAIN
PWM OUT 1 PWM OUT 2 2 ** V+ (NC)
A3 D3 5
HS OUT 1 PWR COM 3 ** V- (NC)
B1 E1
B2 HS OUT 2 E2 PWM OUT 3 4 CAN_H 1 2
B3 PWM OUT 1 E3 PWM OUT 3 5 CAN_L MALE (pins)

C1 HS OUT 3 F1 PWR COM
HS OUT 4 PWR COM **Power & GND are not supplied
C2 F2
to the CAN Bus by the DVC50.
C3 PWM OUT 2 F3 PWR COM
7/27/04

BI006823-00

208 Gold Flat Court
(530) 265-3236
Digital Input Status (Green)
Module Status (MS) (R/G)
Turns on when the corresponding input is
activated. Inputs can be programmed as active Off – There is no power applied to the Module.
high or low. On green – The module is operating in a
normal condition.
need commissioning.
PWM Output Driver Status (R/G)

This LED displays duty-cycle status for
the corresponding PWM output. The
LED will display from red to green as
Application Code).
the duty-cycle changes from 0% to
100% (50% displaying yellow).

in the project.
established.
a timed-out state.
High-Side Output Driver Status (Green) the network.
Off – Output is off
On – Output is being activated
Open Circuit – Blinks once per second
Short Circuit – Blinks 4 times per second

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DVC22 Digital Input Expansion Module


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DVC22 (40 Digital Input Module) Rev. P2.0
DESCRIPTION
The DVC22 Slave Module is a 40 digital input expansion module that is designed to operate in
conjunction with a DVC10 Master Module. The DVC22 module is designed with 40 sinking inputs.
All inputs have programmable features including debounce times, active high/low, and toggle/no-
toggle. The DVC22 communicates to the Master Module through the CAN Bus (high-speed serial
communication bus) and utilizes the RS232 port for setting the MAC ID (node) number and for device
monitoring. The controller is packaged in a small rugged enclosure and encapsulated to withstand
extreme harsh environments.
Three connectors (P19, P20, and P21) are provided for electrical connections. P19 (30 pin) and
P20 (18 pin) are the main input and power connectors which protrude out the side of the enclosure.
P21 is a standard Device-Net Compatible (CAN Bus 2.0B) 5 pin connector.
The status of each input is displayed by a green LED located on the top of the module. If the
input is active then the corresponding LED will light. A Module Status (R/G LED) and a Network
Status (R/G LED) LED are located on the top of the module (see INDICATORS section below for
further details).

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FEATURES
• All sinking inputs
• Programmable debounce times for momentary activations.
• Controller Area Network (CAN 2.0B) provides high-speed serial communications with up to
16 other CAN compatible devices.
• Rugged encapsulated enclosure withstands harsh environments commonly found in mobile
applications.
• User friendly display shows Input and communication status at a glance.
• RS-232 communication used for troubleshooting and node assignment.
• Rugged power supply operates over the full range 8.5Vdc to 32Vdc with reverse polarity and
transient protection up to 1.5K Watts Peak Pulse Power Dissipation
DIGITAL INPUTS – QTY (40)
INPUTS 1 – 40 (SINKING)
1. These inputs are sinking (need +5Vdc to +32Vdc to cause the input to switch from low
to high).
2. Indicators – The corresponding green LED will illuminate when the input is activated
(programmable active high or low).
+PWR
TO DVC21
SINKING INPUT
CONFIGURATION
PROGRAMMABLE FEATURES
A. Inputs
1. Debounce times - 0 to 2.5 seconds.
2. Active High or Active Low.
3. Toggle (latching) or No Toggle (non-latching) mode.
B. Module
1. The DVC22 is a Slave Module and is controlled by the DVC10 Master Module.
2. Programmable by using a DVC10 and DVC Programming Tool.
INPUT PROTECTION
A. Protected against shorts to ground and voltages up to +32Vdc.
COMMUNICATIONS
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1. Can Bus 2.0B – This port is used to communicate to the DVC10 Master Module.
a. Setting MAC ID and Baud Rate.
POWER SUPPLY
2. Reverse polarity protection and transient protection up to 1.5K Watts Peak Pulse
Power Dissipation.
3. Use P19-B2 for the + POWER INPUT (typically +12Vdc or +24Vdc).
4. Use P19-A1, P19-A2, P19-A3, or P19-B1 for the PWR COM (typically tied to
chassis).
INDICATORS
A. Digital Input Status (Qty 40) (Green) – Turns on when the corresponding input is
B. Module Status (MS) (Qty 1) (R/G) –
C. Network Status (NS) (Qty 1) (R/G) –
nodes.
PACKAGING
0.325”.
CONNECTORS
A. The DVC22 uses the Metri-Pack 150 series (or compatible) sealed electronic
header designed for severe under-hood environments.
2. 18-pin Header (P20) – Used for the power supply and output
connections.
B. 5-pin CAN Bus (DeviceNet compliant) connector (P21).
BI006823-00

MATING CONNECTORS
A. Mating for 30-pin Header (P19) and 18-pin Header (P20)
1 - Connector, 30-pin (P19) Delphi Packard
1. 5-pin Female Mini-style DeviceNet compliant connector.
C. Mating to the RS-232 Port – The RS-232 port is accessed through the 18-pin connector
at (P20). A DVC Serial Port Adapter is available to connect to the 18-pin Female
mating connector. A DVC RS-232 Cable can be used to interface from the DVC Serial
Port Adapter to a PC. Drawings for these two cables are supplied for user assembly;
otherwise they are available from HCT.
* Note – The DVC Slave Serial Port Adapter comes with a plug. The plug is used
to keep the cable weather-tight when not connected to peripherals.
ENVIRONMENTAL

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POLLED IO DATA
Vendor ID……………..62
Product Code………….22
Product Type………….x65
Produced IO Data……..5
Consumed IO Data……0
Produced IO Data Produced IO Data Produced IO Data

Word Byte 0 Byte 1 Byte 2
Byte Offset 0 2 4
Name Digital Inputs Digital Inputs Digital Inputs
Bit 0 DI1 DI17 DI33
Bit 1 DI2 DI18 DI34
Bit 2 DI3 DI19 DI35
Bit 3 DI4 DI20 DI36
Bit 4 DI5 DI21 DI37
Bit 5 DI6 DI22 DI38
Bit 6 DI7 DI23 DI39
Bit 7 DI8 DI24 DI40
Bit 8 DI9 DI25 -
Bit 9 DI10 DI26 -
Bit 10 DI11 DI27 -
Bit 11 DI12 DI28 -
Bit 12 DI13 DI29 -
Bit 13 DI14 DI30 -
Bit 14 DI15 DI31 -
Bit 15 DI16 DI32 -

BI006823-00
High Country Tek

3
2
1
A B

C D E
P21
14 13 12 11 10 9 8 7 6 5 4 3 2 1
15
MS
CAN BUS
F
16
NS
G H J
DIGITAL VALVE CONTROLLER
17
5-PIN CAN CONNECTOR

18
DVC22 40
K
19 39
20 38
40 DIGITAL INPUT MODULE
21
A B
MAC ID =
22 37
23 24 25 26 27 28 29 30 31 32 33 34 35 36
C
D E F

A1 PWR COM D2 DIG IN 6 (SINKING) G3 DIG IN 16 (SINKING)
A2 PWR COM D3 DIG IN 7 (SINKING) H1 DIG IN 17 (SINKING)
A3 PWR COM E1 DIG IN 8 (SINKING) H2 DIG IN 18 (SINKING)
B1 PWR COM E2 DIG IN 9 (SINKING) H3 DIG IN 19 (SINKING)
B2 +POWER IN E3 DIG IN 10 (SINKING) J1 DIG IN 20 (SINKING)
B3 DIG IN 1 (SINKING) F1 DIG IN 11 (SINKING) J2 DIG IN 21 (SINKING)
C1 DIG IN 2 (SINKING) F2 DIG IN 12 (SINKING) J3 DIG IN 22 (SINKING)
C2 DIG IN 3 (SINKING) F3 DIG IN 13 (SINKING) K1 DIG IN 23 (SINKING)
C3 DIG IN 4 (SINKING) G1 DIG IN 14 (SINKING) K2 DIG IN 24 (SINKING)
D1 DIG IN 5 (SINKING) G2 DIG IN 15 (SINKING) K3 DIG IN 25 (SINKING)
18 PIN Metri-Pak (P20) 5 PIN CAN (P21)

P21
A1 DIG IN 26 (SINKING) D1 DIG IN 35 (SINKING) 4 3
1 N/C
A2 DIG IN 27 (SINKING) D2 DIG IN 36 (SINKING) 2 N/C
5
A3 DIG IN 28 (SINKING) D3 DIG IN 37 (SINKING) 3 N/C
B1 DIG IN 29 (SINKING) E1 DIG IN 38 (SINKING) 4 CAN_H 1 2
B2 DIG IN 30 (SINKING) E2 DIG IN 39 (SINKING) 5 CAN_L MALE (pins)
B3 DIG IN 31 (SINKING) E3 DIG IN 40 (SINKING)
C1 DIG IN 32 (SINKING) F1 RXD

C2 DIG IN 33 (SINKING) F2 TXD
C3 DIG IN 34 (SINKING) F3 SIG COM
10/31/02

BI006823-00

208 Gold Flat Court
(530) 265-3236
DVC21/22 LED Indicators
Module Status (MS) (R/G)
Digital Input Status (Green)
Off – There is no power applied to the Module.
Turns on when the corresponding input is
activated. Inputs can be programmed as active On green – The module is operating in a
high or low. normal condition.
need commissioning.

Application Code).

in the project.
established.
a timed-out state.
the network.

BI006823-00
DVC10 Valve Controller Module

The valve controller is a modular, microprocessor-based unit and with the addition of the input/output
expansion modules, controls and monitors the hydraulic functions of the machine. This provides improved
precision and control of the hydraulic systems.

BI006823-00
High Country Tek DVC 10 Module

DVC10 (Master Module) Rev. P5.2
DESCRIPTION
The DVC10 Master Module is the main control module for all DVC series modules. It has a
large number of inputs and outputs to work as a stand-alone unit or it can be the main
module for a large CAN Bus system with up to 16 DVC expansion modules (see the DVC
Series Modular Configuration drawing for available DVC expansion modules). An RS-232
port is used for programming, monitoring and driving an external display.
The DVC10 has 3 Universal inputs (programmable to accept the most common sensor
inputs), 3 analog inputs, and 8 digital inputs. All universal and analog inputs have a
corresponding Pot Reference output. All digital inputs have an indicator to show input activity.
The DVC10 has 6 High-Side (sourcing) and 3 PWM outputs. The High-Side outputs provide
+POWER IN when turned on. The PWM outputs are used to vary current to the valves
(switch to ground at a high frequency). This regulated valve current provides a constant valve
output, which is unchanged by coil resistance or power supply fluctuations. An indicator
located on the module displays the status of each output. The High-Side and PWM outputs
can be used stand-alone or in conjunction with one another (High-side attached to the + coil
and PWM to the –coil).
The DVC10 software provides each individual user the ability to program this module to work
in a variety of applications without large outside development costs (knowledge of
Windows98, programming, and electro-hydraulic needed).
The controller is packaged in a small rugged enclosure. All connectors are sealed and the
module is encapsulated to withstand extreme conditions in the harsh mobile operating
environment.

BI006823-00
FEATURES
• Multiple closed loop capabilities. • Flash Memory accessible through

• Closed loop current regulation. the RS-232 port. This feature
• Control valves from multiple allows the customer to program the
manufacturers. module in the field.
• Powerful 16-bit Processor. • Rugged power supply operates
- fast over the full range 8.0Vdc to 32Vdc
- versatile with reverse polarity protection and
- multi-function transient protection up to 1.5
• Controller Area Network (CAN 2.0B) KWatts Peak Pulse Power
provides high-speed serial Dissipation.
communications with up to 16 • All inputs and outputs are
other CAN compatible devices. protected from shorting to ground
• Rugged encapsulated enclosure or the power supply.
withstands harsh environments • Large amounts of on board
commonly found in mobile memory for complex programming.
applications. • Compact packaging.
• User friendly display shows I/O
status at a glance.
SOFTWARE FEATURES
PRE-PROGRAMMED CONTROLLERS • controller networking
DVC10 Controllers can be supplied with
customer-specific application software
created by High Country Tek. Many UN-PROGRAMMED CONTROLLERS
application modules have been written to Software and programming kits are
reduce development time, such as: available for programming the DVC10 .
• Power management such as anti-stall, The kits includes:
horsepower limit, and load limit. • User-friendly software generated by
• Speed control/idle control using PID High Country Tek and designed for
control algorithms. the mobile environment. This
• Brake and clutch control algorithms software will include:
utilizing adjustable valve transfer - DVC Programming Tool
functions. - DVC Program Loader Monitor
• steering control for mobile steering - sample software
requirements • DVC10 Programming User Guide
• hydrostatic transmission control
• pressure control
• multiple valve control

BI006823-00
TECHNICAL DATA
UNIVERSAL INPUTS – Qty (3)
All Universal inputs can be configured for analog, current, or pulse inputs (see the DVC10
software manual for programming examples). A Pot Reference output (+5Vdc reference
through a series 1K ohm resistor) is supplied with each Universal Input for a potentiometer
(recommend 10K ohm) connection. All Universal inputs have 10-bit resolution.
*Note: Pulse inputs are rated up to 8 KHz.
PROGRAMMABLE MODES
A. Inputs Modes
1. Analog – +/- 1Vdc, 0 to +5Vdc, or 0 to +10Vdc.
2. Pulse - +/- 1Vdc, 0 to +5Vdc, or 0 to +10Vdc.
a. Pulse Timeout – sets a flag if a pulse has not been detected for a certain amount
of time.
b. Pulses Per Rev – used for calculating RPM.
* Note - The maximum speed for all three universal inputs is 21khz (total of all three inputs added together).
*Note: Pulse inputs are rated up to 8 KHz.
3. Current - 0 to 20ma
* Note – This output will shut off and stay at the maximum current for 5 seconds if the input exceeds 22.8ma.
This is to avoid internal circuitry failure do to miswires.
B. Joystick Configuration
1. Enable Center - sets up upper and lower configuration for single axis joystick.
C. Voltage Calibration – Setting for the actual voltage/current received at the input (Min,
Center and Max).
D. Voltage/Current Limits – sets the Min a Max limits of the input. A flag is set when these
* Note – The input will go high if the input is open (no connection).
E. Invert Output – Simply inverts the output control with respect to the input command.
F. Pot Reference Flag – Detects an open circuit to the Pot Ref output (mainly used with
potentiometers).
ANALOG INPUTS – Qty (3)
The Analog inputs have a range of 0 to +5Vdc. A Pot Reference output (+5Vdc reference
through a series 1K ohm resistor) is supplied with each Analog Input for a potentiometer
(recommend 10K ohm) connection. All Analog inputs have 10-bit resolution.

BI006823-00

PROGRAMMABLE MODES
A. Joystick Configuration
1. Enable Center - sets up upper and lower configuration for single axis joystick.
B. Voltage Calibration – Setting for the actual voltage/current received at the input (Min,
Center and Max).
C. Voltage Limits – sets the Min a Max limits of the input. A flag is set when these limits
are met. This feature detects unwanted conditions so that the controller can be safely
programmed to a default condition.
D. Invert Output – Simply inverts the output control with respect to the input command.
E. Pot Reference Flag – Detects an open circuit to the Pot Ref output (mainly used with
potentiometers).
DIGITAL INPUTS – Qty (8)

All digital inputs are sinking inputs (connect to voltage to turn on). The voltage required to
turn on this input is between 3.0Vdc and 32Vdc (see Figure 1). All Digital inputs are
connected internally to PWR COM through a series resistor (> 10K ohm). Use a Pot Ref
output in conjunction with Digital Input if you are switching the Digital Input to PWR COM
instead of switching to a voltage (see Figure 2). The Pot Ref inputs are connected
internally to +5Vdc through a 1K ohm series resistor.
* The following are two common examples of Digital Input connections.
+ PWR to any POT REF

( +3Vdc to +32Vdc)
to DIGITAL IN to DIGITAL IN
FIGURE 1 PWR COM FIGURE 2

BI006823-00

POT REFERENCE – Qty (6)
POTENTIOMETER HOOK-UP
All Universal and Analog inputs have a Pot Reference
output. These outputs are designed to supply a to any POT REF
+5Vdc reference to a potentiometer. Each Pot
Reference is connected to an internal +5Vdc power 10K ohm 0 to 4.5Vdc to Analog In
supply through a 1k ohm series resistor. All Pot

Reference Outputs are protected against shorts to to any SIG COM
ground and voltages up to +32Vdc.

FIGURE 3
OUTPUTS – Qty (9)
The outputs are designed to give the user a great deal of flexibility. The software gives the
user the ability to control the sourcing voltage (HS OUT) to the positive side of the coil and
control the pwm sinking capability (PWM OUT) to the negative side of the coil.
HIGH-SIDE OUTPUTS (HS OUT) – Qty (6)
These outputs are designed to source (supply) power supply voltage when activated.
Each output is short protected and has open detection. The maximum current capability is
3 Amps.
PWM OUTPUTS (PWM OUT) – Qty (3)
These outputs are designed to sink current to ground at a pwm frequency. Each output
can be configured for a specified current range for maximum current sensing resolution (10
bit). See the DVC10 Ordering Guide for typical current ranges. All outputs are short circuit
protected and most current ranges have open circuit and short circuit detection (see
Current Range Details for more information).
A. Current Ranges – Each PWM output can be configured to a current range, which will
produce the maximum current sensing resolution (see ordering guide).
* Note - Current ranges “L”, “H”, and “D” are short circuit protected but do not have short circuit detection.

BI006823-00

OUTPUT GROUPS (3)
The outputs are divided up into 3 output groups. Each output group has (2) High-Side
outputs and (1) PWM output.
OUTPUT GROUP CONFIGURATIONS

DUAL COIL HIGH-SIDE SINGLE COIL HIGH-SIDE
To HS OUT
PWM BANG
PWM PWM BANG
To PWM OUT To PWM OUT To PWR COM
SINGLE COIL LOW-SIDE HIGH-SIDE ONLY

To +POWER IN To HS OUT
BANG BANG BANG BANG

BANG PWM BANG BANG BANG
To PWR COM To PWR COM To PWR COM

To PWM OUT
FIGURE 4
A. Programmable Features
1. Dither Amplitude
2. Dither Frequency
3. Ramp Up and Ramp Down
4. PID setting for current regulation and I/O functions.
5. Min and Max current
6. Output Group Selection
7. Process selection including: Current regulation, Enable process PI, Enable current
ramps, and PWM Duty cycle mode.
* Note – See the DVC10 Programming User Guide for more details on programmable features.

BI006823-00

INPUT/OUTPUT FUNCTIONS – Qty (8)
There are eight Input/Output Functions that can be programmed individually. The I/O
Function gives the user the ability to change the response of the output with the change of
the input (see sample screen below). The input and output are based on a percentage
scale - 0 to 100% - (Min. to Max.). Different adjustable points on the response curve give
the user full flexibility to control non-linear responses. These functions are adjustable while
the controller is running in order to adjust unknown output characteristics.
* Note – See the DVC10 Programming User Guide for more details.
COMMUNICATIONS

1. Can Bus 2.0B – This port is used to communicate to other DVC modules as well as
an ECM (engine control module).
a. Downloading and uploading software.
c. Setting parameters on the fly (fine-tuning).
d. Driving an external display.
* Note – Consult factory for compatible displays.

BI006823-00

POWER SUPPLY

2. Reverse polarity protection and transient protection up to 1.5K Watts Peak Pulse
Power Dissipation
3. More than one power and ground pin must be used if driving over 8 amps (at one
time). Use P1-K1, P2-A1, or P2-A2 for the + POWER INPUT (typically +12Vdc or
+24Vdc). Use P2-E1, P2-F1, P2-F2, or P2-F3 for the PWR COM (typically tied to
chassis).
MEMORY SIZE
A. 1MByte Flash Memory (up to 100,000 erase/write cycles)

B. 128 Kbytes RAM
C. 2 Kbytes EEPROM (non-volatile memory)
INDICATORS
A. Power LED (Qty 1) (Green) – Blinks if the power supply voltage is above +30Vdc.
Turns off if the power supply voltage drops below +8.0Vdc.
B. Status LED (Qty 1) (Red) – This LED is programmable and is commonly used for error
status or blink codes.
C. Digital Input Status (Qty 8) (Green) – Turns on when the corresponding input is
D. High-Side Output Driver Status (Qty 6)(Green) – Turns on when the corresponding
High-side output is activated. Blinks once per second for an open circuit. Blinks four
times per second for a short circuit.
E. PWM Output Driver Status (Qty 3) (R/G) – This LED displays duty-cycle status for the
corresponding PWM output. The LED will display from red to green as the duty-cycle
changes from 0% to 100% (50% displaying yellow).
F. Module Status (MS) (Qty 1) (R/G) –
G. Network Status (NS) (Qty 1) (R/G) –
nodes.

BI006823-00

PACKAGING

0.325”.
CONNECTORS
A. The DVC10 uses the Metri-Pack 150 series (or compatible) sealed electronic header
designed for severe underhood environments.
2. 18-pin Header (P2) – Used for the power supply and output connections.
B. 5-pin CAN Bus (DeviceNet compliant) connector
MATING CONNECTORS
A. Mating for 30-pin Header (P1) and 18-pin Header (P2)

C. Mating to the RS-232 Port – The RS-232 port is accessed through the 30-pin connector
at (P1). A DVC10 Serial Port Adapter is available to connect to the 30-pin Female (P1)
mating connector. A DVC RS-232 Cable can be used to interface from the DVC10
Serial Port Adapter to a PC. Drawings for these two cables are supplied for user
assembly; otherwise they are available from the HCT.
* Note – The DVC10 Serial Port Adapter comes with a plug. The plug is used to keep the cable weather-
tight when not connected to peripherals.

BI006823-00

1. DVC10 Serial Port Adapter HCT P/N - 999-10076
ENVIRONMENTAL
• Operating Temperature -40 Celsius to 85 Celsius
• Storage Temperature -40 Celsius to 85 Celsius

BI006823-00
DVC41 Sourcing Output Expansion Module


BI006823-00
DVC41(12 Sourcing Output Module) Rev. P2.0
DESCRIPTION
The DVC41 slave module is a 12 Sourcing Output module that is designed to operate in
conjunction with a DVC10 master module. The 12 Sourcing outputs can be configured to drive
substantial loads up to 3 amps. The DVC41 can also be configured to drive LED outputs. The
outputs are short protected and have built in open detection. The DVC41 communicates to the
Master Module through the CAN Bus (high-speed serial communication bus) and utilizes the RS-
232 port for setting the MAC ID (node) number and for device monitoring. The controller is
packaged in a small rugged enclosure and encapsulated to withstand extreme harsh environments.
Two connectors P8 and P9 are provided for electrical connections. P8 (30 pin) is the main
input and output connector which protrudes out the side of the enclosure. P9 is a standard Device-
Net Compatible (CAN Bus 2.0B) 5 pin connector.
The status of each output is displayed by a green LED located on the top of the module. If
the output is activated, the corresponding LED will light. If the output is being used and has an
open circuit, then the corresponding LED will blink slowly (once a second). If the output is
shorted, the corresponding LED will blink fast (four times a second). A Module Status (R/G LED)
and a Network Status (R/G LED) LED are also located on the top of the module (see INDICATIORS
section below for further details).

BI006823-00
FEATURES
• All outputs are sourcing.
• Outputs are programmable to work with heavy loads or light loads (LED’s).
• Controller Area Network (CAN 2.0B) provides high-speed serial communications with up
to 16 other CAN compatible devices.
• Rugged encapsulated enclosure withstands harsh environments commonly found in mobile
applications.
• User friendly display shows output and communication status.
• RS-232 communication used for troubleshooting and node assignment.
• Rugged power supply operates over the full range 8.0Vdc to 32Vdc with reverse polarity
protection and transient protection up to 1.5K Watts Peak Pulse Power Dissipation.
• Compact & rugged packaging.
OUTPUTS – QTY (12)
OUTPUT OPERATION
A. All outputs are sourcing.
1. Vehicle +Power will be applied to the output when the output is activated.
B. Maximum Output Load = 3amps.
C. Each output has a corresponding indicator to tell whether the output is on, off, shorted or
open (see INDICATORS below for more details).
*Note – The output will not detect an OPEN circuit when in LED mode.
D. Short Circuit Operation
1. Output is turned off.
2. Short Circuit is detected only when the output is being commanded to activate.
3. If after 10 seconds the output command goes away and the output is no longer
shorted, then the next output command will clear the short and try to activate the
output.
E. Open Circuit Operation
1. Output is turned off.
2. Only detected when the output is commanded off.
3. Opens are reset immediately but only in the commanded off state.
DVC41 SOURCING OUTPUT (+PWR)

LOAD
SAMPLE
LOAD
CONFIGURATION
GND

BI006823-00
PROGRAMMABLE FEATURES
A. DVC41 programmable features are set by using the DVC Programming Tool and
then stored in the DVC10 Master Module.
1. Each output can be named (16 characters).
2. Normal load mode – Used for driving all loads up to 3amps.
3. LED output mode – Used for driving LED’s or low current indicators.
*Note – Not using LED mode to drive LED’s or low current indicators can cause the outputs to
dimly light when turned off.
B. The MAC ID and Baud Rate settings are set at each DVC41 module through the RS-
232 serial port.
*Note – All DVC41 modules will ship from HCT with the MAC ID set to 41 and a Baud Rate set to
125k unless otherwise noted.
COMMUNICATIONS
1. Can Bus 2.0B – This port is used to communicate to the DVC10 Master
Module. A DeviceNet protocol is used.
a. Setting MAC ID and Baud Rate.
POWER SUPPLY
1. Range - +8.0Vdc to +32Vdc
2. Reverse polarity protection and transient protection up to 1.5K Watts Peak
Pulse Power Dissipation
3. Power is supplied to the module through P8 (not the Can Bus).
4. +POWER IN 1 - This input supplies power to the DVC41 controller and
outputs 1, 2, 3, and 4.
5. +POWER IN 2 - This input supplies power to outputs 5, 6, 7, and 8.
6. +POWER IN 3 - This input supplies power to outputs 9, 10, 11, and 12.
7. GND (PWR) - This is the DVC41 main common (usually connects to
chassis ground).
INDICATORS
A. Output Status (Qty 40) (Green)
1. Off – output is off.
2. On – output is being activated.
3. Open Circuit – blinks once per second.
4. Short Circuit – blinks 4 times per second.
B. Module Status (MS) (Qty 1) (R/G) –
C. Network Status (NS) (Qty 1) (R/G) –
nodes.
BI006823-00
PACKAGING
0.325”.
CONNECTORS
A. The DVC41 uses the Metri-Pack 150 series (or compatible) sealed electronic
header designed for severe under-hood environments.
1. 30-pin Header (P8)
B. 5-pin CAN Bus (DeviceNet compliant) connector (P9).
MATING CONNECTORS
A. Mates to the 30-pin Metri-Pak Connector (P8):
3. Plugs Delphi Packard P/N – 12034413-B
4. Terminal Crimp Tool Delphi Packard P/N – 12039500
5. Extraction Tool Delphi Packard P/N – 12094429
C. Mating to the RS-232 Port – The RS-232 port is accessed through the 30-pin
connector at (P8). A DVC Serial Port Adapter is available to connect to the 30-pin
Female mating connector. A DVC RS-232 Cable can be used to interface from the
DVC Serial Port Adapter to a PC. Drawings for these two cables are supplied for
user assembly; otherwise they are available from HCT.
* Note – The DVC Slave Serial Port Adapter comes with a plug. The plug is
used to keep the cable weather-tight when not connected to
peripherals.
ENVIRONMENTAL

BI006823-00
POLLED IO DATA
Vendor ID……………..62
Product Code………….41
Product Type………….x67
Produced IO Data……..2
Consumed IO Data……4
Produced IO Data Consumed IO Data Consumed IO Data

Word Byte 0 Byte 0 Byte 1
Byte Offset 0 0 2
Name Outputs Shorts Opens
Bit 0 HS1 Sht01 Opn01
Bit 12 - - -
Bit 13 - - -
Bit 14 - - -
Bit 15 - - -

BI006823-00
P9
3
2
1
12 11 10 9 8 7 6 5 4 3 2 1
B
MS
C
CAN BUS
D
DIGITAL VALVE CONTROLLER NS
E
DVC41
5-PIN CAN CONNECTOR

12 SOURCING OUTPUT MODULE
F
G
H
MAC ID =
J
K
5 PIN CAN (P9)

*** SPECIAL NOTES: PIN FUNCTION
P9
1. +POWER IN 1 supplies power to the DVC41 module and HS OUT 1, 1 **DRAIN (NC) 4 3
HS OUT 2, HS OUT 3, and HS OUT 4. ** V+ (NC)
2
2. +POWER IN 2 supplies power to HS OUT 5, HS OUT 6, HS OUT 7, 5
3 ** V- (NC)
and HS OUT 8.
3. +POWER IN 3 supplies power to HS OUT 9, HS OUT 10,
4 CAN_H 1 2
HS OUT 11, and HS OUT 12. 5 CAN_L MALE (pins)
** Not connected internally

to the DVC41 module.
A1 HS OUT 1 D2 PWR COM G3 PWR COM
A2 PWR COM D3 PWR COM H1 HS OUT 12
A3 RXD E1 HS OUT 5 H2 PWR COM
B1 HS OUT 2 E2 HS OUT 6 H3 PWR COM
B2 PWR COM E3 HS OUT 7 J1 +POWER IN 1
B3 TXD F1 HS OUT 8 J2 +POWER IN 2
C1 HS OUT 3 F2 HS OUT 9 J3 +POWER IN 3
C2 SIG COM F3 HS OUT 10 K1 +POWER IN 1
C3 PWR COM G1 HS OUT 11 K2 +POWER IN 2
D1 HS OUT 4 G2 PWR COM K3 +POWER IN 3
9/26/01

BI006823-00

208 Gold Flat Court
(530) 265-3236
High-Side Output Driver Status (Green)
Off – Output is off Module Status (MS) (R/G)
On – Output is being activated Off – There is no power applied to the Module.
Open Circuit – Blinks once per second On green – The module is operating in a
normal condition.
Short Circuit – Blinks 4 times per second
need commissioning.

Application Code).

in the project.
established.
a timed-out state.
the network.

Schematics BI006823-00
The hydraulic and electrical schematics follow. Full size electrical and hydraulic schematics can be
found in the inside front cover pocket of this manual.

BI006823-00
Hydraulic Piping
AIR
DRILL HPR 45
407596
(OPTIONAL) (OPTIONAL) L2
C1 V1
LINEAR ROD CHANGER MANIFOLD BULKHEAD @ BOOM
CAROUSEL ROD CHANGER MANIFOLD B
417226 417226 BULKHEAD @ BOOM 3000
P R
CARRIAGE LOCK
R TRAM
G2 C6 BULKHEAD @ DRIVELINE G2 C6 BULKHEAD @ DRIVELINE CASE DRAIN
401426
R OSCILLATION C5 C5
BULKHEAD ROD WRENCH ROD WRENCH M3
@ BOOM
AUX MANIFOLD 400
CARRIAGE LOCK
400
CLAMP (LOWER) CLAMP (UPPER) C2 3000
V2
PSI PSI
432748 A BULKHEAD @
L OSCILLATION DRILL SLIDE
OE1 S2 S2
2
"LOCK"
EMDV-10-N-3E .067(#51))( .067(#51))( L1
OE2 3
1
PARKER C10-3
OR C3 C3 A C2 3000 V2
"3" MCH-101 "2" MCH-101 "1" MCH-101
ROD LOCK BULKHEAD @
E
TENSIONER
PARKER CDD-1010 Work Port (2) PARKER CDD-1010 Work Port (2) PARKER CDD-1010 Work Port (2)
H C4 C4
BULKHEAD Pilot Port

(1)
Pilot Port
(1)
Pilot Port
(1)
SRC INDEX CYL. L TRAM
I S1 S1
@ BOOM Valve Port (3) Valve Port (3) Valve Port (3)
PPB V1 C1
.0465(#56))(
Y Z S2
3000
S2 BULKHEAD @
X PPA
OPTION DRIVELINE
CA BB
V1 2 1
C1 M3
CB CC M1
CARRIAGE M1
3
C1 3000
V1
"CENT"DSL105 "SPARE"DSL105 "PUP"DSL105 "OSC"DSL105 PICK UP POT
DS102N "PUMP" 2 4 PARKER C10-4 2 4 PARKER C10-4 2 4 PARKER C10-4 2 4 PARKER C10-4
MOTOR B
CENTRALIZER PARKER C10-2
M2 M2
3
OPTION .026(#71))(
V2 2 C2
R
1
3 1 3 1 3 1 3 1
CP 1 FC1015600 "FC" S1 S1
A B C D E
2 PARKER C10-2
P2 2 1 P1 COUNTERBALANCE VALVE
RB R TRAM BRAKE 3000
C2 CRC INDEX MOTOR
B "PR" PRH101
S2 V2 S2
TWO SPEED 2S
2
"2SP" DSL103
PARKER C10-3 2
PARKER C10-3
2
"B1" DSL103
PARKER C10-3 2
"B2" DSL103
PARKER C10-3
LB
L TRAM BRAKE V1 2 1
C1
COMPRESSOR MOTOR
1
3
G1 C1 G1 C1
3
431741 A B
3 1 3 1 3 1
T2 3
RP C2 C2 V2 2 1 C2
GAUGE PORT S1
ROD S1 .0465(#56))( .0465(#56))(
WRENCH
2000 2000
PSI PSI
COUNTERBALANCE VALVE
ROD WRENCH ROD WRENCH
SWING (LOWER) SWING (UPPER)
P T P T
ROD CHANGER
MANIFOLD RETURN
LINEAR ROD LINEAR ROD CAROUSEL ROD CAROUSEL ROD B A B A B A LSPB
CHANGER PSI CHANGER RETURN CHANGER PSI CHANGER RETURN
PS
240 240 240 240
AIR
ROD CHANGER
MANIFOLD PSI DRILL ATW
P1
407201
DUST COLLECTOR DUST

VALVE P R
THERMAL
MANIFOLD COLLECTOR
421599 432201
HEAT EXCHANGER
G
PRESSURE PL BULKHEAD @
P M1
RETURN MANIFOLD 35
DRILL SLIDE
MANIFOLD 415885
PX
250
415885 LS
OUT
M2
T
BULKHEAD @
IN TENSIONER
T1
LS LS T2B TRAM VALVE BULKHEAD @

431743 DRIVELINE
RP1 A GPA GPA A RP1
A B C D E F
DRILL CONFIGURATIONS
1 1A B B 1A 1
PUMP 1 431744 PUMP 2 D C PUMP FEED

431716 431740
B
SEE DRILL CONFIGURATIONS C1 C2

HAND
PUMP A B C D E F
3000
3000
C1 C2
3000
3000
BULKHEAD @
DRIVELINE V1 V2 V1 V2
BULKHEAD
@ BOOM
BULKHEAD
@ BOOM
TO COMPRESSOR BOOM FEED

BOOM
BOOM LIFT EXTEND FEED DUMP FEED SWING EXTEND
HAMMER ROTATION SWING BLANK
FEED
.060
PS
B A B A B A B A B A B A B A B A B A B A
TPB
T1
P2B
TANK
35
240
T2B
T3B
P1
LSPB
PL PX LSB LSA LSB LSA LSB LSA BOOM VALVE
LS
431742
RELIEF MANIFOLD
431748
REFER TO AIR PIPING
1 2
(ref. 432231 rev. C)

FEED PRESSURE CONTROL MANIFOLD
TRANSDUCER MANIFOLD 438113
431749

Boom and Feed Piping BI006823-00
BULKHEAD
@ BOOM
AUX MANIFOLD
432748 BULKHEAD
@ BOOM
OE1 "LOCK"
2
EMDV-10-N-3E BULKHEAD @ DRIVELINE
OE2 PARKER C10-3
1
CARRIAGE LOCK
(OPTIONAL)
3
BULKHEAD OR
LINEAR ROD CHANGER MANIFOLD
@ BOOM "3" MCH-101 "2" MCH-101 "1" MCH-101
PARKER CDD-1010 Work Port (2) PARKER CDD-1010 Work Port (2) PARKER CDD-1010 Work Port (2) E 417226
H
Pilot Port Pilot Port Pilot Port
(1) (1) (1)
I
Valve Port (3) Valve Port (3) Valve Port (3)
PPB PRESSURE MANIFOLD G2 C6

Y Z
X PPA C5
CA BB
CC
CB "CENT"DSL105 "SPARE"DSL105 "PUP"DSL105 "OSC"DSL105 CARRIAGE LOCK
DS102N "PUMP" 2 4 PARKER C10-4 2 4 PARKER C10-4 2 4 PARKER C10-4 2 4 PARKER C10-4
400
PARKER C10-2
PICK UP POT PSI
3 1 3 1 3 1 3 1
R
CENTRALIZER CP 1 FC1015600 "FC"
2 PARKER C10-2
P2 2 1 P1 S2
RB
B "PR" PRH101
PARKER C10-3
2S "2SP" DSL103
2
"B1" DSL103 "B2" DSL103
LB
C3
2 PARKER C10-3 2 PARKER C10-3 2 PARKER C10-3

3
ROD LOCK
1
3 1 3 1 3 1 C4
T2
S1
RP DRILL
S2
AIR
V1 C1
1
M1
3
CARRIAGE
M2
MOTOR
3
S1
1
P R V2 C2
S2
G1 C1
INDEX LOCK 'C6'
FEED EXTEND 'B' ROD LOCK 'C3'

INDEX LOCK 'C5'
C2
S1
ROD
2000
PSI WRENCH FEED EXTEND 'A' ROD LOCK 'C4'
P T
FEED SWING 'B' BLANK
CARRIAGE 'M2' CARRIAGE 'M1'

FEED SWING 'A' BLANK
PICK UP POT 'A'

PICK UP POT 'B'
RETURN MANIFOLD FEED DUMP 'B'
OUT
CENT. 'A'
IN FEED DUMP 'A' AIR GREASER

BULKHEAD @ DRILL SLIDE CENT. 'B'
B A CASE DRAIN CASE DRAIN
BULKHEAD @ TENSIONER FEED THREAD GREASE
BLANK
ROD WRENCH 'C1'
ROD WRENCH 'C2'
C1 C2
C1 C2 HAMMER PRESSURE
BULKHEAD @ 1 1
1 1
DRIVELINE 3 3
3 3
2 2 2 2
HAMMER RETURN
ROTATION FORWARD
V1 V2 AIR
BULKHEAD
V1 V2
@ BOOM FEED DOWN ROTATION REVERSE
BULKHEAD @ BOOM
FEED UP
DETAIL A
VIEWING FROM BOOM BASE.
BOOM FEED
HAMMER BOOM LIFT
BOOM
EXTEND FEED DUMP EXTEND
(NTS.)
ROTATION SWING FEED SWING BLANK
AIR SUPPLY FEED
.060
PS
TPB
P2B
35
240
T2B
T3B
LSPB
PL PX LSB LSA LSB LSA LSB LSA
LS
(ref. 433445 rev. E)

BI006823-00
Boom Valve Circuit
RETURN MANIFOLD
415885
OUT
IN
AIR
DRILL
407201
P R FEED
431740
BULKHEAD @ B A
DRILL SLIDE
C1 C2
1 1
BULKHEAD @ 3 3
TENSIONER C1 C2 2 2
1 1
3 3
2 2
BULKHEAD @
DRIVELINE
V1 V2
V1 V2
BULKHEAD
@ BOOM
BULKHEAD
@ BOOM
TO COMPRESSOR BOOM
BOOM FEED
BOOM LIFT EXTEND FEED DUMP FEED SWING EXTEND
HAMMER ROTATION SWING BLANK
FEED
.060
R F
PS
TPB
T1
P2B
35
240
T2B
T3B
P1
PL PX LSB LSA LSB LSA LSB LSA BOOM VALVE LSPB
LS
431742
RELIEF MANIFOLD
431748
REFER TO AIR PIPING
1 2
TRANSDUCER MANIFOLD
431749
(ref. 428266 rev. E)

Electrical Schematic BI006823-00
BATTERY DISCONNECT
BATTERIES
SWITCH 327669
+24 VDC MACH. GROUND
SUPPLIED/ENERGIZED BY ENGINE ECM

135A
RD 6G WE 6G
DVC41
BK #0
BK #0
AIR INLET
HEATER
MAC ID 41 Boom_Ext_Out
B
STARTER PE #5
S BE 14G S
B
A1 HS OUT 1
BK #0
50A 20A START
S
MOTOR A2 PWR COM DVC22
M
RD 6G RD 1OG B RD #0 Boom_Ext_In MAC ID 22

A3 RXD PE #6
BK #0
10A DVC50 A1 PWR COM
B1 HS OUT 2
RD/BK 16G ACC R
BR MAC ID 50 RS232 B2 PWR COM A2 PWR COM
GN #2
RD #0 B3 TXD Feed_Ext_Out A3 PWR COM
2.5A A1 RXD POWER + A1 BK #0 PK #1
GN #2 B1 PWR COM
40A RS232 A2 TXD C1 HS OUT 3 RD #0
ALTERNATOR POWER + A2 B2 PWR IN +
Load Switch B A3 PE #3 C2 SIG COM
BK #0 BOOM_Swing_PWM Drill Joy WE Button
B1 COM PWM1 A3 C3 PWR COM
B2 COM WE #3 Feed_Ext_In Collaring BN #0
GND BOOM_Swing_Left PK #2 B3 DIG IN 1
B3 COM HS1 B1 D1 HS OUT 4
F4
FUSE BE #19 C1 WE #4 BOOM_Swing_Right D2 PWR COM Drill Joy RD Button
ROT_TR3 C2 P/A1 HS2 B2 D3 PWR COM Hammer BN #1
10A DIG IN 2
PE #4 DC_On C1
CAT ECM C3 COM BOOM_Swing_PWM TN #2
RD 16G YW #12 D1 PWM1 B3 E1 HS OUT 5
PIN #1 Feed_TR3 D2 P/A2 WE #7 Feed_Dump_Up C2 DIG IN 3
YW/BK 16G HS3 C1 WATER_On
PIN #26 JS1-Right_Joystick D3 COM TN #1
YW #13 E1 E2 HS OUT 6 AirOn BN #3
GN #1 WE #8 Feed_Dump_Down
PIN #27 C-D PROP. OUTPUT
E2 A1 C3 DIG IN 4
NC
RT_forward HS4 C2 OFF BN #4
GN #2 NO E3 COM AIR_Direction D1 DIG IN 5
PIN #28 PE #8 Feed_Dump_PWM TN #8 10 2
NC
RT_Reverse
YW #14 F1 PWM2 C3 AirOff
GN #9 CONNECTION FROM DVC 41-2 NO E3 HS OUT 7
PIN #29 F2 A2 WE #9 Feed_Swing_Left
YW #15 7 OE/WH Water_Inj
GN #9 F3 D1 HS5 D1
PIN #30 6 BN #5
G1 Feed_Swing_Right 5 D2 DIG IN 6
RD 16G YW #16 HS6 D2 TN #0
PIN #31 G2 A3 AIR_Off/On RELAY #7 DC_On
JS2-Left_Joystick
RD 16G G3 D2 TN #9 9 OE/GN BN #6
PIN #32 C-D PROP. OUTPUT YW #17 PWM2 D3 PE #7 Feed_Dump_PWM F1 HS OUT 8 D3 DIG IN 7
H1 11
8 RC_Mode
H2 A4 PWR COM E1
BN #7
A-B PROP. OUTPUT PE #9 Feed_Swing_PWM E1 DIG IN 8
OSC_Forward
NC
LT_forward YW #18 PWM3 E2 TN #4
NO H3 D3 F2 HS OUT 9 Drill_Mode BN #8
NC
LT_Reverse YW #19 E2 DIG IN 9
AIR BLOWDOWN VALVE NO J1 D4 OFF BN #9
YW/BK 16G 98883 OSC_Reverse E3 DIG IN 10
NC
LT_Left WE #10 Feed_Swing_PWM
NO J2 D5 PK #0 TN #5 Tram_Mode
WE #11 PWM3 E3
NC
LT_Right F3 HS OUT 10
NO J3 D6
TILT PWR COM F1
YW/BK 16G DISPLAY OSC_Lock_RH Rope_Kill_Sw GY #7
K1 POWER TN #6
RED 98501 GND BLACK F1 DIG IN 11
VIN JS2_PB_LB
G1 HS OUT 11
GROUND
WE #12 PWR COM F2 Drill Joy BK Button
V+ X Y V- K2 D7 G2 PWR COM Thread_Grease GY #0
YELLOW
F2 DIG IN 12
W/RED
W/BLK
G3 PWR COM
BLUE
JS2_PB_LT
WE #13 OSC_Lock_LH Smart_Drill
K3 D8 PWR COM F3 TN #7 GY #1
H1 HS OUT 12 F3 DIG IN 13
PE #13
V-
BLACK
H2 PWR COM High_Idle
BK #0
PE #14 YELLOW
GY #2
PWR COM
Y
TILT
H3 G1 DIG IN 14
PE #15 SENDER J1 PWR IN 1
BK #0
BK #0
BLUE
X
97849
BK #0
GROUND
RELAY #1 PE #16 J2 PWR IN 2
V+
RED
30A Cent_Open GY #3
J3 PWR IN 3 G2 DIG IN 15
YW/BK 16G
K1 PWR IN 1 GY #4
EN GND G3 DIG IN 16
RD 14G F6 K2 PWR IN 2 Cent_Closed
RD #9 14G 23A
DVC50
FUSE AIR CONDITION UNIT
IN NO K3 PWR IN 3
30A LOW HIGH COMPRESSOR
MAC ID 51
1 2 PRESSURE PRESSURE CLUTCH RD #0 PUP_Up
3 SWITCH SWITCH A1 RXD POWER + A1 GY #5
WHITE 16G WHITE 16G GREEN #4/18G GN #2 H1 DIG IN 17
RS232 A2 TXD
FAN SPEED POWER + A2 GY #6
A3 Drill_Feed_Motor_PWM H2 DIG IN 18
BK #0 BE #9
B1 COM PUP_Down
PWM1 A3
CONDENSOR B2 COM YW #9 Drill_Feed_Motor_Up
FAN B3 COM HS3 B1 Engine_Kill_Sw RD #8
RD 16G C1 H3 DIG IN 19
BE #17 WE #0 Drill_Feed_Motor_Down
C NO AIR_TR3 C2 P/A1 HS4 B2
BK/WE 16G BK/WE 16G C3 COM PE #0 Drill_Feed_Motor_PWM DVC41 Operator_Pres_SW
EN GND BE #18 D1 PWM1 B3 MAC ID 42 Left Track Brake GY #8
J1 DIG IN 20
HAM_TR3 D2 P/A2 YW #7 Drill_Rot_CCW PK #5
D3 COM HS1 C1 A1 HS OUT 1 JS1_PB_LB
JS3-Drill_Joystick
E1 A2 PWR COM GY #9
X_axis_Feed WE #14 YW #8 Drill_Rot_CW J2 DIG IN 21
E2 A1 C2 RD #0 Right Track Brake
HS2 A3 RXD PK #6
E3 COM BE #8 Drill_Rot_PWM JS1_PB_LT
RELAY #2 B1 HS OUT 2
BK #0
Y_axis_Rot
F1 PWM2 C3 OE #7
30A WE #15 RS232 GN #2 B2 PWR COM J3 DIG IN 22
NC
Feed_FOR F2 A2 YW #5 Hammer/Collar DC_Timer_ON
YW/BK 16G WE #16
NO
F3 D1 HS5 D1 BK #0 B3 TXD YW #4 JS2_PB_RB
NC
EN Feed_REV
GND NO
C1 HS OUT 3 OE #8
YW #6 Warm_Oil C2 SIG COM K1 DIG IN 23
FEED
NC
Rot_CCW G1 HS6 D2
NO
LIGHT C3 PWR COM JS2_PB_RT

NC G2 A3 BE #7
NO
Rot_CW
WE #17 PWM2 D3 Drill_Rot_PWM OE #9
G3 D2 K2 DIG IN 24
D1 HS OUT 4
H1 PWR COM E1 D2 PWR COM
LIGHTS BE #5 Hammer_PWM
H2 A4 D3 PWR COM
F1 FRONT DRILL LIGHTS PWM3 E2 Thread_Greaser DIG IN 25
RD 16G 6A WE #18 K3
FUSE H3 D3 BE #6 WarmOil_PWM GN #7
IN NO RD/BE 16G RD/WE 16G
RD/GY 16G
15A SW5 WE #19 PWM3 E3 E1 HS OUT 5

LIGHTS Warm_OIL J1 D4
PE #10 TN/WE 16G Engine Kill 85 86 A1 DIG IN 26
6A REAR DRILL LIGHTS J2 D5 E2 HS OUT 6
SW6 RD/WE 16G J3 D6 87a RELAY #4
LIGHTS RD #0 PWR COM F1 A2 DIG IN 27
F2
RD/YW 16G 1A CAB LIGHT K1 POWER 30
FUSE Osc_LOCK_SW2 GN #1 87
SW27 #27 on CAT ECM
5A
PE #12 PWR COM F2
K2 D7 A3 DIG IN 28
TN/BE 16G High RPM 85 86
1A WIPER #1 Drill Joy YW Button E3 HS OUT 7
M
SW28 Sync_Thread PWR COM F3 RELAY #5
RD #9 87a
K3 D8 B1 DIG IN 29
30
F3 87
1A WIPER #2 GN #2
FUSE M #28 on CAT ECM
10A SW29
B2 DIG IN 30
BK #0
BK #0
WASHER #1 WE/YW 16G Left_Hand_Dead_SW
RD/GN 16G Centrlzr_Open
M WE #5
1A PK #7 B3 DIG IN 31
YW/WE 16G F1 HS OUT 8
BK #0
M
SW7 WASHER #2 Right_Hand_Dead_SW
Centrlzr_Close WE #6
PK #8 C1 DIG IN 32
DVC50 F2 HS OUT 9
C2 DIG IN 33
MAC ID 52 PUP_Up C3 DIG IN 34
RD #0 PK #9 D1 DIG IN 35
DC/DC A1 RXD POWER + A1
CONVETER GN #2 F3 HS OUT 10 D2 DIG IN 36
RS232 A2 TXD
POWER + A2 D3 DIG IN 37
A3 BE #15
12V/10A
PUP_Down E1 DIG IN 38
BK #0 TN #3
B1 COM PWM1 A3
G1 HS OUT 11 E2 DIG IN 39
B2 COM YW #10
E3 DIG IN 40
B3 COM HS1 B1 G2 PWR COM RD #0
F1 RXD
BE #12 C1 Feed Force Coil G3 PWR COM GN #2
F2 TXD
System_TR5 C2 P/A1 HS2 B2 Work RPM 85 86 BK #0
TN/BK 16G RS232 F3 SIG COM
RADIO C3 COM H1 HS OUT 12
D1 PWM1 B3 87a RELAY #6
1K ohm
WE/GN 16G D2 P/A2 H2 PWR COM 30

BK #0
D3 COM HS3 C1
Feed Force Control
H3 PWR COM GN #9
87
BE #13 E1 #29/30 on CAT ECM
J1 PWR IN 1
GROUND
5 VDC
E2 A1 HS4 C2
E3 COM J2 PWR IN 2
Feed Flow Control
BE #14 F1 PWM2 C3 Compressor Coil J3 PWR IN 3

FUSE
F2 A2 GN #0 K1 PWR IN 1
YW/BK 16G
10 A HS5 D1 TERMINATING
F3 D1 K2 PWR IN 2 DVC80 RESISTOR
K3 PWR IN 3 MAC ID 8 120 Ohm
G1 HS6 D2
G2 A3
RELAY #3 POWER OUTLET (Qty 1) PWM2 D3
G3 D2 RD #0
A1 RXD
H1 PWR COM E1 GN #2
EN BE #4 A2 TXD
GND H2 A4 BK #0
PWM3 E2 RS232 A3 SIG COM
H3 D3 B1
RD 16G
PWM3 E3 B2
IN NO J1 D4
BK #0
BK #0
B3
F5 J2 D5 DVC41
C1
FUSE
J3 D6 MAC ID 43 Carriage_UNL 120 Ohm
C2
20 A PWR COM F1 OE #6
K1 POWER A1 HS OUT 1 C3
A2 PWR COM CAT ECM PLUG
D1
PWR COM F2 RD #0 D2
RD #0 K2 D7 Carriage_Mtr_CW
A3 RXD OE #2 D3
BK #O B1 HS OUT 2 E1
PWR COM F3 RS232 B2 PWR COM
GN #2 E2
K3 D8 Carriage_Mtr_CCW E3
BK #O BK #0 B3 TXD OE #3
C1 HS OUT 3 F1
DVC10 F2
C2 SIG COM
MAC ID 10 F3
RD #0 C3 PWR COM
A1 RXD POWER + A1 ROD_Lock
GN #2 OE #4
RS232 A2 TXD D1 HS OUT 4
YW #4 POWER + A2
A3 RTS D2 PWR COM
BK #0 BE #0 RIGHT_Motor_PWM
B1 COM PWM1 A3 D3 PWR COM
B2 COM RIGHT_Motor_Rev ROD_Unlock
YW #0 OE #5
B3 COM HS1 B1 E1 HS OUT 5
C1 U1 POT REF BE #1 RIGHT_Motor_For
GN #8 Rod_Wrench_In
C2 U1 HS2 B2 OE #0
COMP TEMP C3 COM RIGHT_Motor_PWM E2 HS OUT 6
YW #1
GN #6
D1 U2 POT REF PWM1 B3
Rod_Wrench_out
DVC61
D2 U2 LEFT_Motor_Rev MAC ID 61
YW #2 OE #1 Engine
LEVEL D3 COM HS3 C1 E3 HS OUT 7
SENDER E1 U3 POT REF LEFT_Motor_For 3 PWR GND 4
7 TXD
8 RXD
9 RXD
YW #3
E2 U3 HS4 C2 CANH 5
RD #1 E3 COM F1 HS OUT 8 CANL 6
BE #3 LEFT_Motor_PWM
F1 A1 POT REF PWM2 C3
F2 A1 Boom_Lift_Up Drill_Mode
WE #1 PK #4 RD #0
F3 D1 HS5 D1 F2 HS OUT 9 GN #2
G1 RS232
Boom_Lift_Down
G2 A2 WE #2
HS6 D2 BK #0
G3 D2
BE #2 LEFT_Motor_PWM F3 HS OUT 10
H1
PWM2 D3
Tram_Alarm
PWR COM E1 GE #5
PE #17 PE #1 Boom_Lift_PWM G1 HS OUT 11
H2 A3 PWM3 E2 DVC61
H3 D3 G2 PWR COM MAC ID 62
PE #2 Boom_Lift_PWM Hydraulic
J1 D4 G3 PWR COM
PWM3 E3
3 PWR GND 4
7 TXD
8 RXD
9 RXD
2-speed
JS1-Right_Joystick PWR COM F1 CANH 5
PE #11
H1 HS OUT 12 CANL 6
A-B PROP. OUTPUT
NC
RT_left PE #18 H2 PWR COM
NO J2 D5 TERMINATING
H3 PWR COM RD #0 RESISTOR
NC
RT_Right PE #19
NO J3 D6 J1 PWR IN 1 GN #2 120 Ohm
RS232
J2 PWR IN 2
BK #0
J3 PWR IN 3
RD #0
K1 POWER PWR IN 1
PWR COM F2 K1
JS1_PB_RB
BK #0
K2 PWR IN 2
BE #10 K2 D7
K3 PWR IN 3
JS1_PB_RT
BK #O
BE #11
K3 D8 PWR COM F3
(ref. 432233 rev. 2)

BI006823-00
Engine Wiring Harness
GREASER
1 2
BACK UP
ALARM
1 2
BLACK/0-18 GA.
GREEN/7-18 GA.
22
GREEN/5-18 GA.
BLACK/18 GA.
20
17
1
A/C COMP. ON
GREEN/4-18 GA.
WATER VALVE
2
1 2 INSERT ARRANGEMENT SHOWS SOCKET REAR INSERT
STARTER
SOLINOID
ENGAGE
FUEL
SENDER
BLUE/12 GA.
1 2 3 4 5 6 7 8 9 10
A
CAT ECM
C B
15 16
GREEN/6-18 GA.
BLACK/18 GA.
1 2 3 4 5 6 7 8 9 10 11 20
RED/0-18GA.
15 16
11 20
21 30
21 30
25 26 25 26
31 32 33 34 35 36 37 38 39 40
GREEN/9-18 GA.
GREEN/1-18 GA.
GREEN/9-18 GA.
GREEN/0-18 GA.
GREEN/2-18 GA.
31 32 33 34 35 36 37 38 39 40
RED/16 GA.
RED/16 GA.
RED/16 GA.
COLD START
RELAY
(HD36-24-21PN)
COMP.
TEMP. IGNITION BLOW
WIRE TYPE/GA. PIN#
SENDER DOWN VALVE
RED #0/18
GREEN/3-18 GA.
X
A
TAN #1/18 U 1 2
C B
GREEN #0/18 F
GREEN #1/18 H
BLACK/18 GA.
GREEN/8-18 GA.
RED/0 18GA.
GREEN #2/18 J
BLK/0-18 GA.
GREEN #9/18 S
GREEN #9/18 T
GREEN #5/18 M
GREEN #4/18 K
GREEN #3/18 L
GREEN #6/18 N CAT ECM
GREEN #7/18 P
GREEN #8/18 R
RED /16 V
WIRE PIN
BLANK E RED-16GA. #32
RED /16 D
RED-16GA. #31
BLACK #0/18 A
GREEN/9-18GA. #30
C
GREEN/9-18GA. #29
BLUE /12 B
GREEN/2-18GA. #28
BLANK W
GREEN/1-18GA. #27
BLANK G
GREEN/0-18GA. #26
RED-16GA. #1
(ref. 431332 rev. 4)

NOTE: WEAVE HARNESS

Cab Electrical Harness #3 BI006823-00
R.H.
JOYSTICK
1 12
2 11
3 10
4 9
5 8
6 7
C B
1 12
2 11
3 10
4 9
5 8
6 7
31 20
30 8 21 B
19
DRILL
9
18 2 10
JOYSTICK
29 7 3
22
A C
17 1 11
28 6 4 RADIO
16 5 12 23
15 13
27 14 24
26 25
(ref. 432293)

BI006823-00
Cab Electrical Harness #4
L.H. JOYSTICK
(433926)
31 20
30 8 21
19 9
18 2 10
29 7 3
22
17 1 11
28 6 4
16 5 12 23
15 13
27 14 24
26 25
A
YELLOW #16/18GA. WHITE #5/18GA.
1 12
YELLOW #14/18GA. RED #0/18GA.
2 11
WHITE #10/18GA. ORANGE #8/18GA.
3 10
WHITE #11/18GA. ORANGE #9/18GA.
YELLOW #18/18GA.
4 9
WHITE #13/18GA.
1 12
C B
5 8
YELLOW #19/18GA. WHITE #12/18GA.
6 7
2 11
3 10
4 9
5 8
6 7
1
RED #9/18GA.
BLACK #9/18GA.
RED #0/18GA.
A 2
RED #0/18GA. BLACK #0/18GA.
C B
BLACK #0/18GA.
BLACK #0/18GA. BLACK #0/18GA.
BROWN #3/18GA. 7
7 7
GRAY #3/18GA. GRAY #5/18GA.
1 1 1
RED #0/18GA.
2 RED #0/18GA. RED #0/18GA.
2 BROWN #4/18GA. 2
3 GRAY #4/18GA. 3 3 GRAY #6/18GA.
CENTRALIZER AIR ON
PUP
(ref. 432294 rev. A)

Control Panel to Console Box Harness BI006823-00
GY#2
3 2 7
ENGINE
IDLE HIGH
2 7
BRN#5
BRN#6
3 2 7
3 2 7
WATER DUST
INJECTION COLLECTOR
2 7 2 7
BRN#7
PUR#12
RED10GA.
1 2 BLUE14GA. 3 2 7
3 2 7
3 4 YEL/BLK OSCILLATION ROD

SEE SHEET 2
LOCK CHANGER
2 7 2 7
POWER COLD E-STOP

(433715) START
START
SWITCH
NO NO BRN#9
B
S
B R GY#1 3 BRN#8 3
2 7
2 1 7
SMART TRAM/DRILL
DRILL
2 7
2 7
BLK#0
RED#0 SEE SHEET 2
HD36-24-31PN SEE SHEET 2
RED/BLK
SEE SHEET 2
WIRE TYPE / GA. PINS
RED/BLU-16GA. 1
RED/YEL-16GA. 2
RED/WHT-16GA. 3
RED/BLK-16GA. 4
BLK/WHT-16GA. 5
BLUE #13-18GA. 6
7
RED #0-18GA. 8
9
RED #1-18GA. 10
BLK #0-18GA. 11
BRN #7-18GA. 12
BRN #6-18GA. 13
BRN #9-18GA. 14
BRN #8-18GA. 15
BRN #5-18GA. 16
PURPLE #10-18GA. 17
PUR #12-18GA. 18
GRY #1-18GA. 19
GRY #7-18GA. 20
GRY #2-18GA. 21
GRN/BRN-16GA. 22
BLK #0-18GA. 23
24
PURPLE #16-18GA. 25
PURPLE #15-18GA. 26 (ref. 432291 rev. B sheet 1 of 2)
PURPLE #14-18GA. 27
PURPLE #13-18GA. 28

BI006823-00
Control Panel to Console Box Harness
SEE SHEET 1
SEE SHEET 1 RED/BLU 1 2
SEE SHEET 1 YEL/BLK

RED/WHT PUR#10
BLK #0
SEE SHEET 1
3 2 7 3 2 7 3 2 7 3 1
CONTROL DRILL LIGHTS
REAR WARM 12V OUTLET 4 2
SYSTEM
OIL
3 7 2 7 7
FRONT DRILL
LIGHTS
YEL/WHT
HD36-24-31PN
RED/WHT
WIRE TYPE/GA. PINS
RED/BLU-16GA. 1
A/C
RED/YEL-16GA. 2
3 2 7 3 2 7
RED/WHT-16GA. 3 C FEED WASHER
FORCE DRILL LIGHTS WIPER 1 2
RED/BLK-16GA. 4 FRONT FLUID
A B
BLK/WHT-16GA. 5 7 2
BLUE #13-18GA. 6 TO FRONT
WIPER
7 RED/YEL 2
RED #0-18GA. 8 2 PIN 2 PIN
1
9
RED #1-18GA. 10
BLK #0-18GA. 11
BRN #7-18GA. 12
BRN #6-18GA. 13
BRN #9-18GA. 14
BRN #8-18GA. 15
BRN #5-18GA. 16
PURPLE #10-18GA. 17
PUR #12-18GA. 18
GRY #1-18GA. 19
GRY #7-18GA. 20
GRY #2-18GA. 21
GRN/BRN-16GA. 22
BLK #0-18GA. 23
24
PUR#16
PURPLE #16-18GA. 25
PUR#15
PURPLE #15-18GA. 26
PUR#14
PURPLE #14-18GA. 27
PUR#13
PURPLE #13-18GA. 28
RED/YEL
1 2 YEL/WHT
3 4 WHT/YEL
WHT/GRN
ACCESSORIES
(ref. 432291 rev. B sheet 2 of 2)

Cab to Console Box Harness BI006823-00
RED 10GA.
1 2 BLUE 14GA.
POWER
3 4 YEL/BLK
RED 14GA.
PLUG 1
PLUG 3
CONSOLE CAB WALL
RED #0
RED #9
FUNCTION C
B PLUG 2
INPUT
(DRILL JOYSTICK) A GRAY #0
2
NOTE: WEAVE HARNESS
A/C WHITE
WIRES FROM PINS TO

SOCKETS ITEM PLUG 2
PLUG 3
BLK #0 23 24 1
BLK #0 24 24 2
BLK #0 11 24 3
PUR #10 17 34 7
GRN/BRN 22 45 9 PINS TO
PUR #12 18 25 10 WIRES FROM ITEM PLUG 1
WIRES FROM PINS TO PINS
SOCKETS ITEM GRY #1 19 29 18
PLUG 3 PLUG 1
GRY #2 21 42 19 RED #10 1 46 B
RED #0 8 16 A GRY #7 20 30 20 POWER RED 14GA. 3 44 D
RED #1 9 17 H BRN #5 16 32 21 PINS BLUE 14GA. 2 35 E
RED #1 10 17 J BRN #6 13 33 22 YEL/BLK 4 47 S
BLU #13 6 18 N BRN #7 12 37 23 RED #0 A 16 C
BLU #14 7 19 P BRN #8 15 39 24 FUNCTION RED #9 B 26 M
BLK/WHT 5 20 R BRN #9 14 43 25 PINS PINS TO
RED/WHT 3 21 T PUR #13 28 49 11 PLUG 2
RED/YEL 2 22 U PUR #14 27 50 12 GRY #0 C 28 17
RED/BLU 1 27 V PUR #15 26 51 13 A/C WHITE 1 41 15 (ref. 433715 rev. D)
RED/BLK 4 23 W PUR #16 25 52 14 PINS

BI006823-00
Wiring Harness–Aux. #1
31 20
1 2 1 2 1 2 1 2 30 21
8
19 9
PURPLE/1 -18 GA.

18 2 10
PURPLE/3-18 GA.
PURPLE/2-18 GA.
PURPLE/4-18 GA.
WHITE/3-18 GA.
29
WHITE/1-18 GA.
WHITE/2-18 GA.
WHITE/4-18 GA.
7 3 11 22
17 1
28 6 4 23
16 5 12
15 13
27 14 25
26 24
HAMMER WARM OIL ROTATION ROTATION FEED FEED
1 2 1 2 1 2 1 2 1 2 1 2
INSERT ARRANGEMENT SHOWS SOCKET REAR INSERT
YELLOW/9-18 GA.
YELLOW/8-18 GA.
PURPLE/0-18 GA.
YELLOW/7 -18 GA.
YELLOW/6-18 GA.
BLUE/9-18 GA.
WHITE/0-18 GA.
YELLOW/5-18 GA.
BLUE/8-18 GA.
BLUE/6-18 GA.
BLUE/7-18 GA.
BLUE/5-18 GA.
(HD36-24-31ST)
RH TRAM RH TRAM LH TRAM LH TRAM COMPRESSOR
1 2 1 2 1 2 1 2 1 2
YELLOW/0-18 GA.
YELLOW/2-18 GA.
YELLOW/1-18 GA.
YELLOW/3-18 GA.
BLACK/0-18 GA.
BLUE/0-18 GA.
BLUE/2-18 GA.
BLUE/4-18 GA.
BLUE/1-18 GA.
BLUE/3-18 GA.
(HD36-24-31ST)
WIRE TYPE/GA. PIN#

BLUE #9/18 31
BLUE #8/18 30
BLUE #7/18 29
BLUE #6/18 28
BLUE #5/18 27
BLUE #4/18 26
BLUE #3/18 25
BLUE #2/18 24
BLUE #1/18 23
BLUE #0/18 22
YELLOW #9/18 21
YELLOW #8/18 20
YELLOW #7/18 19
YELLOW #6/18 18
YELLOW #5/18 17
YELLOW #3/18 16
YELLOW #2/18 15
YELLOW #1/18 14
YELLOW #0/18 13
PURPLE #4/18 12
PURPLE #3/18 11
PURPLE #2/18 10
PURPLE #1/18 9
PURPLE #0/18 8
WHITE #4/18 7
WHITE #3/18 6
WHITE #2/18 5
WHITE #1/18 4
WHITE #0/18 3
BLACK #0/18 2
CLOCKING PIN 1 (ref. 431333 rev. B)

BI006823-00
FEED EXTEND
1 2
FEED SWING FEED EXTEND
1 2 1 2
BOOM EXTEND FEED DUMP FEED SWING
1 2 1 2 1 2
BOOM EXTEND FEED DUMP
1 2 1 2
PURPLE/6-18 GA.
PURPLE/5-18 GA.
PURPLE/8-18 GA.
PURPLE/7-18 GA.
BLACK/0-18 GA.
PURPLE/9-18 GA.
BLACK/0-18 GA.
BLACK/0-18 GA.
BLACK/0-18 GA.
WHITE/8-18 GA.
WHITE/7-18 GA.
WHITE/9-18 GA.
PINK/2-18 GA.
PINK/1-18 GA.
PINK/0-18 GA.
TAN/0-18 GA.
(HD36-24-31ST)
WIRE TYPE/GA. PIN#
CLOCKING PIN 31
ORANGE #6/18 30
ORANGE #5/18 29
ORANGE #4/18 28
ORANGE #3/18 27
ORANGE #2/18 26
ORANGE #1/18 25
ORANGE #0/18 24
PURPLE #9/18 23
PURPLE #8/18 22
PURPLE #7/18 21
PURPLE #6/18 20
PURPLE #5/18 19
TAN #0/18 18
PINK #2/18 17
PINK #1/18 16
PINK #0/18 15
WHITE #9/18 14
WHITE #8/18 13
WHITE #7/18 12
BLACK #0/18 11
BLACK #0/18 10
BLACK #0/18 9
BLACK #0/18 8
BLACK #0/18 7
BLACK #0/18 6
BLACK #0/18 5
BLACK #0/18 4
BLACK #0/18 3
BLACK #0/18 2
BLACK #0/18 1
ORANGE/5-18 GA.
ORANGE/2-18 GA.
ORANGE/1-18 GA.
BLACK/0-18 GA.
ORANGE/3-18 GA.
ORANGE/4-18 GA.
BLACK/0-18 GA.
ORANGE/0-18 GA.
ORANGE/6-18 GA.
BLACK/0-18 GA.
BLACK/0-18 GA.
BLACK/0-18 GA.
BLACK/0-18 GA.
BLACK/0-18 GA.
31 20
30 8 21
19 9
18 2 10
29 7 3 22
17 1 11 1 2 1 2 1 2 1 2 1 2 1 2
28 6 4 23
16 5 12 RC CARRIAGE MOTOR RC ROD LOCK/UNLOCK
RC ROD WRENCH
15 13 RC CARRIAGE MOTOR RC ROD LOCK/UNLOCK
27 25 RC ROD WRENCH
14
26 24
1 2
RC INDEX LOCK
(ref. 431334 rev. B)

(HD36-24-31ST)

BI006823-00
AIR BALL VALVE
1 2
ORANGE/GREEN-16 GA.
ORANGE/WHITE-16 GA.
OSCILLATION
PUP
1 2 1 2
OSCILLATION LOAD
OSCILLATION PRESS. SENSE
LOCK LOCK COMP. COMP. CENTRALIZER CENTRALIZER
1 2 1 2 1 2 1 2 1 2 1 2
20
BLACK/0-18 GA.
31
BLACK/0-18 GA.
BLACK/0-18 GA.
BLACK/0-18 GA.
PINK/8-18 GA.
PINK/7-18 GA.
TAN/5-18 GA.
PINK/9-18 GA.
30 8 21
BLACK/0-18 GA.
BLACK/0-18 GA.
PINK/3 -18 GA.
PINK/4-18 GA.
DUST COLLECTOR 19 9
PUP OSCILLATION 10
TIMER ON
BLACK/0-18 GA.
18 2
DUST COLLECTOR ON 29
TAN/7-18 GA.
BLACK/0-18 GA.
7 3 11 22
TAN/6 -18 GA.

17 1
1 2 1 2 28 6 4 23
1 2 1 2 16 5 12
BLACK/0-18 GA.
15 13
TRAM BRAKE RH TRAM BRAKE LH 27 14 25
YELLOW/4-18 GA.
TAN/2-18 GA.
BLACK/0-18 GA.
26 24
1 2 1 2
BLACK/0-18 GA.
BLACK/0-18 GA.
BLACK/0-18 GA.
BLACK/0-18 GA.
PINK/5-18 GA.
TAN/4-18 GA.
TAN/3-18 GA.
PINK/6-18 GA.
(HD36-24-31PT) (HD36-24-31PN)
WIRE TYPE/GA. PIN#
BLANK 31
YELLOW #4/18 30
TAN #2/18 29
ORG/GRN 16 28
ORG/WHT 16 27
TAN #7/18 26
TAN #6/18 25
TAN #5/18 24
TAN #4/18 23
TAN #3/18 22
PINK #9/18 21
PINK #8/18 20
PINK #7/18 19
PINK #6/18 18
PINK #5/18 17
PINK #4/18 16
PINK #3/18 15
BLACK #0/18
14
BLACK #0/18 13
BLACK #0/18 12
BLACK #0/18 11
BLACK #0/18 10
BLACK #0/18 9
BLACK #0/18 8
BLACK #0/18 7
BLACK #0/18 6
BLACK #0/18 5
BLACK #0/18 4
BLACK #0/18 3
BLACK #0/18 2
BLACK #0/18 1
(ref. 431335 rev. 2)

Wiring Harness–Aux. #4 BI006823-00
2-SPEED
FEED FORCE 1 2
BLACK/0-18 GA.
PUR/11-18 GA.
1 2
31 20
YELLOW/10-18 GA.
30 8 21
BLUE/15-18 GA.
19 9
18 2 10
29 7 3 22
17 1 11
28 6 4 23
16 5 12
15 13
27 14 25
26 24
ROTATION
PSI AIR PSI
A A
C B C B
(HD36-24-31PT)
BLACK/0-18 GA.
BLACK/0-18 GA.
BLUE/17-18 GA.
BLUE/19-18 GA.
RED/0-18 GA.
RED/0-18 GA.
HAMMER
FEED PSI PSI
A A
C B C B
BLU/18-18 GA.
YEL/12-18 GA.
BLK/0-18 GA.
BLK/0-18 GA.
SYSTEM
RED/0-18 GA.
RED/0-18 GA.
PRESSURE
(HD36-24-31PT) C B
WIRE TYPE/GA. PIN#
PURPLE #11/18 22
BLACK/0-18 GA.
BLUE/12-18 GA.
BLUE #19/18 21
RED/0-18 GA.
BLUE #18/18 20
BLUE #17/18 19
BLUE #15/18 17
BLUE #12/18 16
YELLOW #12/18 15
YELLOW #10/18 13
RED #0/18 12
RED #0/18 11
RED #0/18 10
RED #0/18 9
RED #0/18 8
BLACK #0/18 7
BLACK #0/18 6
BLACK #0/18 5
BLACK #0/18 4
BLACK #0/18 3
BLACK #0/18 2
BLANK 1
(ref. 432298 rev. C)

BI006823-00
Section 5
Air System
Air System 5-1

BI006823-00
Notes
5-2 Air System

BI006823-00
Air System Components
Fig. 5-1 Air System Components

1. Air Receiver Tank
2. Minimum Pressure Valve
3. Back Pressure Valve
4. Dust Collector Regulator
5. Compressor Air Filter
6. Air Compressor
7. Compressor Drive Coupling
8. Compressor Drive Motor
9. Air Manifold
Air System 5-3

Compressor Assembly BI006823-00
A A
GAUGE PORT
PRESSURE
RETURN
GAUGE PORT
NOTE:ASSEMBLE WITH 1/8” GAP BETWEEN

COUPLING SHAFT AS SHOWN IN SECTION A-A.
USE LOCTITE #242 BLUE ON SETSCREWS
AND TORQUE TO 50 +/- 5 FT. LBS.
1/8"±1/32"
COMPRESSOR
SHAFT
HYD MOTOR
SPLINED SHAFT
1" 1/32"
SECTION A-A
ORIENT BREATHER CLAMP

(2X) TO THIS SIDE
MOTOR/COMPRESSOR
MOUNT
CASE DRAIN
AUTOMATIC BLOWDOWN VALVE
(OPENS WHEN POWER TO
MACHINE IS SHUT OFF)
AIR OUT
FIXED
DISPLACEMENT
MOTOR
Fig. 5-2 Air Compressor Assembly–300 CFM (ref. 428264 rev. K)
5-4 Air System

BI006823-00
Compressor Assembly
DO NOT attempt lubrication or service while the machine is running.
Compressor Unit
There is no general service on the compressor unit. It is lubricated and cooled by the oil in the air re-
ceiver tank, so if the air receiver tank is maintained properly according to the instructions in this section,
the compressor should run trouble free. The only exception is if leakage occurs around the shaft seal.
Shaft seal replacement is the only recommended service procedure on the compressor unit. Generally, if
the compressor unit requires service, it is more economical to replace it with a new or factory rebuilt unit.
Individual replacement parts are available, if needed; refer to the machine parts manual for compressor
breakdown and parts listing.
Removal and Installation
1. Remove top section of canopy above compressor if so equipped.

2. Tag and remove hoses from compressor drive motor.
3. Tag and remove hoses and electrical connections from compressor.
4. Remove hose from dust collector pressure regulator (fig. 5-1).
5. Remove the 4 bolts that hold the compressor to the frame.
6. Using at suitable lifting device, remove compressor assembly.
7. Installation is the reverse of removal.
Fig. 5-3 Compressor Mounting

1. Compressor Assembly
2. Mounting Hardware
Bolts (4)
Locknuts (4)
Washers (8)
3. Rubber Isolator Pads (4)
Air System 5-5

BI006823-00
Compressor Assembly
Drive Coupling–Replacement
1. Tag and remove hoses to compressor drive motor.
2. Remove the 4 compressor drive motor mounting bolts and remove motor with half of coupling at-
tached to shaft.
3. Loosen setscrew on each coupling half and remove from motor and compressor shafts.
4. Install coupling half on compressor shaft per fig. 5-2. The rear shoulder of the coupling is to be 1
1/4 ± 1/32 in. back from the shaft end. Install setscrew using Loctite and torque to 50 ft. lbs. (68
Nm). Re-check mounting dimension on compressor shaft.
5. Install other coupling half on motor shaft, but do not tighten setscrew. Be sure to position setscrew
so you can reach it through the inspection cover. Install motor to motor mount and tighten mounting
bolts. Check gap between couplings as shown in fig. 5-2. Be sure you have a 1/8 ± 1/32 in. gap.
Apply Loctite to setscrew and torque to 50 ft. lbs. (68 Nm). Re-check gap after tightening setscrew.
Drive Coupling–Replacement of Rubber Drive Blocks

2. Remove the 4 compressor drive motor mounting bolts and remove motor with half of coupling at-
tached to shaft.
NOTE If only replacing the rubber drive blocks, it is not necessary to remove the two cou-
pling halves from the compressor shaft and motor shaft.
3. Remove old rubber drive blocks.
4. Clean surfaces of coupling and install new rubber drive blocks using silicone adhesive. This needs
to be done in order to hold rubber drive blocks in place while installing the other half of the coupling
and motor.
5. Install motor with coupling half, being careful of alignment with other half of coupling and rubber
drive blocks.
6. Install the 4 compressor drive motor mounting bolts and washers and tighten. Install hoses to mo-
tor, be sure all connections are tight.
Thermostatic Bypass Valve

The thermostatic bypass valves for the compressor oil cooler and the hydraulic oil cooler are mounted
externally from the coolers. The valve is normally open which allows oil to bypass the cooler. As the oil
warms up the valve begins to close, forcing more oil to flow through the cooler. The valve closes at 140oF
(60oC) allowing all oil to flow through the cooler. This system provides proper compressor warm-up and
prevents moisture contamination of the oil.
Compressor Air Filter

See Operator and Maintenance Manual for air filter service. Check filter daily.
5-6 Air System

BI006823-00
Compressor Oil Piping
Fig. 5-4 Compressor Oil Piping (ref. 433480 rev. A)
Air System 5-7

Air Receiver Tank BI006823-00
RECEIVER A
TANK
TOP TANK
MOUNTING
BRACKET
FILL PLUG
ELECTRIC
BALL VALVE
DETAIL A
RECEIVER TANK REMOVED FOR CLARITY
BOTTOM TANK
MOUNTING BOLTS
DETAIL B AND WASHERS (4)
Fig. 5-5 Air Receiver Tank Installation (ref. 431007 rev, C)
5-8 Air System

BI006823-00
Air Receiver Tank
DO NOT service strainers when oil is over 100oF (38oC). Hot hydraulic oil can cause seri-
ous personal injury.
Compressor Oil Separator Elements

1. Shutdown engine and bleed any remaining air
pressure by opening the blowing air control on the
control panel.
2. When the compressor air pressure gauge indi-
cates 0 PSI, tag and remove all hoses connected
to the discharge valve.
3. Remove the discharge valve by removing the
seven capscrews and the two capscrews from the
top mounting bracket. To avoid puncturing sepa-
rator elements, lift cover straight out.
4. Lift elements from separator tank, using care not
to dent or damage the elements.
5. Inspect and clean the screen elements.
6. Inspect separator elements and gaskets bonded
to end. Replace if damaged or fouled.
7. Reassemble separator, being careful to center
elements for effective seal and making sure the
o-ring is properly positioned.
8. Remove the oil return line and remove the strain-
er. Clean and reinstall strainer and hose.
9. Install the discharge valve onto the air receiver
tank. Install the capscrews and tighten, reconnect
hoses removed in Step 2.
Fig. 5-6 Air Receiver Tank (ref. 431026)
Air System 5-9

BI006823-00
Air Receiver Tank
Troubleshooting
Description
The receiver tank holds the compressor lubricating and cooling oil; it also holds the separator elements
and acts as a buffer for the compressed air system.
Separator Element Function

The function of the separator elements is to filter oil particles from the air flow. This is accomplished by
allowing the air to pass through a filter media which causes the small droplets of oil to stick to the strands
of the filter media. These droplets of oil then run down the side of the separator element and fall into the
tank on the outside of the element. The droplets of oil on the inside of the element fall into a pan. The oil
that falls into the pan on the inside of the element is siphoned back to the compressor inlet through the
scavenge line. This scavenged oil then re-enters the separator tank through the compressor discharge
piping. The specified amount of oil carryover for this element is 5 parts per million of oil.
The amount of oil that passes through the separator element is a function of the velocity of the air
through the separator element. The air velocity can change from two conditions:
1. If the air inlet filter is not maintained properly, dirt from air entering the compressor can be trapped
in the separator elements and reduce the total effective area for the air to pass through. This will
cause velocity to increase and also cause the pressure drop across the element to increase.
2. Air velocity can also increase due to the increase of air volume passing through the separator ele-
ment. This increase in volume occurs when the air pressure in the system decreases. For example:
All air compressor systems are rated on the volume of free air entering the compressor. This free
air is at atmospheric pressure (approx. 14.7 psia [1 bar]); as this air passes into the air system it
is compressed to a smaller volume. For example: Air pressure at the receiver with the air valve
open is 100 psig (6.9 bar) and the compressor is rated at 300 cfm. The actual volume of 300 cfm
is compressed to 44 cfm at 100 psig (6.9 bar). If the receiver pressure is reduced to 50 psig (3.4
bar), then the actual volume of the 300 cfm is compressed to 88 cfm. In this case there will be more
oil carryover at 50 psig (3.4 bar) receiver pressure than at 100 psig (6.9 bar) system pressure,
because the velocity increases as the square of the volume and the volume passing through the
separator increases as the air pressure in the system drops. The higher velocity causes more of
the oil droplets to be carried through the separator element.
Other Conditions Which Can Effect Oil Carryover

• Cold oil which is thicker and doesn't drain from the separator element, reducing air flow area and
increasing air velocity through the element.
• Water in the oil. Oil with water in solution is thicker and tends to stick in the separator element, it
doesn't drain out properly, thus reducing air flow area and increasing air velocity through the ele-
ment.
• Overfilling the separator tank. This condition does not allow oil to drain completely out of the ele-
ment and the puddle inside the element is carried out by exhausting air.
• Scavenge line plugged or blocked. Similar to overfilling, the oil is not being carried away from the
inside of the separator element. The puddle of oil inside the element is carried out by exhausting
air.
• Dirty separator element. Dirt entering the oil system due to dirty compressor air filter causes the
separator element to plug with these dirt particles, which reduce the effective air flow area.
5-10 Air System

BI006823-00
Air Receiver Tank
DO NOT service strainers when oil is over 100oF (38oC). Hot hydraulic oil can cause seri-
ous personal injury.
Separator Elements–Service Interval and Measuring Pressure Drop

The complicated interaction between the pressure in the air system and the pressure drop across
the elements, makes it difficult to set exact criteria for servicing or replacing the separator elements. It
is recommended that when the unit is new, or when a new separator element has been installed, that a
measurement be taken of the pressure drop across the element. Use the following procedure to measure
the pressure drop across the element:
Use as low a pressure gauge as possible to obtain the most accurate reading (200 PSI [13.8 bar]
is recommended). Use the same gauge for both readings.
1. Shutdown machine and relieve air pressure on receiver tank. Install gauge in the upstream port
located on the side of the receiver tank. Start machine and read pressure with air flowing through
the drill shank.
2. Shutdown machine and relieve air pressure on receiver tank. Install gauge in the downstream port
located on top of the receiver tank. Start machine and read pressure with air flowing through the
drill shank.
3. Subtract the downstream pressure reading from the upstream pressure reading. This is the base
pressure drop.
At some later time, repeat the pressure drop measurement and compare the readings. Subtract the
first reading (with new element) from the second reading (with used element), this number represents the
increase in pressure drop over the time period. When the difference between the readings is greater than
13 PSI (0.9 bar) the separator element should be replaced.
A convenient method of checking the effectiveness of the separator element is to clean the top of the
centralizer and position the drill shank about one foot above the centralizer. Turn air on full for about one
minute. Observe the amount of oil on top of the centralizer, there should be little or no oil present. As the
condition of the separator element degrades, more and more oil will be present on the centralizer when
you perform this test. If you perform this test in conjunction with the pressure drop test, you can get an
indication as to when the separator element needs attention.
Another indication of separator element condition is indicated when oil must be added to the air receiver
tank at regular intervals. This indicates the separator element may be degrading.
Air System 5-11

Thread Grease System BI006823-00
Fig. 5-7 Grease System

1. Grease Container
2. Grease Pump Unit
3. Lubricator
4. Regulator
5. Filter/Water Separator
Fig. 5-8 3-Way Air Valve
5-12 Air System

BI006823-00
Thread Grease System
The R30C is equipped with an automatic drill string thread greasing system. The system uses an air
powered grease pump attached to a 35 lb. (15.9 kg.) grease container (fig. 5-7) located on the right side of
the machine. The system is activated by a button on the Drill joystick control, and the pump delivers grease
to the nozzle (fig. 5-9) mounted on the feed.
Air supply is filtered, lubricated and regulated by the filter/regulator/lubricator mounted on the hydraulic
tank on the right side of the machine (fig. 5-7). Normal pressure setting is 80 PSI (5.5 bar).
Turning the knurled knob on the 3-way air valve (fig. 5-8) increases or decreases the duration of the
grease when the switch is activated.
See Section 8 for maintenance and repair instructions. Refer to machine parts manual for repair part
numbers and kits.
Fig. 5.9 Feed Mounted Grease Nozzle

1. From Air Receiver Tank
2. From Grease Bucket
3. Nozzle with Pipe thread on One End
NOTE: Nozzle to be aligned with the center of steel.
Air System 5-13

BI006823-00
Detergent System
Fig. 5-10 Pressurized Detergent Tank

1. Detergent Tank, 80 gal (302.8 L)
2. Filler Cap
3. Cutoff Valve
4. Check Valve
5. Relief Valve
6. Bleed Valve
Fig. 5-11 Detergent System Piping (ref. 432211 rev. B)
5-14 Air System

BI006823-00
Detergent System
Relieve all pressure before attempting service or maintenance procedures to this ma-
chine.
Servicing the Y Strainer

The detergent system water line strainer
mounted in the "Y" connection in the detergent
line should be inspected every 50 hours and
cleaned or replaced every 600 hours or when-
ever clogged.
To Replace
1. Shutdown machine and relieve pres-
sure from detergent tank by opening
bleed valve (6, fig. 5-10).
2. After pressure is relieved from tank,
close cutoff valve (4) and unscrew the
strainer fitting (2) from the reducer in
the Y connection and remove strainer.
3. Clean the old strainer or install a new Fig. 5-12 Cutoff Valve & Y Strainer
one. Screw in fitting and tighten. Open 1. Detergent Tank
cutoff valve (4). 2. Remove this fitting to access screen and to drain tank
3. Solenoid Valve
4. Cutoff Valve
Detergent System Freeze Protection

Detergent system should not be used when temperatures below freezing are expected. To protect the
detergent system from freezing, the following steps should be taken:
1. Shutdown machine and relieve air pressure by opening the bleed valve and allowing air to bleed
off.
2. When air has bled off, open tank filler cap, then close cutoff valve and remove fitting and screen
from Y strainer. Open cutoff valve to drain tank.
3. After tank is drained, install screen (clean, or replace if necessary) and fitting in Y strainer. Open
cutoff valve and add 2 gal of Recreational Vehicle water line antifreeze or equivalent non-toxic anti-
freeze to detergent tank. Replace detergent tank filler cap and tighten.
4. Start machine and switch to drill mode. Open blowing air valve at control console and turn on deter-
gent valve (detergent metering valve must also be open). When anti-freeze solution comes out of
drill shank or drill bit, shut off air and detergent system. Lines are now full of anti-freeze solution.
Shutdown machine in normal manner.
Air System 5-15

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Notes
5-16 Air System

BI006823-00
Section 6
Boom and Feed Assemblies
Boom and Feed Assemblies 6-1

Boom Assembly BI006823-00
BEFORE repairing or replacing boom, feed, or positioner cylinders, secure feed and
boom to prevent sudden collapse or shift when servicing cylinder(s).
BE SURE hydraulic cylinder bleed screws are installed and tightened before starting
machine.
NOTE Refer to the machine parts manual for parts breakdown and parts listing. See Section
8 herein for hydraulic cylinder repair instructions.
Fig. 6-1 Boom Assembly (ref. 433625 rev. C)

1. Feed Dump Cylinder
2. Boom Swing Cylinder
3. Boom Extend Cylinder (not shown, inside outer boom tube)
4. Boom Lift Cylinder
5. Outer Boom Tube
6. Inner Boom Tube
7. Positioner
6-2 Boom and Feed Assemblies

BI006823-00
Boom Lift Cylinder
DO NOT engage any other control levers, except for the cylinder you are working on.
Serious injury or equipment damage could result.
Boom Lift Cylinder–Removal

1. Secure feed so that it cannot fall to prevent boom from sudden collapse when boom lift cylinder is
removed.
2. Shutdown the hydraulic system.
3. Bleed any pressure from the boom lift cylinder by loosening the two bleed screws (these are hex
plugs marked "TE" and "TR").
4. Tag and remove the two hydraulic hoses from the cylinder.
5. Cap the hose ends and remove the hose adapters from the cylinders.
6. Support the boom lift cylinder and remove the pin retainer and pin from each end of the cylinder.
7. Lift the cylinder free of its pivot points.
Boom Lift Cylinder–Replacement

1. Clean and inspect all pins and bushings for wear or damage, replace if necessary. Apply a thin coat
of grease to pins and bushings before installing.
NOTE When inspecting, pay close attention to cylinder eyes, pins and clevises for cracks or
damage caused by accidents or overloading.
2. Raise the boom lift cylinder into place. Align base end of cylinder with rear mounting bracket. Install
the pin and pin retainer.
3. Clean and install the hose adapters on the cylinder. Be sure bleed screws marked "TE" and "TR"
are tightened.
4. Uncap the hose ends and connect the hoses to the cylinder.
Cylinder Bleeding Procedure and Final Installation
1. With the engine and hydraulic system operating, extend the cylinder to its fully extended position.
2. Remove the hose at the "R" (retract) port to bleed air, place hose end in a container to catch oil.
Actuate the R.H. joystick as if to retract the cylinder. When clear oil (no air bubbles) is observed
coming out of the hose, return valve to neutral position, connect hose to cylinder and tighten fitting.
3. Retract cylinder to its fully retracted position.
4. Remove the hose at the "E" (extend) port to bleed air, place hose end in a container to catch oil.
Actuate the R.H. joystick as if to extend the cylinder. When clear oil (no air bubbles) is observed
coming out of hose, return valve to neutral position, connect hose to cylinder and tighten fitting.
5. Extend cylinder to line up rod end with clevis on boom and install pin and retainer.
6. Lubricate the pivot points with grease.

Boom Swing Cylinder BI006823-00
machine.
Boom Swing Cylinder–Removal

1. Secure feed so that it cannot fall. Make sure ground is level to prevent the boom from pivoting
when swing cylinder is removed.
3. Bleed any pressure from the boom swing cylinder by loosening the two bleed screws (these are
hex plugs marked "TE" and "TR").
4. Tag and remove the hydraulic hoses from the cylinder.
5. Cap the hose ends and remove the hose adapters from the cylinder.
6. Support the boom swing cylinder and remove the retainer and pin from each end of the cylinder.
Boom Swing Cylinder–Replacement

1. Clean and inspect all pins and bushings for wear or damage, replace if necessary. Apply a thin coat
of grease to pins and bushings before installing.
2. Raise the boom swing cylinder into place (rod end toward boom). Align the base end of the cylin-
der with the rear mounting bracket. Install the pin and retainer.
3. Clean and install the hose adapters on the cylinder. Be sure bleed screws marked "TE" and "TR"
are tightened.

BI006823-00
Boom Swing Cylinder
1. With the engine and hydraulic system operating, use the boom swing control lever to extend the
cylinder to its fully extended position.
Actuate the R.H. joystick as if to retract the cylinder. When clear oil (no air bubbles) is observed
Actuate the R.H. joystick as if to extend the cylinder. When clear oil (no air bubbles) is observed

BI006823-00
Feed Dump Cylinder
machine.
Feed Dump Cylinder–Removal

1. Remove drill steel from drill. Position boom so feed dump cylinder is in a horizontal position. Lower
the feed to the ground and lower the drill to the centralizer. Secure feed so it cannot move when
feed dump cylinder is removed.
3. Bleed any pressure from the feed dump cylinder by loosening the two bleed screws (these are hex
6. Support the feed dump cylinder and remove the bolt that retains the pin on the positioner. Remove
the retaining ring and washer from the opposite side and drive the pin out from the retaining ring
side. There is a shoulder on the pin on the bolt retained side, so it cannot be driven out from that
side.
7. Remove the four capscrews from clevis pin on each side of the cylinder trunnion. Install two jack
bolts (5/8-11 NC X 4 1/2 in. long) into the two tapped holes in the clevis pin. Screw the bolts in
evenly to jack out the clevis pin on each side. Be sure to have some tension on the lifting strap
around the cylinder so it will not bind when removing the clevis pins.
Feed Dump Cylinder–Replacement

1. Clean and inspect clevis pins and bushings, replace any worn or damaged parts. Apply a light coat
of grease to bushings and pins.
2. Raise the feed dump cylinder into place with rod end toward drill positioner. Align the cylinder
trunnion with the positioner mounting bores and install the clevis pins on each side. Install the four
capscrews on each side and tighten.
3. Clean and install the hose adapters on the cylinder. Be sure bleed screws on the cylinder marked
"TE" and "TR" are tightened.

BI006823-00
Feed Dump Cylinder

1. With the engine and hydraulic system operating, use the feed dump control lever to extend the
Actuate the L.H. joystick as if to retract the cylinder. When clear oil (no air bubbles) is observed
Actuate the L.H. joystick as if to extend the cylinder. When clear oil (no air bubbles) is observed
5. Extend cylinder to line up rod end with clevis on positioner and install pin and retainer.
NOTE Cylinder provided with accumulators (fig. 6-2) precharged with 25 PSI (1.7 bar) Nitro-
gen.
Fig. 6-2 Feed Dump Cylinder Accumulators

BI006823-00
Feed Assembly–Linear Rod Changer
BEFORE repairing or replacing boom, feed or positioner cylinders, secure feed and
BEFORE removing feed swing pin, the feed MUST be placed in the horizontal plane.
Securely anchor the feed to the boom with a safety chain to prevent the feed from sud-
den pivot when the pin is removed.
machine.
NOTE Refer to the machine parts manual for parts breakdown and parts listing.
Fig. 6-3 Feed Table Installation (ref. 433635 rev. A)

1. Feed Table
2. Feed Swing Cylinder
3. Swing cylinder to Positioner Pin
4. Positioner
5. Feed Extension Cylinder
6. Offset Clevis

BI006823-00
Feed Assembly–Carousel Rod Changer
2
2 3
5
14
3
2
2
20
1 39 38 37 2
40
36
POSITIONER
1
36 40
4 3 4 3 6
1
VIEW A
DETAIL B
POSITIONER
INSTALL SHIMS 4 BETWEEN END OF FEED TABLE

PIVOT PIN AND CAP 3 TO PROVIDE .005/.015
NOTES:
CLEARANCE BETWEEN CAP 3 AND POSITIONER.
1. ADJUST WEAR PADS 40 TO ALLOW
MAXIMUM OF 1/32" CLEARANCE
BETWEEN PAD AND INSIDE OF FEED
CHANNEL.
GREASE FITTING 5 2. TORQUE (DRY) TO 85 FT. LBS.
3. TORQUE TO 110 FT. LBS.
DETAIL D 4. TORQUE TO 282 FT. LBS.
Fig. 6-4 Feed Table Installation 5. RELOCATE GREASE FITTING FROM

EXTENSION CYLINDER TO COUPLING
W/Carousel Rod Changer (ref. T105349) AT END OF TABLE.
1. Feed Table Weldment 20. Swing Cyl to Positioner Pin
2. Feed Swing Cylinder 36. Wear Pad (4)
3. Retaining Cap 37. Shim–10 GA. (8)
4. Shim Set (2) 0.24"/(2) 0.015" 38. Shim–16 GA. (4)
5. Offset Clevis 39. Shim–24 GA. (4)
6. Retainer Cap 40. Inner Wear Pad (4)
14. Feed Extension Cylinder

BI006823-00
Feed Swing Cylinder
Feed Swing Cylinder–Removal

1. Place the feed in a horizontal position as close to the boom as possible, with the drill positioned
directly over the feed pivot, and secure it to the boom with a safety chain so the feed can not swing
when the feed swing cylinder is removed.
3. Bleed any pressure from the feed swing cylinder by loosening the two bleed screws (these are hex
6. Support the feed swing cylinder and remove the retainer and pin from each end of the cylinder.
Feed Swing Cylinder–Replacement

2. Raise the feed swing cylinder into place (rod end toward feed pivot). Align the base end of the
cylinder with the rear mounting bracket. Install pin and retainer. Be sure bleed screws marked "TE"
and "TR" are tightened.
3 Clean and install the hose adapters on the cylinder.

1. With the engine and hydraulic system operating, use the feed swing control lever to extend the
Actuate the L.H. joystick as if to retract the cylinder. When clear oil (no air bubbles) is observed
Actuate the L.H. joystick as if to extend the cylinder. When clear oil (no air bubbles) is observed

BI006823-00
Feed Extension Cylinder
BEFORE repairing or replacing boom, feed or positioner cylinders, secure feed and
machine.
Feed Extension Cylinder–Removal

1. Remove drill steel from drill. Lower the feed to the ground and lower the drill to the centralizer. Se-
cure feed so it cannot move when feed extension cylinder is removed. Position boom so feed dump
cylinder is in a horizontal position.
2. Support the feed extension cylinder and remove the retainer and pin from the rod end.
3. With engine and hydraulic system operating, use the R.H. joystick to retract the cylinder rod to its
fully retracted position.
4. Shutoff machine.
5. Tag and remove the two hydraulic hoses that go to the counterbalance valve. Cap hoses and fit-
tings.
6. Remove the retaining pins and pivot pin from the base end of the cylinder and lift the cylinder free
from its pivot points.
Feed Extension Cylinder–Replacement

2. Clean and install the hose adapters and short hoses on the cylinder. Raise the cylinder into place
with rod end toward top of feed.
3. Align the base end of the cylinder with the mounting bracket. Grease and install pivot pin and pin
retainer.
4. Uncap hose ends and connect at the counterbalance valve, port "C1" is extend, port "C2" is retract.

BI006823-00
Feed Extension Cylinder

1. With the engine and hydraulic system operating, use the R.H. joystick to extend the cylinder to its
fully extended position.
2. Remove the cylinder extend hose (port V1) at the counterbalance valve to bleed air, place hose
end in a container to catch oil. Actuate the joystick as if to retract the cylinder. When clear oil (no air
bubbles) is observed coming out of the hose, return valve to neutral position, connect hose to the
counterbalance valve and tighten fitting.
4. Remove the cylinder retract hose (port V2) at the counterbalance valve to bleed air, place hose end
in a container to catch oil. Actuate the R.H. joystick as if to extend the cylinder. When clear oil (no
air bubbles) is observed coming out of the hose, return valve to neutral position, connect hose to
the counterbalance valve and tighten fitting.
5. Extend cylinder to line up rod end with clevis on feed and install pin and retainer.

BI006823-00
Boom Shim/Wear Pads
Fig. 6-5 Boom Assembly (ref. 431963 rev. A)

1. Outer Tube Assembly 56. Lock Washer (2) 62. Front Wear Pad (4)
2. Inner Tube Assembly 57. Capscrew (2) 63. Rear Wear Pad (3)
46. Boom Extend Cylinder 58. Setscrew (8) 64. Rear Wear Pad, grooved
52. Stand Off, Boom Ext. Cyl. 59. Jam Nut (8) 65. Front Wear Pad Retainer (4)
53. Capscrew (12) 60. Wiper Retainer Plate 66. Shim, 18 ga. (4)
54. Flat Washer (12) 61. Rubber Wiper 67. Shim, 24 ga. (2)
Note: Item numbers correspond to parts manual drawing.

Boom Shim/Wear Pads BI006823-00
Boom Inspection
With the feed in the vertical position and clear of ground and inner boom tube fully extended, measure
12 in. (30.5 cm) from the wiper retaining plate on the outer boom tube (fig. 6-6). The maximum deflection for
a new boom is 0.090 in. (2.3 mm) at the 12 in. (30.5 cm) distance. For a used boom the deflection should
not exceed 0.375 in. (9.5 mm).
Sting feed to ground to support boom. Remove wiper retaining plate and wiper from front of outer boom
tube. Loosen the 8 hex jam nuts and back out the wear pad adjusting screws on the left side and bottom of
the outer boom tube (fig. 6-8). Remove the 4 wear pad retainers with the wear pads and inspect wear pads
for wear. A new wear pad is approximately 0.55 in. (14 mm) thick and should be replaced when it is worn
to half of its original thickness. The rear wear pads can not be inspected without removing the inner boom
tube; however, they usually wear at the same rate as the front wear pads or faster if the boom is extended
more than half way frequently.
If the boom is not routinely extended more than half way out you can adjust the front wear pads by
turning in the 8 adjustment screws at the front of the outer boom tube (refer to boom tube, wear pad and
shims installation); however this is only a temporary fix and reshimming and/or replacing all wear pads
should be done at the earliest convenience.
Fig. 6-6 Measuring Boom Tube Deflection

BI006823-00
Boom Shim/Wear Pads
Fig. 6-7 Feed Swing Cylinder

1. Swing Cylinder Pin
2. Pin Retaining Bolt
3. Swing Cylinder
4. Retaining Cap for Feed Table
5. Retaining Cap for Feed Mounting Pin
6. Capscrews (6)
Fig. 6-8 Offset Feed Table (ref. 432023)

DO NOT remove feed swing cylinder pin until feed is secured with lifting straps and
crane. If feed swing cylinder pin is removed, the feed is free to pivot which could cause
equipment damage, injury or death.
Feed and Feed Table–Removal

The feed and feed table must be removed from the positioner and the inner boom tube must be removed
from the outer boom tube to install the rear wear pads and shims. This procedure is best done in a shop
with an overhead crane; however, it can be done in the field using an adequate truck mounted crane.
Remove feed assembly with feed table from boom, using the following procedure:
1. Position the machine on a level surface. Remove drill steel and position feed and boom in as near
horizontal position as possible with the hydraulic rock drill centered over the positioner pivot.
2. Install adequate lifting straps to support feed in a balanced position. Lift slightly to put enough tension
on feed so it can not pivot when the feed swing cylinder pin is removed.
3. Remove the four socket head capscrews and lock washers from the feed table retaining caps (4).
There is one retaining cap on each side. Remove both.
4. With feed supported so it can not swing; remove the feed swing cylinder pin at the rod end and swing
cylinder clear of positioner.
5. Remove the 6 capscrews and the retaining cap that retains the feed table pin in the positioner (5).
Be careful not to loose the shims inside the cap. Carefully rotate the feed and feed table so they are
perpendicular to the boom. This must be done so the retainer gussets on the feed table (fig. 6-8) will
align with the notches in the flanged bushing in the positioner (fig. 6-9).
6. Slowly, lift the feed and feed table from the positioner, watching to make sure the feed table retainer
gussets clear the notches in the flanged bushing in the positioner. Keep an eye on any hoses that
were not removed, to be sure they are not being stretched. Carefully lay the feed and feed table down
onto the ground or suitable supports.
Fig. 6-9 Positioner and Boom (ref. 431963)

BI006823-00
Boom Shim/Wear Pads
Fig. 6-10 Front of Outer Boom Tube

1. Wiper Retaining Plate
2. Wiper
3. Wear Pad Adjusting Screws (8 total)
4. Wear Pad Retainers
Fig. 6-11 Boom Extend Cylinder Pin

1. Boom Extend Cylinder Pin
2. Pin Retaining Bolt

BI006823-00
Boom Shim/Wear Pads
Inner Boom Tube–Removal

1. Extend boom tube all the way out and place boom in a horizontal position.
2. Remove wiper retainer plate and wiper from front of outer boom tube (fig. 6-10).
3. Loosen the jam nuts on the eight wear pad adjusting screws at the front of the outer boom tube and
back out the setscrews to take pressure off the wear pads (fig. 6-10).
4. On booms with 5 ft. extension and internal boom extend cylinder, remove hoses from boom extend
cylinder, cap hose ends and fittings on cylinder. Remove the pin that retains the boom extend cylin-
der at the rear of the boom (fig. 6-11).
5. Position lifting straps just behind the yoke of the inner boom tube for proper balance and with a
proper lifting device, guide the inner tube with boom extend cylinder (if so equipped) out. Remove
wear pads and retainers from front of outer boom tube as you slide the inner tube out. Check bal-
ance of inner boom tube and cylinder as cylinder barrel approaches the end of the outer boom
tube. You may need to adjust the position of the lifting straps or place an additional strap around
the cylinder barrel (if so equipped) before removing completely.
6. Check to be sure there are no old wear pads or shims left in the back of the outer boom tube.

BI006823-00
Boom Shim/Wear Pads
Fig. 6-5 Boom Assembly (ref. 431963 rev. A)

1. Outer Tube Assembly 56. Lock Washer (2) 62. Front Wear Pad (4)
2. Inner Tube Assembly 57. Capscrew (2) 63. Rear Wear Pad (3)
46. Boom Extend Cylinder 58. Setscrew (8) 64. Rear Wear Pad, grooved
52. Stand Off, Boom Ext. Cyl. 59. Jam Nut (8) 65. Front Wear Pad Retainer (4)
53. Capscrew (12) 60. Wiper Retainer Plate 66. Shim, 18 ga. (4)
54. Flat Washer (12) 61. Rubber Wiper 67. Shim, 24 ga. (2)
Note: Item numbers correspond to parts manual drawing.

BI006823-00
Boom Shim/Wear Pads
Boom Tube, Wear Pad and Shims Installation

1. Check the inner surfaces of the outer boom tube for any debris and clean out inside of outer boom
tube. Check and clean surfaces of inner boom tube.
2. Slide wiper retaining plate and a new wiper onto inner boom tube (see fig. 6-5).
3. Put a light coat of grease on the surface of the wear pads that will contact the inside of the outer
boom tube. Install 3 rear wear pads (63) on bottom, top and one side of inner boom tube. Install
wear pad (64) with groove on the side of inner boom tube that faces the weld seam of the outer
boom tube (fig. 6-12).
NOTE Groove cut in side of wear pad is positioned so it fits over the weld seam of the inside
of the outer boom tube. Weld seam may be on either left or right side.
Fig. 6-12 Rear Wear Pad Installation–

left side view of boom tube.
2. Inner Boom Tube
63. Wear Pad (3)
64. Grooved Wear Pad
4. Test fit inner tube by sliding into outer tube about 4 ft. (1.2 m). Be sure both tubes are aligned with
each other.
5. Add shims (66 & 67) until a tight fit is attained between wear pads and outer boom tube.
6. On booms with 5 ft. extension, align rod eye of boom extend cylinder with hole towards rear of
outer boom tube and install pin and retaining bolt. Install the two hydraulic hoses and tighten.
7. Install front wear pads (62) into wear pad retainers (65) as shown in fig. 6-5. Install wear pads with
retainers into front of outer boom tube.
8. Extend boom tube out all the way and lift end of extended boom with overhead crane. There should
be a 0.030 in. (0.8 mm) max. gap between the front lower wear pads (62) and the outer boom tube.
Adjust the setscrews (58) at the bottom of the outer boom tube to get the correct tolerance and
tighten the jam nuts (59). The side wear pads should be adjusted in the same manner with a side
load placed on the inner boom tube.
9. Slide rubber wiper (61) and retaining plate (60) into place and secure with the 12 capscrews and
washers. Note: These same capscrews also secure the front wear pad retaining plates (65).
10. Retract and extend boom tube a few times to be sure everything functions correctly and smoothly
before installing the feed assembly.

BI006823-00
Boom Shim/Wear Pads
Fig. 6-13 Feed, Feed Table, and Positioner

1. Feed Table 4. Retainer Cap (2)
2. Capscrews (8) 5. Positioner
3. Swing Cylinder
Fig. 6-14 Measuring Boom Tube Deflection

BE SURE feed swing cylinder pin is installed BEFORE removing lifting straps from feed.
If feed swing cylinder pin is not installed the feed is free to pivot which could cause
equipment damage, injury or death.
Feed and Feed Table–Installation

1. Be sure feed table pin and positioner bushings are clean. Apply a coat of grease to pin and bush-
ings.
2. Attach suitable lifting straps and a suitable hoist to the feed and feed table assembly and raise into
position above the positioner. Feed and feed table assembly must be perpendicular to boom. Care-
fully lower feed assembly and guide feed table pin into positioner bushing. Make sure that the feed
table retainer gussets fit down under the collar on the positioner bushing. Rotate the feed 90o so
the centralizer is facing forward.
3. Install the pin retaining cap (fig. 6-13) using the same number of shims that were removed. Install
the six capscrews and spring washers. Torque capscrews to 282 ft. lbs. (384 Nm). Now check
clearance between cap and positioner, there must be a gap of 0.005–0.015 in. (0.13–0.38 mm). If
not, add or remove shims until correct gap is attained (see fig. 6-15).
4. Install the two feed table retainer caps, using four socket head capscrews and lock washers on
each cap (fig. 6-16).
5. Line up feed swing cylinder rod end to positioner clevis (fig. 6-13), and install pin and retaining bolt
and lock nut. Lifting straps can now be removed.
6. Start machine and check for leaks and that all functions operate correctly.
7. Extend boom all the way out with feed in vertical position and clear of ground. Observe inner boom
tube and check for free movement up and down according to fig. 6-14. Swing feed to left and right
and observe side movement of inner boom tube. There should be no more than 0.030 in. (0.8 mm)
gap between the front wear pads and outer boom tube. Adjust wear pad setscrews at front of boom
if necessary.

BI006823-00
Boom Shim/Wear Pads
DO NOT remove more than one wear pad at a time, or feed could come off feed table
causing serious injury or death.
Feed Table Wear Pads–Adjustment

1. Refer to fig. 6-15. The maximum clearance between the inner wear pad and the feed channel is
1/32 in. (0.8 mm). This is achieved by placing a 24 ga. shim between the inside of the feed channel
and the inner wear pad (1).
2. Adjust the clearance between the outer wear pad (3) and feed channel to 1/16 in. (about the thick-
ness of a U.S. quarter). Add or remove shims (2) as necessary. The shim kit contains 10 ga., 16
ga. and 24 ga. shims.
3. Install bolts, flat washers, and locknuts. Tighten bolts to 110 ft. lbs. (150 Nm).
Fig. 6-15 Feed Table Wear Pads

1. Inner Wear Pad
2. Shims
3. Outer Wear Pad

Feed Table Pivot Pin BI006823-00
Feed Table Pin must be inspected and maintained according to instructions below.
Pin failure could result in serious injury or death.
Adjustment and Maintenance

Daily
Be sure to check that the pivot pin bushings are getting grease. Grease all boom and feed pivot
points daily.
Every Three (3) Months
1. Refer to fig. 6-16. Check gap between pin retaining cap (3) and positioner casting. Position feed
in the horizontal position with the drill centered over the positioner pin. The gap should be in the
range of 0.005 to 0.015 in. (0.13 to 0.38 mm).
2. If adjustment is required, remove the six capscrews that retain the cap to the pin. Install necessary
shims from Shim Kit 1418734. Install cap and capscrews, torque capscrews to 282 ft. lbs. (383
Nm). Check gap again and adjust as required.
Fig. 6-16 Feed Table Pivot Pin and Positioner

1. Grease Fittings (2)
2. Capscrews (6)
3. Pin Retaining Cap

BI006823-00
HPR45/51 Hydraulic Rock Drill
Fig. 6-17 HPR45 Drill Mounting Bolts

1. Front Mounting Bolts (2), 1-14 UNS x 2 in. Long, GR 5
2. Rear Mounting Bolts (2), 1-14 UNS x 2 1/4 in. Long, GR 5
3. Spring Washers (4)
Removal from Mounting Slide

1. Remove drill steel and place the feed in a horizontal position (or as close as possible).
2. Shutdown the engine.
3. Tag and remove all hoses connected to the drill.
NOTE If drill is being removed for repair, loosen the four side rod nuts and the six nuts that
hold the rotation housing to the cylinder while it is still bolted to the mounting slide.
This is much easier than trying to loosen these nuts on the work bench.
4. Attach two lifting straps to drill and using a 1/2 ton (454 kg.) hoist, put a slight amount of tension on
the drill. Remove the four drill mounting bolts carefully and lift the drill free of the mounting slide.
Installation on Mounting Slide

1. Raise the drill into position using a 1/2 ton (454 kg.) hoist and two lifting straps.
2. Be sure the keyway in the drill cylinder fits into the milled slot of the mounting slide. Install the 2 in.
long mounting bolts and spring washers in the front mounting holes. Install the 2 1/4 in. long mount-
ing bolts and spring washers in the rear mounting holes.
3. Torque to all four mounting bolts to 483 ft. lbs. (657 Nm).
4. Clean and install the hoses to the drill. Note that on the HPR45 drill the supply line is on the right
side (as viewed from the rear) and the return is on the left. This is opposite of an HPR1H-ATW drill.
5. Charge the accumulators (if necessary). Refer to drill service manual.

BI006823-00
Drill Mounting Slide
Fig. 6-18 Mounting Slide Detail for HPR45 Drill (HPR1H-ATW similar)
Mounting Slide Adjustment

1. Add or remove shims as required to obtain 0.060 to 0.070 in. (1.5 to 1.8 mm) gap between outer
wear pad and feed channel. This gap between the outer wear pad and feed channel is equal to
about 1/16 in. or the thickness of a U.S. quarter.
NOTE Check leading edge of wear pad for sharp edges. Break any sharp edges to prevent
gouging into feed flange.
2. Leave wear pad bolts loose and slowly move drill slide through full travel range. Then slowly tight-
en wear pad bolts to find any high spots on the feed channel. Add additional shims if necessary.
3. There should be a minimum of 0.03 in. (0.76 mm) clearance between the wear pad and any high
spot on the feed channel.

BI006823-00
HPR1H-ATW Hydraulic Rock Drill
Fig. 6-19 HPR1H-ATW Drill Mounting Bolts and Hose Connections

1. Vertical Mounting Bolts (2), torque to 320 ft. lbs. (435 Nm)
2. Horizontal Swivel Bolts (2), tighten–see NOTE
3. Horizontal Mounting Bolts (2), torque to 220 ft. lbs. (299 Nm)
4. Reverse Rotation Port (drill rotation is clockwise–viewed from rear)
5. Forward Rotation Port (drill rotation is counterclockwise–viewed from rear)
6. Motor Case Drain Port
7. Drill Return Port
8. Drill Pressure Port
9. Air/Water Connection
NOTE The swivel bolts are used to pivot the drill on the mounting slide to gain access to the
accumulators for service. Remove the two vertical mounting bolts, one pivot bolt and
one horizontal mounting bolt. Loosen the other horizontal mounting bolt and pivot the
drill to one side.

HPR1H-ATW Hydraulic Rock Drill BI006823-00
Removal from Mounting Slide

1. Remove drill steel and place the feed in a horizontal position (or as close as possible).
2. Shutdown the engine.
3. Tag and remove hoses connected to the drill (fig. 6-19).
4. Attach two lifting straps to drill and using a 1/2 ton (454 kg.) hoist, put a slight amount of tension on
the drill. Remove the drill mounting bolts carefully and lift the drill free of the mounting slide.
NOTE If drill is being removed for repair, loosen the side rod nuts while it is still bolted to
the mounting slide. This is much easier than trying to loosen the side rod nuts on the
work bench.
Installation on Mounting Slide

1. Raise the drill into position using a 1/2 ton (454 kg.) hoist and two lifting straps.
2. Install the four mounting bolts and two swivel bolts, hand tight only. Keep some tension on the drill
with the lifting straps until mounting bolts are tightened.
3. Tighten the two horizontal mounting bolts at rear of the drill first. Torque to 220 ft. lbs. (299 Nm).
4. Tighten the two horizontal swivel bolts at the front of the drill.
5. Tighten the two vertical mounting bolts at front of drill. Torque to 320 ft. lbs. (435 Nm).
6. Clean and install the hoses to the drill.
7. Charge the accumulators (if necessary). Refer to rock drill service manual.

BI006823-00
Feed Chain
Fig. 6-20 Measuring Feed Chain Sag

Feed Chain BI006823-00
Feed Chain Tension

With feed in horizontal position and drill raised to top of feed, measure chain sag at lowest point (fig
6-20). Measure distance from lower edge of chain to inside edge of feed channel (distance "A") and upper
edge of chain to inside edge of feed channel (distance "B"). The difference should be in the range of 3/8
to 1/2 in. (9.5 to 12.7 mm), if not, adjust the chain using the procedure listed under "adjustment."
Feed Chain Adjustment

The feed chain requires periodic adjustment. It is better if the chain is too loose than too tight. If the
chain is too tight it will place added stress on the chain rollers and sprocket bearings as well as hindering
feed force.
With feed in the horizontal position and drill raised to top of feed, loosen jam nuts and turn adjusting
nut in (clockwise) to tighten or out (counterclockwise) to loosen chain tension. When correct chain tension
is achieved, tighten the jam nuts (fig. 6-21).
Fig. 6-21 Feed Adjustment

1. Adjusting Nut
2. Jam Nuts

BI006823-00
Hose Reel
Fig. 6-22 Hose Reel Assembly (ref. 432093)

Hose Reel BI006823-00
If the timing is not properly adjusted, permanent damage will result to the drive sys-
tems.
Fig. 6-23 Hose Reel Drive Sprocket (ref. 432093)
Hose Reel Timing

NOTE When drill travels to rear end of the feed, the drill slide should meet the hose reel as-
sembly exactly at the same instant as the hose reel assembly reaches the stops at the
rear end of the feed.
Refer to Figures 6-22 and 6-23

1. Move the drill forward until the hose reel drive sprocket is completely uncovered by the drill slide
assembly.
2. Loosen the drill drive chain tension by moving the drive chain tensioner sprocket forward. To do
this, loosen the hex jam nut at the top (rear) of the feed, then back off the adjusting nut to relieve
tension on the sprocket.
3. Remove the hose reel drive sprocket from the feed.
4. Move the hose reel slide forward or backward until (L1) and (L2) distances are exactly the same.
Temporarily secure the hose reel slide in position on the feed.
5. Install the hose reel drive sprocket on the hose reel slide.
6. Tighten the drive chain to proper tension (see Feed Chain Adjustment on previous page) and re-
lease the temporary securing device on the hose reel slide from the feed.
7. Move the drill carefully backwards and test to be sure the setting is correct.
8. Install the hoses on the hose reel.
9. Shim clearance between feed and wear pad to 0.060 + 0.020 in. (1.5 + 0.5 mm). Slide must move
freely.
10. Tighten all bolts according to the Bolt Torque Specifications in Section 10.

BI006823-00
Section 7
Pressure Settings and Adjustments
NOTE The adjustments in this section require two persons; one in cab operating machine
and observing readings and one making the adjustments.
Pressure Settings and Adjustments 7-1

Pump Adjustments BI006823-00
Fig. 7-1 Hydraulic Pumps and Gauges–Oilgear

1. Pump No. 1
2. Pump No. 2
4. Pump No. 1 Gauge
5. Pump No. 2 Gauge
Fig. 7-1a Hydraulic Pumps and Lines–Oilgear

2. Pump Discharge to Pressure Manifold Lines
3. Pump Case Drain Lines
4. Tandem Hydraulic Pumps
5. Gauge Ports to Pressure Gauges above Pumps.
7. Supply Lines from Hydraulic Tank
8. Supply Line from Hydraulic Tank
9. Pump Discharge Line to Dust Collector Manifold
7-2 Pressure Settings and Adjustments

BI006823-00
Pump Adjustments
BEFORE making any adjustments to the main hydraulic pump, be sure machine is on
level ground. Block tracks and set feed on ground.
Disengage track final drives (see Section 2).
BE SURE hydraulic and pneumatic systems are not pressurized before loosening or
removing any connections.
Disengage brake valve (see below).
NOTE Pump pressure adjustment procedure is easier with two people. If installing a new
pump, be sure to prime pump first by filling case with hydraulic oil.
Turn engine over for 5 seconds, but do not allow engine to start, pause 5 seconds
and turn over for additional 5 seconds.
Pump Pressure Adjustment–Oilgear

1. With machine on level ground, tracks blocked and final drives disengaged, disconnect brake valve
by removing wire to brake solenoid valve.
2. Read pressure from hydraulic system pressure gauges, located above hydraulic pumps when mak-
ing pump adjustments.
3. Disconnect compensator line (6, fig. 7-1a) from one of the pumps. Order of adjustment does not
matter. Plug line, but leave fitting open to atmosphere.
4. Start machine and allow a few minutes to warm up. Place the system control switch ON and switch
to TRAM mode.
5. Set pump to 3200 PSI (220 bar) by turning the adjustment on the compensator.
NOTE This is a good starting point for the compensator setting. It may have to be varied
slightly according to specific drilling conditions up to a maximum of 3500 PSI (241
bar).
6. Reconnect the compensator line to the adjusted pump and disconnect the compensator line from
the other pump.
7. Repeat the adjustment procedure and reconnect the compensator line.
8. Reinstall pinion shaft into final drives (per instructions in Section 2), and reinstall brake solenoid
wire.

Pump Adjustments BI006823-00
BEFORE making any adjustments to the main hydraulic pump, be sure machine is on
level ground. Block tracks and set feed on ground.
Disengage track final drives (see Section 2).
BE SURE hydraulic and pneumatic systems are not pressurized before loosening or
removing any connections.
Disengage brake valve (see below).
NOTE Pump pressure adjustment procedure is easier with two people. If installing a new
pump, be sure to prime pump first by filling case with hydraulic oil.
Turn engine over for 5 seconds, but do not allow engine to start, pause 5 seconds
and turn over for additional 5 seconds.
Fig. 7-2 Hydraulic Pumps and Gauges–Linde

1. Pump No. 1
2. Pump No. 2
4. Pump No. 1 Gauge
5. Pump No. 2 Gauge
Pump Pressure Adjustment–Linde

1. With machine on level ground and tracks blocked, disconnect brake valve by removing wire to
brake solenoid valve.
2. Read pressure from hydraulic system pressure gauges, located above hydraulic pumps when mak-
ing pump adjustments.
3. Prior to starting, adjust the load sense screws on both compensators to a starting position by turn-
ing them both all the way in and then five (5) turns out.
4. Disconnect compensator line (fig. 7-2a) from one of the pumps. Order of adjustment does not mat-
ter. Plug line, but leave fitting open to atmosphere.

BI006823-00
Pump Adjustments
Fig. 7-2a Main Pumps Adjustment–Linde

2. Main Compensator Adjustment (both compensators)
3. Load Sense Adjustment (both compensators)
4. Disconnect Line to Adjust Pump
Pump Pressure Adjustment–Linde (cont.)

5. Start machine and allow a few minutes to warm up. Place the system control switch ON and switch
to TRAM mode.
6. Set pump to 3200 PSI (220 bar) by turning the adjustment on the compensator.
NOTE This is a good starting point for the compensator setting. It may have to be varied
slightly according to specific drilling conditions up to a maximum of 3500 PSI (241
bar).
7. Reconnect the compensator line to the adjusted pump and disconnect the compensator line from
the other pump.
8. Repeat the adjustment procedure and reconnect the compensator line.
9. Reinstall brake solenoid wire and unblock the tracks.
10. If pumps do not remain loaded while under load, adjust each load sense screw out 1/2 turn at a
time until normal operation is attained.

Drill/Boom Valve Adjustments BI006823-00
Hammer Pressure
1. Start engine, control switch ON, switch to DRILL mode and turn hammer ON.
2. Reading hammer pressure on the cab display, adjust each screw shown in fig. 7-3 to set pressure to
2800 +/- 50 PSI (193 +/- 3.5 bar).
3. This is the factory setting, further adjustment may be required depending upon drilling conditions.
NOTE Remember to maintain a 600–1000 PSI (41–69 bar) pressure differential between the
hammer and feed pressures. So if feed pressure is 1500 PSI (103 bar), hammer pres-
sure should be 2100 to 2500 PSI (145 to 172 bar). Refer to operator's manual "drilling
procedures."
Fig. 7-3 Drill/Boom Control Valve 433404 (10 Bank Valve)

Hammer Pressure Adjustment

BI006823-00
Drill/Boom Valve Adjustments
Rotation Speed
1. Start machine, control switch ON, switch to DRILL mode.
2. Vary the movement of the Drill joystick to the right or left. Rotation speed should vary. Maximum
rotation speed for the HPR1H-ATW or HPR45 drill is 200–250 rpm.
3. Adjust the screws on the drill/boom valve shown in fig. 7-4 to set rotation speed to 120 +/- 10 rpm.
Fig. 7-4 Drill/Boom Control Valve 433404 (10 Bank Valve)

Rotation Speed Adjustment

Feed and Rotation Pressure Manifold BI006823-00
Rotation Pressure Adjustment

1. Start engine, control switch ON, switch to DRILL mode.
2. Place coupling on the drill shank and close the centralizer. Move the Drill joystick to maximum rota-
tion and observe pressure reading on the cab display.
3. Pressure should be 2500 +/- 100 PSI (170 +/- 7 bar).
4. Adjust if required using the adjustment shown in fig. 7-5.
Fig. 7-5 Feed and Rotation Manifold (located under cab)

Rotation Pressure Adjustment

BI006823-00
Compressor Adjustments
KEEP hands, hair and clothing away from rotating parts.

DO NOT wear loose clothing or jewelry when working on machinery.
Compressor Speed Adjustment

1. Remove access cover from compressor motor mount.
2. Start engine, control switch ON, switch to DRILL mode and switch compressor switch ON.
3. Turn air control to maximum ON position and let air blow through open shank. The compressor
should come up to maximum speed. Compressor rotation speed should be 2400 +/- 50 rpm.
4. Check compressor speed by using a strobe tach. There is a white timing mark on the compressor
motor coupling which can be seen with the access cover removed (fig. 7-6).
5. To adjust compressor rotation speed, adjust the screw on the tram valve as shown in fig. 7-7.
6. After correct speed is obtained, shutdown the machine and replace the access cover.
Fig. 7-6 Air Compressor Drive Motor and Coupling

1. Drive Motor
2. Motor Coupling (shown with access cover removed)
Fig. 7-7 Tram Valve Compressor Speed Adjustment

BI006823-00
Compressor Drive Coupling
Replacement of Rubber Drive Blocks

2. Remove the four compressor drive motor mounting bolts and remove motor with half of coupling
attached to shaft.
NOTE If only replacing the rubber drive blocks, it is not necessary to remove the two cou-
pling halves from the compressor shaft and motor shaft.
3. Remove old rubber drive blocks.

4. Clean surfaces of coupling and install new rubber drive blocks using silicone adhesive. The ad-
hesive will hold the rubber drive blocks in place while installing the other half of the coupling and
motor.
5. Install motor with coupling half, being careful of alignment with other half of coupling and rubber
drive blocks.
6. Install the four compressor drive motor mounting bolts and washers and tighten. Install hoses to
motor, be sure all connections are tight.
Replacement of Drive Coupling

If complete coupling is being replaced, be sure to follow set-up dimensions shown in fig. 7-8 and
7-9. Clean threads of coupling setscrews and apply loctite to threads.
1. Position coupling half on compressor shaft so it is not touching the housing and torque setscrew to
50 ft. lbs. (68 Nm).
2. Install rubber drive blocks with silicone adhesive.
3. Install coupling half on motor shaft, positioned to provide access to setscrew through hole in hous-
ing.
4. Install motor and the four mounting bolts and washers and tighten.
5. Leave about a 1/8 in. (3 mm) gap between coupling halves and be sure coupling does not touch
motor housing. Tighten setscrew to 50 ft. lbs. (68 Nm).

BI006823-00
Compressor Drive Coupling
Fig. 7-8 Compressor/Motor Coupling Installation (ref. 428264)
Fig. 7-9 Coupling Installation (ref. 428264)

BI006823-00
Dust Collector Assembly
PRECLEANER
A A
DUST COLLECTOR
PICKUP POT
OUTLET
FILTER
AIR FILTER/REGULATOR AIR LINES

(SUPPLIED WITH VIEW B-B
DUST COLLECTOR)
DUST COLLECTOR
SUPPORT
DUST COLLECTOR MOTOR

(COVER REMOVED)
DUST COLLECTOR
VALVE MANIFOLD
VIEW A-A
Fig. 7-10 Dust Collector Installation (ref. 428252 rev. C)

BI006823-00
FAN HOUSING
CLEAN AIR COVER
EXHAUST
DRAIN
TUBE
WATER AIR HOSE
DRAIN HOSE
TIMER
CLEAN AIR
EXHAUST
MOTOR FAN AND
HUB ASSY
WATER PULSE AIR
FAN DRAIN INLET
HOUSING
TIMER
UPPER TEST DOOR
PORT
FILTER LOWER TEST

PORT JUMP
CARTRIDGE TUBE
CONTAMINATED
AIR INLET
Fig. 7-11 Dust Collector Assembly (ref. 432209 rev. A)

Dust Collector Assembly BI006823-00
Function of Dust Collector

The function of the dust collector is to convey the dust and rock chips from the hole collar to the filter
housing and separate the solid particles from the clean air.
Detailed Function of Components

Pick Up Pot: The pot is of special design, sized to the collector's performance. The pot must be
mounted to the drill feed in such a manner that it provides unrestricted entry of make-up air (approxi-
mately 2 in. above the hole collar). The offset suction hose outlet and the accelerator ring inside the
lower section of the pot blend to create a vortex air flow in the pot. Two wear resistant flexible seals,
mounted on the top plate, form an effective seal between the drill steel and the pot, to prevent the cut-
tings escaping into the atmosphere.
Primary Separation: This function takes place in the hopper which is the lower section of the col-
lector. The separator deflects the heavier particles downward into the hopper, so they do not come into
contact with the filters. The hopper stores the separated material for final discharge through the dump
flap, attached to the lower section of the hopper. The dump flap is held closed by the internal vacuum
and releases the separated material when the fan is turned off. When drilling is in progress, should the
volume or weight of the separated material overcome the vacuum effort, the dump flap will automatically
discharge. This feature permits uninterrupted drilling to continue indefinitely.
Final Separation: The main body of the collector is divided into separate chambers. The lower, dirty
air chamber, contains the filters and the top section (the clean air chamber) houses the pulse air mani-
fold and the impulse valves. The pleated filters are attached to the bulkhead, forming a barrier so that
only clean air can pass. The dust laden air is drawn upwards from the hopper where it passes through
the filters which remove the remaining microfine dust particles, allowing only clean air to enter the top
chamber. The trapped dust builds up in layers on the filters, forming a dust cake, which if left undis-
turbed, would block the passage of air through the filters. To prevent the dust cake from building up, it is
removed from the filters by reverse flushing. The electronic timer controls the impulse valves by cycling
the firing order of the valves, delivering a measured quantity of compressed air to the inside of the filters.
This charge of compressed air is transformed into a high velocity flow that dislodges the built up dust
cake from the filters and causes it to settle in hopper. This repeated cleaning cycle enables continuous
drilling, while providing sufficient air flow to prevent blockage of the filters and the suction hose.
Fan: The fan generates the required vacuum and air flows which convey the material through the
system. The taperlock coupling secures the fan wheel to the motor shaft while providing adjustment for
setting the wheel clearance.

BI006823-00
Dust Collector Adjustments
ALWAYS wear eye protection when on or around machinery.
NEVER look directly into the fan outlet. Loose particles in the fan housing may exit at
high velocity and cause eye damage.
Initial Start-up and Tuning
Fig. 7-12 Dust Collector Control Valve

1. Relief Valve
2. Flow Control Adjustment (fan speed)
3. Solenoid Valve (NC) 24VDC
Control Valve Adjustment

Normally, the initial start up service is carried out by the drill manufacturer or by the distributor's field
personnel. It is, however, advantageous to understand this procedure as the same principles apply when
tuning the collector, to maintain optimum performance. Two people are required to carry out this proce-
dure.
1. Remove the hose from the inlet connection at the dust collector fan motor. This is the hose that
connects to the "M1" port of the dust collector control valve. Install a #8 plug in the hose end and
install a #8 cap on the adapter of the motor inlet.
2. Install a 5000 PSI (345 bar) gauge in the gauge port (G) on the dust collector valve.
3. Loosen the locknut and turn the pressure relief adjustment (fig. 7-12) all the way out (CCW).
4. Turn dust collector switch to OFF. Start machine, control switch ON and switch to DRILL mode.
Leave system in low idle. Reading on pressure gauge installed in dust collector control valve
should be very low or zero.
5. Turn dust collector switch ON and air switch ON; this will increase engine rpm.
6. Turn adjustment screw until gauge on control valve reads 2350 PSI (162 bar). Tighten locknut.
7. Turn dust collector switch OFF and air OFF. Shutdown machine, remove gauge and connect hose
to dust collector motor "M1" port.

Dust Collector Adjustments BI006823-00
Air Pressure Regulator Adjustment (fig. 7-13)
1. Start machine, control switch ON and switch to

DRILL mode. Leave system in low idle.
2. Switch dust collector ON (pulse mode, no air).
3. Open the valve in the air line going to the
regulator.
3. Adjust pressure regulator to 60 PSI (4.1 bar).
Lift up on the cap and turn cap to adjust pres-
sure. When pressure is set, push cap down.
Timer Adjustment (fig. 7-14)
1. Start machine and switch dust collector ON

Fig. 7-13 Dust Collector Regulator Adjustment
(pulse mode, no air). 1. Air Valve
2. Open small door on upper side of dust col- 2. Regulator/Filter)
lector to expose timer panel. The green pilot 3. Regulator Pressure Gauge
light should be illuminated, indicating power is 4. Regulator Adjustment Cap
reaching the panel. The red indicator lights will
flash in rotation.
3. Turn the step control knob to the time delay between each flash of the red pulse indicator lights.
Time between each flash should be 3 to 5 seconds.
4. Turn the pulse control know to adjust the duration of each flash to 0.2 seconds (200 milliseconds).
5. These adjustments will result in each of the valves pulsing in sequence for a short interval 3 to 5
seconds apart.
Fig. 7-14 Dust Collector Timer Panel

BI006823-00
Dust Collector Adjustments
Fan Speed Adjustment
1. Ensure dust collector relief valve and air pressure regulator are set as previously described.
2. Ensure pick up pot is at least 6 in. (152 mm) clear of the ground.
3. Start machine, control switch ON and switch to DRILL mode. Switch dust collector ON. Turn air ON
momentarily to activate dust collector fan and then turn OFF. As fan slows, observe direction of ro-
tation through exhaust opening (fig. 7-11). Fan should turn clockwise when viewed from top. If fan
rotation is correct, turn air ON, if not, the hydraulic hoses are incorrectly installed. Port "M1" from
the dust collector valve is the pressure port to the motor, port "M2" is the return. The motor ports
are marked "A" for pressure, "B" for return.
4. Remove jump tube from the lower test port (fig. 7-11). Connect one end of the manometer to the
lower test port and leave other end of manometer open to atmosphere (see manometer setup in-
structions).
5. Remove dust collector hose and have a helper block the dust collector inlet with a piece of wood or
similar object.
6. Switch dust collector ON and read suction pressure in the top chamber (after the filters) of the dust
collector.
7. Adjust flow control valve (fig. 7-12) to obtain a reading of 16–18 in. WG (Water Gauge) of suction.
The dust collector is now set up to run at about 75% capacity. Further adjustments can be made
depending on ground conditions.
In lighter duty applications (drilling smaller diameter holes in rock of light specific gravity) energy may
be saved by decreasing purging air pressure and increasing time between pulses. In heavier duty appli-
cations the time between pulses may be decreased and the air pressure may be increased.

BI006823-00
Operational Variables
Variables: Are a combination of factors that influence what is commonly known as "Drilling Condi-
tions". These include: The hardness of the formation, the moisture content, the specific gravity of the
material, the ratio of microfine dust particles to larger sized chips in the drill cuttings, the size and type
of drill bit used and the drill penetration rate.
Suction Air Velocities: It is generally accepted that when using a smooth bore suction hose, air
velocities of 3000 FPM (915 MPM) are required the convey light, fine, particles, while velocities in the
range of 4000 FPM (1220 MPM) are needed for heavier, larger, cuttings. Should the drilling conditions
include material with a high specific gravity, such as iron ore, or contain a high moisture content such as
sticky clays that tend to impinge on surfaces, air velocities greater than 4500 FPM (1372.5 MPM) could
be required to prevent the suction hose from blocking.
Degree of Difficulty: Any combination of the fixed and variable factors will dictate the Degree of
Difficulty under which the dust collector will operate. The governing factors controlling the dust collector
performance are the air velocity in the suction hose and the pressure drop across the filters. The first
can be governed by adjustment of the fan speed and the second by maintaining clean filters with suit-
able purge air pulses.
Fine Tuning
As outlined previously, drilling conditions dictate the degree of difficulty the dust collector has to
operate.
Assuming the electronic timer and fan speed settings are in accordance with the "Initial Start Up and
Tuning" instructions and drilling is in progress, the initial setting can be assessed and adjusted to com-
ply with the degree of difficulty. If the settings are too low, suction hose blocking problems will result.
If the suction hose is free from blockage, the setting is either correct or too high. If the setting is too
high, an "overkill" condition exists, which if allowed to continue, will result in unnecessary wear of the
suction hose, the inlet tube and the separator. The filter life will also be reduced.
Suction Hose Blocking: Remove the suction hose blockage. Connect manometer to upper and
lower test ports and start drilling. The manometer is now reading the pressure drop across the filters.
If the reading is over 4 in. (10.2 cm) H2O the filters are contaminated to the extent that air flow is being
restricted. To correct this, shorten the interval between valve firing by gently adjusting the step control
knob. In doing so, the H2O reading should decrease, which in turn permits more air to pass through the
system preventing blockage. If the reading is below 2 1/2 in. (6.4 cm) H2O, the filters are not restricting
the air flow. Gradually increase the fan speed until the hose stays free from blockage.
Overkill Situation: This condition is reached when the dust collector performance far exceeds the
degree of difficulty being encountered in drilling the hole. Ideally, the level of performance is set just
above the level required to create a dust free environment at the hole collar, with sufficient air flow to
prevent the suction hose from blocking.
Reducing the fan speed to the "just above" level will prolong the life of the wear components.

BI006823-00
Manometer
Manometer Setup Instructions
ATMOSPHERE
UPPER TAP UPPER TAP UPPER TAP
LOWER TAP LOWER TAP LOWER TAP
ATMOSPHERE
Measurement of Vacuum Measurement of Vacuum Measurement of

on clean side of Filter on dirty side of Filter Pressure Drop across
(Upper Tap) (Lower Tap) Filter (Connect to
both Upper and Lower
Taps)
Fig. 7-15 Illustration of Slack Tube Manometer

Manometer BI006823-00
Manometer Setup Instructions

Introduction
A manometer is a simple device used to measure static pressure, vacuum or differential pressure.
The unit can be purchased from Dwyer Instruments Inc. or a simple manometer can be made using a
length of clear plastic tubing and a 24 in. (610 mm) ruler.
Filling
Use distilled water and add 3/4 oz. bottle of Dwyer A-126 Fluorescein green color concentrate or
equal to color water. Remove a tubing connector from manometer and add water to mid-point level. Tap
tubing to remove air bubbles.
Installation
1. Make sure both ends of tubing are open to atmosphere. Connect one end of manometer to lower
test port on dust collector, leave other end free for reading fan speed. Connect both ends of ma-
nometer to upper and lower test ports to read pressure drop across filters.
2. Mount manometer to dust collector as shown in fig. 7-15.
3. Slide scale so zero mark of scale is in line with water level (fig. 7-15).
Reading
1. With manometer installed per instructions and dust collector running with dust collector hose con-
nected to precleaner and pick up pot (pick up pot must be at least 6 in. above the ground) observe
the vacuum produced by the air flow in inches of water.
2. One column will travel up and the other column will go down a like amount.
3. To measure the vacuum in inches, measure the distance between the two columns (fig. 7-15).
4. After reading is taken, close the connectors, which seals the tube and no fluid will be lost.
5. Connect jump tube to test ports on dust collector to seal out dirt.

BI006823-00
Dust Collector Timer
Timer Installation
Fig. 7-16 Timer Installation Diagram
The solenoid coils are 24 VDC. Wiring from timer junctions 1 2 3 4 is to solenoid coils .
1 2 3 4
Wiring from solenoid coils 1 2 3 4 bunched at connector, from connector to C on timer

junction.
From timer junction + to connector to air pressure switch to manual switch to + pos. battery
terminal.
From timer junction - to connector to - neg. battery terminal
To Set Timer: Start machine and switch dust collector ON (pulse mode, no air). Switch timer
on. The green light in top right hand corner indicates power on. Gently turn pulse control to set du-
ration of pulse to about 0.2 of a second duration (indicated by red lights flashing). Gently turn step
control to set the time between pulses between 3 to 5 seconds (indicated by red lights flashing).

BI006823-00
Dust Collector Control Circuit
Control Circuit
Fig. 7-17 Hydraulic, Electrical, and Air Circuits
Hydraulic Circuit
1 Hydraulic Pump
2 Electric Solenoid Control Valve With Pressure Regulator
3 Manual Flow Control Valve
4 Hydraulic Motor
Electrical Circuit
5 Manual Switch (console mounted)

6 Air Pressure Switch–normally open, 20 PSI (1.4 bar)
7 Timer Circuit Switch (console mounted)
8 Electronic Timer
Air Circuit
9 Blowing Air To Drill Valve (console mounted)

10 Drill
11 Manual Air Valve To Impulse Valves (console mounted)
12 Air Strainer/Regulator

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Dust Collector Fan
Fan Removal and Installation
Fig. 7-18 Dust Collector Fan Assembly
Removal
1. Tag and remove any hoses if complete housing is to be removed from machine.
2. Remove the capscrews that hold the fan housing cover to the fan housing and remove cover along
with fan and motor.
3. Remove the 3 capscrews holding the taperlock bushing.
4. Use a wheel puller to remove the bushing.
Installation
1. DO NOT hard hammer the bushing onto the shaft. Hammering can damage the bearings and
shorten the life of the motor. Use a soft mallet or other cushioned device to tap the bushing on the
shaft. The correct location of the bushing is when the end of the shaft protrudes approximately
0.150 in. (3.8 mm) from the bushing.
2. The preferred way to install the fan, is to remove the fan housing from the dust collector; this en-
ables the check of the actual clearance shown in fig. 7-18.
NOTE The correct clearance of the fan from the inlet ring is 0.12–0.18 in. (3–4.6 mm). Excess
clearance will reduce the efficiency of the fan wheel.
3. Clean old silicone from all mating surfaces and seal with new silicone sealant before assembling
parts.
4. Install any hoses that were removed.

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Troubleshooting Hints
Impulse Valves Not Pulsing (fig. 7-16): First check that the compressed air is turned on to the
impulse manifold (gauge on filter regulator). If air supply is over 100 PSI (6.9 bar), reset to 60–75 PSI
(4.1–5.2 bar). If air supply is okay, check that the green pilot light is illuminated in timer; if not, fault is
in the electric current supply. Check switch, battery condition, corroded terminals, any fuses that may
be in circuit, electric wiring, connectors and ground. Ensure that step and pulse control knobs are not
turned off by gently turning both knobs. If no faults are found, finally check test the + and – terminals at
timer junction block with test lamp. If power is reaching block, replace timer and return it to distributor for
service.
Impulse Valves Misfiring (fig. 7-16): If the red indicator lights are flashing on and off in the pro-
grammed order and the misfire is regular (one valve misfiring), the problem is either that electric current
is not reaching the coil or that the coil is faulty. The misfiring valve can be identified quickly by noting the
terminal number of the valve that fails to fire when the red indicator light flashes above it. Inspect the coil
wiring for damage and make sure that all connections are tight. If the wiring is not at fault, check the coil
by removing the DIN fitting and supply power directly to the coil. If faulty, replace the coil.
If misfiring is of an irregular nature and the green power 'on' light flickers, the fault is that intermittent
current is reaching the timer. Check wiring circuit to timer. If the green light is steady, the fault may be
loose terminals. If the irregular firing persists, change out timer and return it to distributor for service.
NOTE The dust collectors have 3 to 6 filters and the red indicator lights will operate in se-
quence; for instance, if the unit has 4 filters, 4 lights will function.
Solenoid Valves: In the event that air is passing through the solenoid valve when the timer is off,
check that there is no contamination under the valve seat and that the diaphragm is not damaged.
Remove contamination or replace diaphragm to correct. If the seat of the valve is damaged, replace the
valve. A broken diaphragm return spring also prevents the valve from seating; replace broken spring.
Suction Hose Blocking: First check that suction hose is not damaged or flattened and has no
sharp bends. As the dust collector is higher than the pick up pot, the cuttings must be moved upwards,
the suction hose should be kept as short as possible, rising steeply from the pot then leveling out to the
collector. If the material is of a very damp, sticky clay nature it may be necessary to remove the suc-
tion hose from the pot and to discharge the cuttings from the pot outlet; when drilling conditions return to
normal, reconnect hose to the pickup pot. This procedure should also be followed if high inflows of water
are encountered in the hole.
Dust is emitted from exhaust of dust collector:

A. Check that filters are not loose. Do not overtighten filter retaining bolt as this could cause the filter
to split, collapse or suffer other mechanical damage.
B. Inspect filters for damage, holes, splitting and correct sealing. Replace damaged filter or seal. Dust
passing the fan will cause rapid wheel erosion and failure.

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Dust Collector Troubleshooting
Troubleshooting Hints (cont.)

Fan: The fan has ample capacity to produce the required air flow and suction. The governing factors
affecting the volume of air moved through the fan are:
A. The clearance between the fan wheel and the housing inlet ring.
B. The fan wheel rotation speed.
NOTE To set the fan wheel clearance and fan speed see previous instructions in this section.
Ensure that the direction of fan rotation is correct, clockwise when viewed from the top. Ensure that
fan wheel speed does not exceed 3400 RPM, overspeed can cause the fan to go into cavitation, result-
ing in loss of efficiency.
If the fan wheel speed fails to respond to increased pressure or flow adjustments, check hydraulic oil
level in supply tank. Check that filters in the hydraulic system are not restricting oil flow.
Finally, check the condition of the hydraulic pump and motor and replace or repair as needed.
Although suction is increased to 20–25 (50.8–63.5 cm) WG, the collector is not operating ef-
ficiently:
A High suction pressures will not allow the purging air to repel the dust cake from the filters.
B. Reduce the suction air pressure to 18–20 in. (45.7-50.8 cm) WG and make sure the fan is not run-
ning during rod change or tramming. Absence of suction makes purging much more efficient.
Dust and cuttings around the hole collar are not being sucked into the collector:
A. Make sure the hoses are clear.
B. Suction in the top test port is 18 in. (45.7 cm) WG.
C. Pick up pot is 2 in. (50.8 mm) above ground during drilling.
D. Make sure fan is off during rod changing and tramming and purging air pulse is operating.
Dust and cuttings blow through the seals of the pickup pot:
A. Reduce the volume of blowing air.
B. There should be two seals installed in every pick up pot. If trouble persists, more seals may be
added as necessary.

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Notes

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Centralizer Assembly
Keep clear of moving centralizer. DO NOT actuate centralizer until personnel are clear.
Fig. 7-19 Centralizer

1. Centralizer Assembly
2. R.H. Centralizer Liner
3. L.H. Centralizer Liner
4. Centralizer Mounting Bolts (4)
Adjustment
1. Start machine, control switch ON and switch to DRILL mode. Using Drill joystick, lower drill down
the feed until drill shank threads are centered between the centralizer jaws.
2. The shank threads should be centered within the centralizer liners within 1/16 in. (1.5 mm).
3. If adjustment is required, loosen the centralizer mounting bolts and adjust as required for correct
alignment. Tighten bolts.
4. Move centralizer switch to OPEN position, move switch from OPEN to CLOSE, then back to middle
position. Centralizer should stop at an intermediate open position.
NOTE In the middle position the centralizer has no holding power, this is a float position.
When adding or removing drill steel, with the centralizer clamped around the coupling,
the centralizer switch must be in the CLOSE position or drill steel will be lost in the
hole.

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Description
The angular display is connected to the sensor mounted on the feed. There are 10 display lights in
each axis (Y+, Y-, X+ and X-). The maximum angle from plumb is + or - 6 degrees, thus each light repre-
sents 0.6 degrees. The lights remain lit if the feed is more than 6 degrees from plumb. The lights will go
out successively as the feed approaches plumb in each direction.
Vertical Adjustment
1. Position feed vertical (plumb) and check with a level, adjust the sensor to indicate plumb (no lights
on).
2. Move feed to non-vertical position, then move back until all lights go out (plumb). Feed should be
plumb within + or - 0.6 degrees.
Fig. 7-20 Vertical Indicator Display and Wiring Diagram

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Vertical Indicator
Wiring
Wire the element as follows:
1. +24 volts to Red wire of display; -24 volts (ground) to Black wire of display.
2. Wire White/Red wire from the display to the Red wire of the sensor.
3. Wire the White/Black wire from the display to the Black wire of the sensor.
4. Wire the Blue wire of the display to the Blue wire of the sensor.
5. Wire the Yellow wire of the display to the Yellow wire of the sensor.
Troubleshooting
1. Measure voltage from the display White/Red wire to the display Black wire, this should be +6 volts.
2. Measure voltage from the display White/Black wire to the display Black wire, this should be -6 volts.
3. Measure voltage from the display Blue wire to the display Black wire, the voltage should go from
a +0.6 volts when the sensor is tilted maximum in one direction (approximately 6 degrees) to -0.6
volts at the other extreme (approximately 6 degrees in the other direction from zero angle). The
Black ground wire is a mid point between +0.6 volts and -0.6 volts.
4. Measure voltage from the display Yellow wire to the display Black wire, the voltage should go from
a +0.6 volts when the sensor is tilted maximum in one direction (approximately 6 degrees) to -0.6
volts at the other extreme (approximately 6 degrees in the other direction from zero angle). The
Black ground wire is a mid point between +0.6 volts and -0.6 volts.
5. If 6 volts is not measured from the display White/Red to Black and Black/White to Black, then the
display is defective.
6. If the Yellow to Black and Blue to Black voltage does not change as the sensor is moved to +0.6
and -0.6 volts, then the sensor is defective.

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Drill Backpressure Valve
Functional Description
The drill backpressure valve (fig. 7-23) is installed in the return manifold). The function of the back-
pressure valve is to prevent cavitation of the drill. It does so by maintaining sufficient charge pressure on
the low pressure accumulator. This assures the drill will not run out of oil. Typically, this can occur while
the drill is operated in "free oscillation" mode, as when "hammering" out of the hole to help remove stuck
drill steel.
Fig. 7-21 Front View of Hydraulic Tank

1. Hydraulic Tank
2. Drill Backpressure Valve
3. Pressure Manifold
4. Return Manifold
Adjustment
1. With machine shut down and pressure relieved, install a tee and a 500 PSI (35 bar) gauge in
the return line of the drill. The return port is on the left side when facing the rear of the drill for
HPR45/51 or HPR1H-ATW drills.
2. Start machine and allow system to warm up. Test must be made while drilling a hole.
3. Unscrew cap on backpressure valve and adjust so gauge reads 250 PSI (17.2 bar). The backpres-
sure valve is set at 150 PSI (10.3 bar) and there is 100 PSI (7 bar) on the return side of the drill.
4. Once pressure is set, no further adjustment to the valve is needed. Tighten locknut and screw cap
on valve.

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Drill Backpressure Valve
Maintenance
To dismantle valve for cleaning and inspection, follow the steps below:
1. Shutdown machine and relieve all pressure from the hydraulic system.
2. Remove Cap (B)
3. Remove O-Ring (E)
4. Remove Locknut (F)
5. Remove Adjusting Screw (C)
6. Remove Retainer (D)
7. Remove Spring (G)
8. Remove Piston (I)
9. Stop Ring (H) should not be removed
as special tools are required for installation.
Inspect valve bore and piston for wear

and scoring. Replace broken or damaged parts.
Clean all parts thoroughly and coat with hydraulic
oil of the same type used in the machine.
Reassembly is the reverse of disassembly.
Fig. 7-22 Backpressure Valve
Recommended spare parts are: A. Body F. Locknut
O-Ring (E) B. Cap G. Spring
C. Adjusting Screw H. Stop Ring
Spring (G)
D. Retainer I. Piston
Piston (I) E. O-Ring

Notes BI006823-00

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Section 8
Vendor
Service Information
Vendor Service Information 8-1

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Index to Service Information
Page
Vendor/Model Part No. Description No.
Char-Lynn–Type S 1406057 HPR1H-ATW Drill Rotation Motor (part of 1416647) 8-3
Char-Lynn–2000 Series 420250 HPR45 Drill Rotation Motor, 8.0 cu. in 8-13
Char-Lynn–2000 Series 420251 HPR51 Drill Rotation Motor,11.9 cu. in. 8-13
Fairfield/S1A 1417795 Gear Reducer–Feed Drive 8-21
Lincoln/82716–Series "F" 96956 Air Operated Grease Pump (part of 1417103) 8-37
Wilkerson C16-03-000 1417102 Filter/Regulator/Lubricator–Grease Pump 8-45
Filter Model F16B 8-46
Lubricator Model L16 8-47
Regulator Model R16 8-48
Norgren B74G 419067 Filter/Regulator–Dust Collector 8-49
Oilgear PVG130 431744 Tandem Hydraulic Pumps 8-51
Parker F12 431740 Hydraulic Motor–Feed Drive 8-71

434333 Hydraulic Motor–Compressor
Parker F11 432201 Hydraulic Motor–Dust Collector 8-91
Texas Hydraulics Hydraulic Cylinder Repair 8-107
NOTE When repairing Texas Hydraulics cylinders, follow the general information instruc-
tions and then check to see what type of piston and head is in the cylinder and follow
those specific instructions.
Refer to parts manual for your machine for specific cylinder information.
8-2 Vendor Service Information

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Feed Drive Gear Reducer

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Drill String Grease System
Thread Grease Kit

The R30C track drill uses an automatic drill string thread greasing system. The system uses an air pow-
ered grease pump attached to a 35 lb. (15.9 kg.) grease container located on the right side of the machine.
The system is activated by The Drill joystick in DRILL mode, and the pump delivers grease to the nozzle
mounted on the feed.
Air supply is filtered, lubricated and regulated by the filter/regulator/lubricator mounted on the hydraulic
tank on the right side of the machine.
The following pages give maintenance and repair instructions. Refer to machine parts manual for repair
part numbers and kits.
Pressure Setting
• Normal pressure setting is 80 PSI (5.5 bar).
• Loosen locknut on regulator cap and turn knob to correct pressure. Tighten locknut.
Fig. 8-1 Grease System

1. Grease Container
2. Grease Pump Unit
3. Lubricator
4. Regulator
5. Filter/Water Separator

Drill String Grease System BI006823-00
Fig. 8-2 Grease Pump and Cover Components

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Dust Collector Filter/Regulator

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Tandem Hydraulic Pumps

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Safety First
Read and understand this entire instruction sheet The cleanliness of working on this pump or
NOTE the hydraulic system is extremely
before repairing, or adjusting your Oilgear product.
important to the safety and reliability of the
Those who use and maintain this equipment must pump and the system. Always make sure
be thoroughly trained and familiar with the product. the fittings are clean on the outside before
If incorrectly used or maintained, this product and removing them from their connections, are
its equipment can cause severe injury. capped and plugged when removed and
placed in a clean rag or container until they
SAFETY SYMBOLS are reinstalled.
The following signal words are used in this

instruction sheet to identify areas of concern where ! WARNING
your safety may be involved. Carefully read the text Some service operations may require
and observe any instructions provided to ensure special tools or equipment. If you require
your safety. information on these items, please contact
Oilgear before attempting these repairs
! DANGER ! and service operations.
THIS SIGNAL WORD INDICATES AN IMMI-
NENTLY HAZARDOUS SITUATION WHICH, ! WARNING
IF NOT AVOIDED, WILL RESULT IN DEATH Read, understand, and follow the safety
OR SERIOUS INJURY. guidelines, dangers, and warnings
contained in this instruction sheet to
! WARNING promote reliable operation and prevent
serious personal injury.
This signal word indicates a potentially
hazardous situation which, if not avoided,
could result in death or serious injury. ! WARNING
DO NOT attempt to service this machinery
CAUTION in an environment where safety regulations
are not established and in place.
This signal word indicates that a potentially
hazardous situation exists which, if not
avoided, may result in damage to ! WARNING
equipment or minor personal injury. DO NOT operate the hydraulic system if a
leak is present. Serious injury may result.
While not directly relevant to the topic being
NOTE discussed, the NOTE is used to emphasize
information provided, or provide additional ! WARNING
information which may be of benefit. Hydraulic systems operate under very high
pressure. Hydraulic fluid escaping from a
! WARNING pressurized system can penetrate
unprotected body tissue. DO NOT inspect
This service information is designed for for hydraulic leaks with bare hands or other
the maintenance of your Oilgear product. exposed body parts. As a minimum, wear
It contains the information on the correct leather gloves prior to inspecting for leaks
procedures determined by Oilgear for the and use cardboard or wood. If leaks are
safe manner of servicing. Always keep present, relieve pressure and allow system
this instruction sheet in a location where it to cool prior to servicing. If injured by
is readily available for the persons who escaping hydraulic oil, contact a physician
use and maintain the product. Additional immediately. Serious complications may
copies of this instruction sheet are arise if not treated immediately. If you have
available through the Oilgear Company. questions regarding inspecting for
(Contact phone number.) Or visit our hydraulic leaks, please contact Oilgear
website: www.oilgear.com. Please contact prior to servicing.
us if you have any questions regarding the
information in this instruction bulletin.
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Safety First
! WARNING ! WARNING
Hydraulic hoses and tubing must be Hydraulic cylinders can be holding a
inspected on a daily basis for leaks, cuts, function in a certain position when
abrasions, damage and improper thepump is OFF. An example of this is a
clearance along any mounting frame for function being held in the lift or partial lift
hidden damage before the unit is put into position by the cylinders. If a hydraulic
service. Replace damaged hoses or hoses line is removed or the hydraulic circuits or
you suspect are damaged before the controls are being worked on, gravity may
system is returned to service! Hoses must allow the function being held in position to
be replaced every two years. Failure to drop. All workers and personnel must
properly inspect and maintain the system remain clear of these areas when working
may result in serious injury. on or operating the hydraulic system.
Block and secure all devices and
functions which apply before beginning
! WARNING work or operation. Failure to comply with
Hydraulic systems are hot. DO NOT this can result in serious injury or death.
TOUCH! Serious personal injury may
result from hot oil. When you have
completed working on the hydraulic ! WARNING
system, thoroughly clean any spilled oil Any hydraulic pipe which is replaced must
from the equipment. Do not spill any conform to SAE J1065 specifications. If
hydraulic fluids on the ground. Clean any incorrect hydraulic pipe is installed, the
hydraulic fluids from your skin as soon as hydraulic system may fail, causing
you have completed maintenance and serious injury. Damaged or leaking
repairs. Dispose of used oil and system fittings, pipes or hoses must be replaced
filters as required by law. before the system is returned to service.
! WARNING ! WARNING
Use correct hoses, fittings, and adapters DO NOT heat hydraulic pipe. The carbon
with the correct SAE rating when content of this steel tube is such that if
replacing hoses to prevent possible heated for bending, and either water or air
serious injury. Always replace hoses, quenched, the pipe may lose its ductility
fittings, and adapters with replacements and thereby be subject to failure under
that have a proper, suitable, working high pressure or hydraulic chock
pressure rating. Replacement hoses must conditions. Serious injury can result.
be of the correct length and must comply Damaged or leaking pipes must be
with the hose manufacturer’s and replaced before the system is returned to
Oilgear’s installation guidelines and service. Please contact Oilgear if you
recommendations. require assistance or have questions.
! WARNING ! WARNING
Hydraulic hoses have the SAE ratings All hydraulic pressure must be relieved
marked on the hose to assist you in from the hydraulic system prior to removing
selecting the correct hose. The same manu- any components from the system. To
facturer must supply any replacement relieve the hydraulic pressure from the
hydraulic hoses and fitting assemblies. As hydraulic system, turn off the motor and
an example: Brand “X” hose and brand “Y” operate the control panel with the key in the
fitting will not normally be compatible. No ON position. Failure to comply can result in
“Twist” is allowed in the hydraulic hoses. serious injury. If you have any questions
“Twist” may result in premature hose concerning relieving the hydraulic pressure
failure. This can cause serious injury. from the system, please contact Oilgear.
Please contact Oilgear for assistance when
required.

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Safety First
! WARNING ! WARNING
Hydraulic components can be heavy. Use Any Oilgear pump safety decals must be
caution while lifting these components. replaced anytime they are damaged,
Serious personal injury can be avoided missing, or cannot be read clearly. Failure
with proper handling of the components. to have proper decals in place can result
in serious injury or death. (If you require
safety decals, please contact Oilgear for
! WARNING replacement safety decals, at no charge.)
Please contact Oilgear if you require
assistance, when performing hydraulic
test procedures, use the proper hydraulic ! WARNING
gauges. Installing an incorrect test gauge Be sure everyone is clear of the area
could result in serious injury if the gauge around the hydraulic system before
fails. Use properly rated hydraulic hoses operating after servicing. Remain attentive
to allow the test gauge to be read away at all times when operating to check your
from moving parts and functions. work until you are completely sure it is
safe to return to service. Failure to heed
this warning may result in serious
! WARNING personal injury or death.
Increasing hydraulic pressure beyond the
recommendations may result in serious
damage to the pump and system or ! WARNING
serious personal injury and may void the Wear the proper protective clothing when
Oilgear Warranty. If you have questions operating, servicing or maintaining the
concerning hydraulic pressures or testing hydraulic system or the Oilgear pump. Wear
procedures, please contact Oilgear before the correct protective gear, safety glasses,
attempting the test procedures or making gloves, and safety shoes. Serious injury
adjustments. can result without proper protective gear.
! WARNING ! WARNING
An Oilgear pump must not be modified in Make sure to keep hands and feet and
any way without authorization from other parts of your body clear of revolving
Oilgear. Modifications may not comply or moving parts. Failure to comply can
with safety standards, including ANSI cause serious injury.
safety standards, and may result in
serious personal injury. Please contact
Oilgear if you require assistance. ! WARNING
DO NOT wear watches, rings, or jewelry
while working with electrical and mechani-
! WARNING cal equipment. These items can be hazard-
DO NOT enter under hydraulic supported ous and can cause serious and painful
equipment unless they are fully supported injuries if they come into contact with elec-
or blocked. Failure to follow this procedure trical wires, moving parts, or hydraulic
can result in serious injury or death. equipment.

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Service Instructions
PREPARATION AND
! WARNING
INSTALLATION Running the pump in NEUTRAL position
(zero delivery) for extended periods
MOUNTING without a supercharge circuit can damage
Pump Without Reservoir - The pump can be the pump. The system and pump must be
mounted in any position. But, the recommended protected against overloads by separate
mounting position is with the drive shaft on a high pressure relief valves. Install bleed
horizontal plane and the case drain port 1 on the valve(s) at the highest point(s) in system.
top side. Secure the pump to a rigid mounting
surface. Refer to the referenced Oilgear Piping POWER
Information Bulletin 90011. Power is required in proportion to volume and
pressure used. Motor size recommendations for
Pump With Reservoir - These pumps are usually specific applications can be obtained from The
fully piped and equipped. It may be necessary to Oilgear Company. Standard low starting torque
connect to a super-charge circuit when used. motors are suitable for most applications.
Mount reservoir on level foundation with the
reservoir bottom at least six inches above floor
level to facilitate fluid changes. CAUTION
DO NOT start or stop unit under load
PIPING AND FITTINGS unless system is approved by Oilgear. It
Refer to the referenced Oilgear Piping Information may be necessary to provide delivery
Bulletin 90011 and individual circuit diagram before bypass in some circuits.
connecting the pump to the system. Inlet velocity
must not exceed 5 fps (1,5 mps). Inlet should be DRIVE
unrestricted and have a minimum of fittings. Verify rotation direction plate on the pump's housing.
Clockwise pumps must be driven clockwise and
DO NOT use an inlet strainer. counterclockwise pumps must be driven
NOTE
counterclockwise. Use direct drive coupling. Size
Arrange line from “case drain” so the case remains and install coupling per manufacturer's instructions.
full of fluid (non-siphoning). Case pressure must be
less than 25 psi (1,7 bar). For higher case CAUTION
pressures and the special shaft seals required,
DO NOT drive the coupling onto the pump
contact our Customer Service. Each drain line
drive shaft. If it is too tight, it may be
must be a separate line, unrestricted, full sized and necessary to heat coupling for installation.
connected directly to the reservoir below the lowest Refer to manufacturer's instructions.
fluid level. Make provisions for opening this line
without draining (siphoning) reservoir. Misalignment of pump shaft to driver's shaft should
not exceed 0.005 inches (0,13 mm) Total Indicator
Readout (TIR) in any plane.

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FILTRATION FLUID, FILLING AND STARTING

RECOMMENDATIONS
Keep the fluid clean at all times to ensure long life
from your hydraulic system. Refer to the referenced Refer to instruction plate on the unit, reservoir,
Oilgear Filtration Recommendations bulletin 90007 machine and/or reference, Fluid Recommendations
and Oilgear Contamination Evaluation Guide bulletin. Fire resistant fluids and phosphate ester
Bulletin 90004. Oilgear recommends use of a filter fluids can be used in accordance with fluid
in the pressure or return line. Replace filter manufacturer's recommendations.
element(s) when the filter condition indicator
reaches change area at normal fluid temperature. 1. Pump all fluid into reservoir through a clean
Drain and thoroughly clean filter case. Use (beta 10 ratio of 4 or more) filter. Fill reservoir
replacement element(s) of same beta 10 ratio to, but not above, “high level” mark on the sight
(normally a ratio of 4 with hydraulic oils). gauge.
2. Remove case drain line and fill pump case
FLUID COOLING with hydraulic fluid.
3. Turn drive shaft a few times by hand with a
When the pump is operated continuously at the spanner wrench to make sure parts rotate.
rated pressure or frequently at peak load, auxiliary
cooling of the fluid may be necessary. Fluid Unit 048/065/075/100/130
temperature should not exceed limits specified in
the referenced Oilgear Fluid Recommendations Approximate Torque 9-24 ft•lb
Bulletin 90000. to turn drive shaft (12-32 N•m)
AIR BREATHER Table 1. Torque to Turn Shaft
On most installations, an air breather is mounted With pump under “no load” or with pump control at
on top of fluid reservoir. It is important for the NEUTRAL:
breather to be the adequate size to allow air flow in
and out of reservoir as fluid level changes. Keep 4. Turn drive unit ON and OFF several times
the breather case filled to the “fluid level” mark. before allowing pump to reach full speed. The
About once every six months, remove cover, wash system can usually be filled by running the
screen in solvent and allow screen to dry, clean pump and operating the control.
and refill case to level mark and install screen. 5. The fluid level in the reservoir should decrease.
Refer to the manufacturer's recommendations. Stop the pump. DO NOT allow the fluid level to
go beyond the “low level.” If the level reaches
“low level” mark, add fluid and repeat step.
With differential (cylinder) systems, the fluid

NOTE must not be above “high level” when the
ram is retracted or below “low level” when
extended. Bleed air from the system by
loosening connections or opening petcocks
at the highest point in the system. Close
connections or petcocks tightly when solid
stream of fluid appears.

BI006823-00
CONSTRUCTION 6. The shoe retainer is held in position by the

fulcrum ball (103) which is forced outward by
See Figures 2, 8 and 9.
the shoe retainer spring (105).
1. A drive shaft (301) runs through the center line 7. The spring acts against the pump cylinder
of pump housing (001) and valve plate (401) barrel, forcing it against the valve plate while
with the pump cylinder barrel (101) splined to it. also forcing the piston shoes against the
2. A bearing (306) supports the outboard end of swashblock.
the drive shaft and a bushing supports the 8. The semi-cylindrical shaped swashblock limits
inboard end. (The bushing is part of valve plate the piston stroke and can be swiveled in arc
assembly.) shaped saddle bearings (204).
3. The pump cylinder barrel is carried in a 9. The swashblock is swiveled by a control
polymerous (journal type) cylinder bearing (included in referenced material). Refer to
(202). PRINCIPLE OF OPERATION.
4. The valve plate (401) has two crescent shaped
ports. SPECIFICATIONS
5. The pumping piston/shoe assemblies (102) in
the cylinder barrel are held against a Refer to reference material, pump control
NOTE material and individual application circuit
swashblock (201) by a shoe retainer (104).
for exceptions.
FLOW RATE at POWER

THEORETICAL RATED 1800 rpm rated INPUT at rated
MAXIMUM MAXIMUM
MAXIMUM CONTINUOUS continuous pressure continuous
Unit PRESSURE SPEED
DISPLACEMENT PRESSURE and 14,7 psia (bar abs) pressure &
inlet condition 1800 rpm
in 3/rev ml/rev psi bar psi bar gpm l/mi rpm hp kw
PVG 048 2.93 48,0 5000 344,8 5800 400,0 21.1 79,9 2700 73 54,5
PVG 065 3.98 65,0 5000 344,8 5800 400,0 28.8 108,9 2700 100 74,6
PVG 075 4.60 75,4 3750 258,6 4250 293,1 33.3 126,0 2700 89 66,4
PVG 100 6.00 98,3 5000 344,8 5800 400,0 42.4 160,5 2400 150 111,9
PVG 130 7.94 130,2 3750 258,6 4250 293,1 57.6 218,0 2400 150 111,9
Case pressure should be less than 25 psi (1,7 bar). For higher pressure, consult factory.
Higher speeds available - consult factory.
Table 2. Nominal Performance Data with 150--300 SSU viscosity fluids.
Length Width Height Weight

Unit Face Mounting
inches mm inches mm inches mm lbs. kg
PVG 048, 065, 075 12.0 303,0 6.9 174,5 6.3 160,4 68* 31 SAE “B” 2 and 4 bolt
PVG 100, 130 13.0 330,5 8.4 212,9 7.3 185,7 110* 50 SAE “C” 2 bolt
All dimensions (without controls) are approximate. For detailed dimensions, contact your Oilgear Representative.
* Weight with P Control and rear port valve plate
Table 3. Nominal Dimensions and Weights without controls.
Refer to installation drawings for more detailed dimensions and port configurations.

BI006823-00
TROUBLESHOOTING
PROBLEM CAUSES REMEDY
Low control input (pilot) pressure for “R” and “V” volume type
Unresponsive or Refer to referenced control instruction material.
controls only.
Sluggish Control
Swashblock saddle bearings (204) worn or damaged. Inspect bearings. Replace.
Delivery limited by faulty control Refer to appropriate control instruction material.
Obstructed suction circuit or insufficient supercharge volume. Inspect for obstruction and verify supercharge.
Insufficient drive motor speed. Refer to appropriate power material.
Insufficient Pump Worn or grooved cylinder barrel (101) and/or valve plate (401)
Volume mating surfaces.
Worn piston/shoe assemblies (102) or piston bores in cylinder Inspect components. Replace.
(101).
Worn or damaged piston shoe or swashblock (201).
Faulty control. Inspect components. Replace.
Fluid level in reservoir is low or supercharge is insufficient. Verify fluid level and/or supercharge.
Irregular or Air entering hydraulic system. Inspect system for leak.
Unsteady Operation Worn axial piston pump. Inspect components. Replace.
Faulty output circuit components (cylinder, motors, valves or
Inspect components. Replace.
other related components).
Worn piston pump.
Worn or grooved cylinder barrel (101) and/or valve plate (401)
Loss of Pressure mating surfaces. Inspect components. Replace.
Worn piston/shoe assemblies (102) or piston bores in cylinder.
Faulty output circuit components.
Excessive or High
Faulty output circuit components. Check the relief valves.
Peak Pressure
Pump stopped or started incorrectly under load. Verify operation procedure of pump.
Low fluid level in reservoir or insufficient supercharge causing
Verify fluid level and/or supercharge.
cavitation.
Air entering hydraulic system. Inspect system for leak.
Excessive Noise Fluid too cold or viscosity too high. Verify fluid temperature and/or type.
Suction line problem i.e.; obstructions in line, line too long, line
Inspect line and for obstruction.
diameter too small or too many bends and/or loops in line.
Broken or worn piston/shoe assembly (102). Inspect components. Replace.
Pump rotating in wrong direction. Inspect operation direction of pump.
Operating pump above rated or peak pressure. Verify pump limitations.
Low fluid level in reservoir or insufficient supercharge. Verify fluid level and/or supercharge.
Air entering hydraulic system. Inspect system for leak.
Worn piston pump.
Excessive Heating Worn or grooved cylinder barrel (101) and/or valve plate (401)
mating surfaces. Inspect components. Replace.
Faulty output circuit components (continuous blowing relief valves
or "slip" through valves, cylinder or other components.
Insufficient cooling provision or clogged coolers. Inspect for obstruction.

BI006823-00
PRINCIPLE OF OPERATION Position B, Pump During Full Delivery FROM

PORT B - Figure 3
The illustrations show the pump driven clockwise
(right hand) from the top (plan) view. Rotating the drive shaft (301) clockwise turns the
splined cylinder, which contains the pumping
pistons (102). When the cylinder rotates, the
pistons move in and out within their bores as the
shoes ride against the angled (C) swashblock
(201).
As the cylinder rotates, the individual piston bores
are connected, alternately, to the crescent shaped
upper (port A) and lower (port B) in the valve plate.
While connected to the upper side (suction) port A,
each piston moves outward OUT, drawing fluid
from port A into the piston bore until its outermost
stroke (D) is reached. At this point, the piston bore
passes from the upper crescent port A to the lower
crescent port B.
While rotating across the lower crescent, each
piston moves across the angled swashblock face
Figure 2. Cut-a-way of a Typical “PVG” and then each piston is forced inward IN. Each
Pump (92011R) piston then displaces fluid through the lower
crescent to port B until its innermost stroke (D) is
reached. At this point, the piston bore passes from
the lower to the upper crescent again and the cycle
is repeated.
Figure 3. Position B, Pump During Full Delivery From Port B

BI006823-00
Position B/2, Pump During One Half Delivery Position N, Pump In Neutral, No Stroke, No
FROM PORT B - Figure 4 Delivery - Figure 5
This illustration shows that the angle (E) of the Neutral position results when the control
swashblock determines the length of the piston centers the swashblock. The swashblock
stroke (F), (the difference between outermost and angle (G) is now zero and swashblock face is
innermost position) which determines the amount parallel to the cylinder face. There is no
of delivery from the pump. In this case, the stroke inward or outward motion of the pump pistons
angle (E) is one-half of the stroke, which means the as piston shoes rotate around the swashblock
piston stroke is one-half and the pump delivery is face. With no inward and outward motion or
one-half. no stroke (H), NEUTRAL no fluid is being
displaced from the piston bores to the
crescents in the valve plate and there is no
delivery from pump ports.
Illustration reference numbers match the

NOTE part item number in the parts list.
IN B
OUT A
E F
OILG-0002
Figure 4. Position B/2, Pump During One Half Delivery From Port B
NEUTRAL B
NEUTRAL A
H
G OILG-0003
Figure 5. Position N, Pump In Neutral, No Stroke, No Delivery
Refer to SPECIFICATIONS

BI006823-00
TESTING AND ADJUSTING DISASSEMBLY

The cleanliness of working on this pump or
! WARNING NOTE the hydraulic system is extremely important
Shut the pump OFF and release pressure to the safety and reliability of the pump and
from the system before disassembling the system.
components. Failure to comply with these
instructions could result in personal injury When disassembling or assembling the
or death. Blocking the pressure line pump, choose a clean, dry, dust and sand
between the pump and the system (or free area where no traces of abrasive
pump) high pressure relief valve will result particles are in the air which can damage
in damage and could result in serious the pump and system. DO NOT work near
personal injury. welding, sandblasting, grinding benches or
similar conditions.
PISTON PUMP
Always make sure the fittings are clean on
To check for a worn piston pump, make a leak the outside before removing them from
measurement test from the case drain while the their connections. Make sure they are
pump is under pressure. After the unit is warm, capped and plugged when removed. Place
either install a flow meter in the drain line or have them on a clean surface and in a clean rag
the flow from the drain line directed into a large or container until they are reinstalled.
container or reservoir. The pump case must remain When cleaning parts which have been
full of fluid during this test. disassembled, it is important to use
CLEAN cleaning solvents and parts are
allowed to dry. All tools and gauges should
CAUTION be clean prior to working with the system
DO NOT run a pump on stroke against a and use new, CLEAN lint free rags to
blocked output unless it is protected by a handle and dry parts.
high pressure relief valve and then run no
longer than necessary to check slip. Limit
discharge to prevent dropping reservoir ! WARNING
fluid below low level. DO NOT attempt to remove or install any
components or assembly while the pump
With an accurate high pressure gauge in the and system is running. Always stop the
pressure line, start the pump and stall (or block) pump, shut OFF the power and release
output device to raise system pressure to pressure from the system before servicing
maximum (as set by system relief valve). Read the or testing. Be sure provisions have been
measurement on the flow meter or time and made so the case drain line can be
measure the case drain flow used to fill a known disconnected from the unit without
size container and calculate the flow rate in terms causing the line to drain (siphon) the
of cubic inches per minute (cipm). The leakage reservoir.
should conform to Table 4.
(continued)
Additional leakage indicates wear, but
NOTE does not become critical until it impairs
performance.

BI006823-00
DISASSEMBLY (Continued) CONTROL GROUP

Refer to the reference material for the information
1. Disconnect case drain line from port 1 or 1A. which applies to the control your pump is equipped
2. Drain pump case through the remaining (port 1 with. Some force is required to remove the control
or 1A) on the bottom of case. If plugs are housing.
inaccessible, it may be necessary to remove 1. Remove socket head cap screws.
the pump from the mounting and drive motor
before draining it. 2. Lift the control group assembly, with control pin,
straight up from the top of the pump assembly.
3. After removing the pump from the mounting The control pin may or may not remain in the
and before disassembly, cap or plug all ports swashblock (201).
and clean the outside of unit thoroughly to
prevent dust from entering the system. See 3. Remove control gasket and O-rings from the
Figures 9 and 10. pump housing.
Depending on what part or parts are to be VALVE PLATE GROUP
NOTE inspected, it may not be necessary to
completely take apart all assemblies. If another pump is coupled to thru-shaft pumps, it
will be necessary to remove coupling half before
removing valve plate.
1. Block the pump on a bench with the drive shaft
facing down.
2. Remove the valve plate (401) by removing four
hex head cap screws (403) and lifting it straight
up.
3. Remove valve plate gasket (411) and O-ring
(404).
Case Slip at Full Stroke and Indicated Pressure

Unit - Size 500 psi 1000 psi 2000 psi 3000 psi 3750 psi 4000 psi 5000 psi
cipm 130 195 455 760 1070 N/A N/A
048, 065, 075 lpm 2,1 3,2 7,5 12,5 17,5 N/A N/A
cipm 190 250 400 600 900 1200
100 lpm 3,1 4,1 6,5 9,8 14,7 19,7
cipm 300 400 600 1000 1400 N/A N/A
130 lpm 4,9 6,6 9,8 16,4 22,9 N/A N/A
Table 4. NOMINAL CASE SLIP versus High Pressure at 1800 rpm

(Viscosities of 90-110 SSU)

BI006823-00
ROTATING GROUP DRIVE SHAFT GROUP

1. Remove the drive key (303), if used and the
! WARNING drive shaft bearing retainer ring (305).
The rotating group is heavy. Be careful not 2. Grasp outboard end of drive shaft (301) and
to damage cylinder wear surface which pull it out of the pump housing.
mates against the valve plate, bearing
diameters or piston shoes. Use proper 3. Remove the shaft seal retainer (302) and shaft
lifting techniques and assistance from seal (007) from the housing only if necessary.
others to prevent personal injury.
SWASHBLOCK GROUP
On thru-shaft pumps, the tailshaft bushing On 100/130 remove guide plate (203) and (206)
assembly (307, 308, 309) or a coupling will have to first. Reach inside the case and remove the
be removed (a “jacking” screw can be used) before swashblock (201) and saddle bearings (204).
the rotating group can be disassembled.
1. Place the pump in a horizontal position. INSPECTION
2. Remove the rotating group by turning shaft Clean all parts thoroughly and allow them to dry.
(301) slowly, while pulling the cylinder barrel Inspect all seals and O-rings for hardening,
(101) from the housing. cracking or deterioration. Replace if necessary or if
you suspect damage. Check all locating pins for
3. Identify (number) each pump piston shoe damage and springs for cracking or signs of
assembly (102) and its respective bore in the cracking or signs of wear.
cylinder barrel (101) and shoe retainer (104) for
easy reassembly.
! WARNING
4. See Figure 6. Lift out shoe retainer (104) with
Wear proper protective gear when using
pistons (102) and remove the fulcrum ball (103)
solvents or compressed air, servicing or
and shoe retainer spring (105).
maintaining the hydraulic system or the
Oilgear pump. Wear correct protective
gear, safety glasses, gloves, and safety
shoes. Serious injury can result without
proper protective gear.
104 CONTROL GROUP

102 Refer to the reference material on pump controls.
Be sure to carefully check the control pin for cracks
103 and/or signs of fatigue. Check fit of the pin in the
105 swashblock. It should be a slip-fit without side-play.
101 Replace if necessary or if you suspect damage.
OILG-0004
Figure 6. Rotating Group Disassembly (5V-12015-L).
5. Remove retaining ring (208) and pull the

hydrodynamic bearing (202) and roll pins, if
necessary, (205) from the housing. Note the
position of roll pin (205) inside of case.

BI006823-00
VALVE PLATE GROUP

Inspect the valveplate (401) surface which mates
with the cylinder barrel (101) for excessive wear or A
scoring. Remove minor defects by lightly stoning
the surface with a hard stone which is flat to within
0.001 inches (0,03 mm).
Be sure to stone lightly. Any excessive

NOTE stoning will remove the hardened surface. B
If wear or damage is extensive, replace the OILG-0005
valve plate.
Figure 7. Piston and Shoe Inspection (5V-12015-L)
ROTATING GROUP
(A) All shoes must be equal within 0.001 inches
Inspect cylinder barrel (101) piston bores and the (0,025 mm) at this dimension.
face which mate with the valve plate for wear and (B) All shoe faces must be free of nicks.
scoring. Remove minor defects on the face by
lightly stoning or lapping the surface. End play should not to exceed 0.003
NOTE inches (0,076 mm) when new or 0.006
Inspect the cylinder bearing (202) for damage and inches (0,152 mm) when worn.
replace if necessary. Check all piston and shoe
assemblies (102) to be sure they ride properly on SWASHBLOCK GROUP
the swashblock.
Inspect the swashblock (201) for wear and scoring.
Be sure to stone lightly. Any excessive If defects are minor, stone the swashblock lightly. If
NOTE stoning will remove the hardened surface. damage is extensive, replace the swashblock.
If wear or damage is extensive and defects
cannot be removed, replace the cylinder Check the small hole in the face of the
barrel. swashblock. The hole provides “porting” for the
hydrostatic balance fluid of the piston/shoe
See Figure 7. Check each shoe face for nicks and assembly to be channeled through the swashblock
scratches, and the shoe for smooth pivot action on to the face of the saddle bearing, providing
the piston. pressure lubrication.
If one or more piston/shoe assembly needs Compare the saddle bearing (204) thickness in a
NOTE to be replaced, replace all the piston/shoe worn area to thickness in an unworn area. Replace
assemblies. When installing new piston/ saddle bearings if the difference is greater than
shoe assemblies or the rotating group, 0.015 inches (0,4 mm).
make sure the pistons move freely in their
respective bores. Check the mating surface of swashblock for cracks
or excessive wear. The swashblock movement in
the saddle bearings must be smooth. Replace if
necessary.
Be sure to stone lightly. Any excessive

NOTE stoning will remove the hardened surface.
If wear or damage is extensive and defects
cannot be removed, replace if necessary
or if you suspect them of being bad.

BI006823-00
DRIVE SHAFT GROUP 6. Make sure the roll pin (205) is inserted into the
cylinder bearing (202). Position the cylinder
Check: bearing so the pin is located nearest the control
• the shaft seal (007) for deterioration or facing the outboard end of the drive shaft (301).
cracks. Replace if necessary (press-out). The bearing should be positioned with “scarf”
cuts (PVG 130 only) positioned top and bottom
• the shaft bearing (306) for galling, pitting, and with the pin (205) located on top of internal
binding or roughness. cast boss. The bearing should fit into place with
• the rear shaft bushing in valve plate. a little difficulty and be square to the axis of the
pump.
• the shaft and its splines for wear. Replace
any parts necessary. 7. Tap bearing into place if necessary using
extreme care not to damage the bearing.
ASSEMBLY 8. Insert retaining ring (208) to hold bearing in
place.
See Figures 8, 9 and 10. Follow the disassembly
procedures in reverse for re-assembling the pump. DRIVE SHAFT GROUP
During assembly, install new gaskets, seals and O- 1. Place the housing on its side with the axis
rings. Apply a thin film of CLEAN grease or horizontal.
hydraulic fluid to sealing components to ease
assembly. If a new rotating group is used, lubricate 2. Install the seal retainer (302).
thoroughly with CLEAN hydraulic fluid. Apply fluid
generously to all wear surfaces. 3. Lubricate the shaft seal (007) and shaft.
4. Insert the drive shaft (301) and bearing
SWASHBLOCK GROUP
assembly into the housing.
If removed,
5. Lock in place with the drive shaft bearing
1. Press shaft seal (007) into front of pump retainer ring (305).
housing.
ROTATING GROUP
2. Place housing on a bench with the mounting
flange side down. See Figure 6.
3. Press the two roll pins (207) (if they are 1. Place the cylinder barrel (101), wear surface
replaced or removed) into the pump housing so down, on a clean cloth.
the pins extend 0.050 to 0.065 inches (1,3 to 2. Place the shoe retainer spring (105) in the
1,6 mm) from the case. center of the barrel with the fulcrum ball (103)
4. Grease the back side of each saddle bearing on top of it.
(204) and place on the pin to locate the 3. Insert the identified pistons (102) into their
bearings in the pump case. Make sure the pins corresponding identified holes of the shoe
do not retainer (104). As a unit, fit the pistons into their
protrude. corresponding, identified bores in the cylinder
5. PVG 100 and 130, the swashblock is inserted barrel. DO NOT FORCE. If everything is
from the valve plate end. PVG 048, 065 and aligned properly, the pistons will fit smoothly.
075, the swashblock is inserted through the
control mounting face. Insert swashblock (201)
into the pump housing. Once in place, be sure
the swashblock swivels in the saddle bearings.
With new bearings, swiveling may be stiff and
not always smooth. PVG 110, 130; assemble
(203) and (206).

BI006823-00
On thru-shaft pumps without another pump

! WARNING NOTE or device connected to them, slide
The rotating group weight is heavy. Be assembly onto the shaft (301) and secure
careful not to damage cylinder wear surface cap assembly (307, 309) in with socket
which mates against the valve plate, head shoulder screw (308).
bearing diameters or piston shoes. Use
proper lifting techniques and assistance VALVE PLATE GROUP
from others to prevent personal injury.
1. Place the pump housing on a bench with the
open end facing up.
The rotating group can now be carefully installed
over the tail of the drive shaft (301) and into the 2. Install new O-ring (411) and gasket (407) on
pump housing (001). the housing.
When installing the rotating group, support 3. Position the valve plate (401) on pins (005) and
NOTE the weight of the cylinder barrel (101), as housing. Make sure the tail end of shaft
cylinder spline is passed over the tailshaft, engages the bushing.
to avoid scratching or damage.
4. Hand-tighten the hex head cap screw (403)
4. Push cylinder forward until the cylinder spline closest to O-ring (404) first, then alternately
reaches the drive shaft spline and rotate tighten the other cap screws. On thru-shaft
slightly to engage shaft splines. Continue to units connected to another pump or device,
slide cylinder forward until it encounters the install coupling (half).
cylinder bearing (202). Lifting the tailshaft
slightly helps the cylinder (101) and the cylinder Refer to PREPARATION and INSTALLATION
bearing (202) engagement. Continue pushing when pump is ready to be returned to service.
the cylinder forward until the piston shoes
contact the swashblock, the back of the cylinder
should be located approximately 0.4 inches
(10,2 mm) outside the back of the pump
housing.
PVG Assembly Torques

Pump
Item no. 048/065/075 100/130
002 100 ft-lb 100 ft-lb
004 37 ft-lb 37 ft-lb
206 N/A 87 in-lb
308 57 in-lb 57 in-lb
403 100 ft-lb 100 ft-lb
408 45 in-lb 45 in-lb
409 45 in-lb 45 in-lb
410 120 in-lb 120 in-lb
503 cover plate 28 ft-lb 28 ft-lb
503 SAE A or A-A adapt 15 ft-lb 15 ft-lb
503 SAE B adapter 37 ft-lb 37 ft-lb
503 SAE C adapter N/A 74 ft-lb
507 28 ft-lb 28 ft-lb

BI006823-00
PARTS LIST ordering replacement parts, be sure to include

pump type and serial number, bulletin number and
Parts used in these assemblies are per Oilgear item number. Specify type of hydraulic fluid to
specifications. Use only Oilgear parts to ensure assure seal and packing compatibility.
compatibility with assembly requirements. When
Item Qty. Description

HOUSING ASSEMBLY GROUP
001 1 Housing, Pump
003 1 Nameplate, Identification
004 1 Plug
005 4 Pin, Roll - 048, 065, 130
005 2 Pin, Roll - 100, 130
006 2 Pin, Roll - 100, 130
007 1 Seal, Shaft
008 2 Screw
010 1 Seal, O-ring
ROTARY ASSEMBLY GROUP
101 1 Barrel, Cylinder
102 9 Assembly, Piston/Shoe
103 1 Ball, Fulcrum
104 1 Retainer, Shoe
105 1 Spring, Shoe Retainer
SWASHBLOCK ASSEMBLY GROUP
201 1 Swashblock
202 1 Bearing, Cylinder
203 1 Guide Plate - 100, 130 only
204 2 Bearing, Saddle
205 1 Pin, Roll (2 for PVG 130)
206 2 Screw - 100, 130 only
207 2 Pin, Roll
208 1 Ring, Retainer
PARTS LIST drawings on pages 19, 20 and 30.

Parts are common between pumps. Only the differences are shown.
O-ring Sizes
ARP 568 Uniform Size number with
Durometer
Pump
Item Number 048, 065, 075 100, 130
010 916 - 70 916 - 70
404 012 - 90 013 - 90
405 902 - 90 902 - 90
406 903 - 90 903 - 90
407 904 - 90 904 - 90
413 138 - 70 138 - 70

BI006823-00
Item Qty. Description

DRIVE SHAFT ASSEMBLY GROUP
301 1 Drive Shaft
302 1 Retainer, Seal Side
303 1 Key, Drive Shaft (keyed shafts only)
304 1 Ring, Retainer, External
305 1 Ring, Retainer, Internal
306 1 Bearing, Front
307 1 Bushing (used on thru-shaft w/ cover plate)
308 1 Screw (used on thru-shaft w/ cover plate)
309 1 Roll Pin (used on thru-shaft w/ cover plate)
VALVE PLATE ASSEMBLY GROUP
401 1 Valve Plate w/bearing
403 4 Screw, Socket Head Cap (048, 065, 075)
403 4 Screw, Hex Head Cap (100, 130)
404 1 Seal, O-ring
405 1 Seal, O-ring
406 1 Seal, O-ring (not required for all versions)
407 1 Seal, O-ring
408 1 Plug, #2 HP
409 1 Plug, #3 HP (not required for all versions)
410 1 Plug, #4 HP
411 1 Gasket, Valve Plate
PARTS LIST drawings on pages 19, 20 and 30.

Parts are common between pumps. Only the differences are shown.
Parts used in this assembly are per Oilgear specifications. Use only Oilgear
parts to ensure the compatibility with the assembly requirements. When
ordering replacement parts, be sure to include pump type and serial number,
bulletin number and item number. To assure seal and packing compatibility,
specify type of hydraulic fluid.

BI006823-00

BI006823-00

Feed Drive Hydraulic Motor
BI006823-00
Compressor Hydraulic Motor
Service Manual
ASM 3.1 - F12
F12-030 until -110
Catalog 9129 8249-12

August 2003, GB

Hydraulic Motor/Pump Series F12
BI006823-00
Table of contents
General information........................................... 3
Specifications..................................................... 4
Disassemble....................................................... 5-10
Assemble............................................................ 11-16
Chang of shaft seal............................................ 17
Valve plates........................................................ 18

Hydraulic Motor/Pump
BI006823-00
Series F12
General information
F12 is bent axis, fixed displacement heavy- The pump version has highly engineered
duty motor/pump seris. They can be used in valve plates for increased selfpriming speed
numerous applications in both open and and low noise, available with left and right
closed loop circuits. hand rotation.
Series F12 conforms to current ISO and SAE The F12 motors produce very high torque at
mounting flange and shaft end configurations. start-up as well as at low speeds.
A very compact cartridge version is also
available.
Our unique timing gear design synchronizes
Frame sizes: F12-30, -40, -60, -80 and -110.
shaft and cylinder barrel, making the F12
Thanks to the unique spherical piston design, very tolerant to high G forces and torsional
F12 motors can be used at unusually high vibrations.
shaft speeds. Operating pressures to 480
bar provides for the high output power Heavy duty roller bearings permit substantial
capability. external axial and radial shaft loads.
The 40° angle between shaft and cylinder The F12s have a simple and straightforward
barrel allows for a very compact, lightweight design with very few moving parts, making
motor/pump. them very reliable motors/pumps.
The laminated piston ring offers important The unique piston locking, timing gear and
advantages such as low internal leakage and bearing set-up as well as the limited number
thermal shock resistance. of parts add up to a very robust design with
long service life and, above all, proven
reliability.
F12 cross section 9

8
7
6
5
4
3
2
1 1 2 3 4 5 6 7 8 9
1. Barrel housing
2. Valve plate
3. Cylinder barrel
4. Piston with piston ring
5. Timing gear
6. Tapered roller bearing
7. Bearing housing
8. Shaft seal
9. Output/input shaft

BI006823-00
Specifications
Frame size F12-30 -40 -60 -80 -110

Displacement [cm³/rev] 30.0 40.0 59.8 80.4 110.1
Motor operating speed [rpm]

max intemittent 7 100 6 400 5 600 5 200 4 700
max continuous 5 600 5 000 4 300 4 000 3 600
min continuous 50 50
Max pump selfpriming speed¹

L or R function; max [rpm] 2 850 2 650 2 350 2 350 2 200
Torque (theor.) at 100 bar [Nm] 47.6 63.5 94.9 128 175
Motor input flow

max intemittent [l/min] 213 256 335 418 517
max continuous [l/min] 168 200 257 322 396
Output power (motor)

max intemittent [kW] 110 130 175 220 270
max continuous [kW] 70 85 110 153 165
Operating pressure
max intemittent [bar] 480 480
max continuous [bar] 420 420
Max case pressure

shaft seal type H, 1500 rpm [bar] 14 12 12 10 9.5
Main circuit temp., max [ºC] 80 80

min [ºC] -40 -40
Fluid viscosity, max. [mm²/s] 1 000 1 000

min. [mm²/s] 8 8
Fluid contamination level

(ISO code 4406) 18/13 18/13
Mass moment of inertia

(x10³) [kg m²] 1.7 2.9 5.0 8.4 11.2
Weight [kg] 12 16.5 21 26 36
¹) Valid at sea level.

BI006823-00
Series F12
Disassemble
491
Fasten the unit in a vice. Loosen the 4 boults

(item 491).
110
Lift off the barrel housing (item 110). Make

sure that the valve plate doesnt fall out when
lifting the barrel housing off.
411
Lift off the cylinder barrel (item 411). Take the
shim (item 488) away.
488

BI006823-00
430
Lift off the barrel support (item 430).
440
Remove the pistons (item 440).
221
Remove the O-ring (item 221).

BI006823-00 Series F12
237
Remove the retaining ring (item 237).
231
Remove the seal carrier (item 231).
225
Remove the O-ring (item 225).

BI006823-00
478
476
Lift off the spacer washer (item 476).
311
211 Place the bearing housing (item 211) on a

tube.
Push out the shaft (item 311) with a press.

470
Remove the small tappered roller bearing
(item 470).
Tap the small bearing ring off with a mandrel.
Tap the large bearing ring off with a mandrel.

BI006823-00
311 Place the ring gear (item 452) on a tube.

Push out the shaft (item 311) with a press.
452
Tube

Assemble
Push on the tappered roller bearing (item

460) and the ring gear (item 452) on the shaft
with a press. Use a tube (see page 16).
460
452
Push on the bearing ring (item 460) in the

bearing housing (item 211) with a press. Use
a tube to match the outer diameter off the
bearing ring.
211
Push on the bearing ring (item 470) in the

bearing housing (item 211) with a press. Use
a tube to match the outer diameter off the
bearing ring.
211

BI006823-00
476 Push on the Bearing (item 470) with a press

until correct preload is achieved. Install the
spacer washer (item 476).
478
Install the retaining ring (item 478).
225
Install the O-ring (item 225).

Install the seal carrier (item 231).
231
237
Install the retaining ring (item 237).
221
Install the O-ring (item 221).

BI006823-00
440
Install the pistons (item 440).
430
Install the barrel support (item 430).
488
Install the shim (item 488).

BI006823-00
Series F12
411
Install the cylinder barrel (item 411). Ensure

correct timing. (Marking, punch mark)
.
.
121
110 Put some grease on the valve plate (item

121) and install it into the barrel housing
(item 110).
Make sure you have installed the valve plate
correct (see page 18).
110
Install the barrel housing (item 110).

BI006823-00
491 Fasten the 4 boults (item 491) to specified

torque.
F12-030 60 ± 10 Nm
F12-040 60 ± 10 Nm
F12-060 60 ± 10 Nm
F12-080 105 ± 20 Nm
F12-110 105 ± 20 Nm
Tools to be used to facilitate the

installation of the tappered roller
bearings.
Type ØA ØB ØC
F12-030 60 49 42
F12-040 65 58 52
F12-060 73 64 57
F12-080 74 70 62
3300 ° F12-110 82 75 67
3300°
1.5
1.5
33
0.5×45°
0.5x45
+0.2
f ØC 0
C / +0.20
ØB
f B
0
ØA -1
f A / +0-1

Change of shaft seal
237
231
Remove the seal carrier (item 231).
Tap the shaft seal out with hammer and

mandrel.
Tap the new shaft seal back with a tube and a

hammer.
The outside diameter on the tube is 65mm.

BI006823-00
Valve plates F12
Following valve plates can be fitted in F12.
M
M = Bi-directional, motor operation
Against cylinder barrel
L
L = L.H. rotation, pump operation
R
R = R.H. rotation, pump operation
G
G = L.H. rotation, internal drain, motor
operation
X
X = Bi-directional, pump operation, high self
priming speed

Operational Check
The general condition of the unit can be established by checking the drain flow. Remove the drain
line and keep the drain port above a suitable container. Run the unit at normal speed and
pressurize the system to 2000-3000 psi. (150 - 200 bar)
Measure the drain flow for one minute; if it exceeds the maximum figures shown below, the unit is
worn or damaged internally and should be replaced or repaired. Also, check for leakage at the
shaft seal and between the bearing and barrel housings.
Series Normal Max

cu.in./min (l/m) gpm. (l/m)
F12-30 24 0.4 .55 2.0

F12-40 30 0.5 .65 2.5
F12-60 43 0.7 .70 2.7
F12-80 61 1.0 .80 3.0

F12-110 61 1.0 .80 3.0

BI006823-00
Notes

"ULLETIN(9 -5+
Dust Collect Hydraulic Motor
BI006823-00
3ERVICE-ANUAL
3ERIES&
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BI006823-00
3ERIES&
Specifications
Size 5 10 12 14 19 28 39 58 78 110 150 250
Displacement (cm3/rev) 4,9 9,8 12,5 14,0 19,0 28,1 38,7 58,2 78,2 110 150 242
Operating Pressure
Peak (bar) 420 420 420 420 420 420 420 420 420 420 420 420
Max continuous (bar) 350 350 350 350 350 350 350 350 350 350 350 350
Operating speed (rpm)
Max intermittent 1) 12000 11000 10200 10000 9000 6500 5200 4500 3500 3300 3000 2700
Max continuous 10800 9900 9200 9000 8100 5000 4200 3600 3100 2800 2600 2400
Min continuous 50 50 50 50 50 150 125 125 100 100 50 50
Pump self priming speed (rpm)
L or R operation 2) 4600 4200 3850 3500 3500 2800 2300 2200 1900 1600 1700 1500
Main circuit temp.
Max (°C) 80 80 80 80 80 80 80 80 80 80 80 80
Min (°C) -40 -40 -40 -40 -40 -40 -40 -40 -40 -40 -40 -40
Weight (kg) 5 7,5 8,3 11 11 14 22,5 23 39 46 70 77
1)
Intermittent: max 6 seconds in any one minute.
2)
Self priming speed valid at sea level.
Phased out
Screw Tightening Torque.

Tightening torque
Series (Nm)
See table
F11 - 5 24±4
- 10 48±8
- 19 48±8
- 28 60±10
- 39
- 58
- 78
-110
-150 F11-5 through F11-150
-250 See Fig.

220±35 Nm
325±25 Nm
F11-250

3ERIES& BI006823-00
Gear Backlash
F11-005 through F11-110
0.05 - 0.20 mm
F11-150 through F11-250

0.10 - 0.30 mm
Frame size mm
F11-005 25.0
F11-010 31.3
F11-019 37.5
F11-028 42.0
F11-039 47.5
F11-058 55.0
F11-078 62.5
F11-110 65.6 "R"
F11-150 75.0
Design
Series F11 pumps/motors consist of a rotating group contai- A spring device (a retaining ring, a leaf spring, or Belleville
ned in a split housing. Spherical pistons (1) with laminated washers) maintains the barrel against the valve plate (item 5,
piston rings (2) operate at a 40° angle relative to the shaft F11-5 through -150) or the end cap (item 7, F11-250). A ring
(3). Series F11-5 through -78 employ five pistons, series gear (6) on the shaft meshes with the corresponding teeth of
F11-110 and -150 seven, and series F11-250 nine pistons. the barrel (4) so that the cylinder barrel always rotates at the
As the shaft turns, the pistons are driven in a reciprocating same speed as the shaft (3). The shaft is supported by two
movement in the cylinder barrel (4). When the unit is used heavy duty tapered roller bearings (8).
as a pump, the oil passes from the inlet port to the cylinder
barrel and is then forced to the outlet port through the pum-
ping action of the pistons.
7
4
5
4
2
2
1
1
6
6
3 3
8
8
Series 5 through 150 Series 250

BI006823-00
3ERIES&
Operational Check
The general condition of the unit can be established by Measure the drain flow for one minute; if it exceeds the
checking the drain flow. Remove the drain line and keep the maximum figures shown below, the unit is worn or damaged
drain port above a suitable container. Run the unit at normal internally and should be replaced or repaired. Also, check
speed and pressurize the system to 150 - 200 bar . for leakage at the shaft seal and between the bearing and
barrel housings.
Drain Flow
Series Normal Max.

(l/m) (l/m)
F11-5 0.2 1.0

F11-10 0.3 1.5
F11-19 0.4 2.0
F11-28 0.4 2.0

F11-39 0.5 2.5
F11-58 0.7 2.7
F11-78 1.0 3.0

F11-110 1.0 3.0
F11-150 1.2 3.0
F11-250 1.5 3.0
Repair
Tools and Supplies
Metric Allen keys, retaining ring spanners, and a torque
wrench with suitable metric sockets are required for the
disassembly and assembly of the F11 series, plus common
hand tools.
A special tool, contact Parker, is required for the removal

and re-assembly of the F11-250 barrel post.
Barrel post installation tool

3ERIES& BI006823-00
Shaft Seal Replacement Disassembly, Series F11-5 through

-150
Note
The unit does not have to be taken apart. Before taking the unit apart, remove the shaft coupling (if
applicable) and thoroughly clean the outside of the unit; seal
Remove the retaining ring and the back-up washer (units the ports with suitable plugs or covers.
designated F11C and F11D might not have a back-up
washer). Without damaging the shaft, punch through the 1. Remove the four metric cap screws. By utilizing two
casing of the seal with a screwdriver and remove the seal. screwdrivers, pull the housings apart as shown. Retain
Check the shaft sealing surface for corrosion and other the split shim located between the spacer ring and the
damage. barrel housing.
Chamfer
The tool shown in the figure can be used to facilitate the instal-
lation of the new seal. Be careful not to cut the seal on the
shaft key or spline. The chamfer of the back-up washer should
face THESEALWHENINSTALLEDCONCERNS. SEAL
2. Mark the pistons and the corresponding ball sockets

with a felt-tipped pen.
Dia."D" 3. Remove the pistons by pulling them out when in line

with the shaft as shown.
3 mm
Series Dia. "D"

(mm)
F11- 5 35
10 35
19 52
28 62
39 65
58 65
78 72
110 72

BI006823-00 3ERIES&
4. Using a bearing press, push the shaft assembly out 7. To remove the cylinder barrel from the housing (does
of the bearing housing on a suitable support. The shaft not apply to Series F11-28 and -58), carefully hit the
assembly can also be removed by grasping the housing housing/barrel assembly against a piece of wood as
and carefully hitting the shaft against a wooden block as shown; the barrel as well as the valve plate will be forced
shown. out. Be careful to protect the barrel and valve plate from
damage.
5. Remove the retaining ring, the back-up washer, and

the shaft seal.
6. Do not disassemble the shaft assembly unless the Series F11-28 and -58 cylinder barrel can be removed
bearings are worn or damaged. If the bearings or the from the barrel post after removal of the leaf spring
shaft have to be replaced, remove the locknut and the locating pin (utilizing a screwdriver as shown), the leaf
tab washer, and position the shaft assembly on a piece spring, and the hold-down bearing ring.
of pipe or other suitable support that fits snugly around
the shaft and supports the ring gear. The shaft can now
be pressed out.

3ERIES& BI006823-00
Disassembly, Series F11-250

Position the unit on a table provided with a hole for the shaft 3. Remove the four cap screws and the barrel hous-
or on a suitable fixture. ing. Remove the cylinder barrel off the pistons.
4. With a felt-tipped pen, mark the pistons and the

1. Remove the cap over the barrel post locating corresponding shaft sockets so that the pistons can
screw by forcing a screwdriver through the top of the be re-installed in their original positions. Hold the
cap and pulling it out. Remove the locating screw. pistons as shown and lift them out.
2. Insert tool, contact Parker (without the sleeve)

and knock the barrel post out of the end cap. Re-
move the three cap screws and the end cap. Retain
the split shim located between the barrel housing and
the end cap.
Older version F11-250
5. Using a bearing press, push the shaft assem-

bly out of the bearing housing while positioning the
housing on a suitable support. The shaft assembly
can also be removed by grasping the housing and
carefully hitting the shaft against a wooden block.

BI006823-00 3ERIES&
Reconditioning and Replacement of Production of the spherical piston ring is discontinued.
Parts The old ring and piston has to be replaced by the
After disassembly, all parts should be thoroughly clea- laminated version.
ned in a suitable solvent.
Caution: Follow directions for use of solvent carefully. 3. On series F11-5 through -150, the valve plate
Protect your hands and eyes from the solvent.Solvent surface can be reconditioned by careful lapping.
may also be inflammable.
Series F11-250 end cap port surface can be lapped
If leakage of the F11 unit was too high, the following but the bearing plate must be replaced if worn.
parts are generally worn or damaged:
Series F11-5 through -150: Note

- Valve plate
- Cylinder barrel port surface (facing valve plate) When lapping the valve plate, up to .002 in. can be
- Piston rings or piston assy removed. If .002 in. is not sufficient to obtain a flat
surface free of scratches, the part should be repla-
Series F11-250: ced.
- Bearing plate
- End cap port surface (facing bearing plate)
- Piston rings or piston assy 4. If the bearing cups are loose, the shaft lock nut
should be tightened. Correct bearing pre-load has
Scratches and wear marks on these parts always affect the been obtained when the spacer ring can be moved
performance of the unit; they should be replaced if scrat- sideways without being loose. Note, for the bigger
ched or worn. units quite a substantial force is required.
1. Shaft seal and o-rings should always be replaced.
2. Replace spherical piston rings that are worn more

than 50 % of the spherical surface as shown. A small
retaining ring pliers will facilitate the removal. When
installing a new piston ring, make sure the spherical
surface coincides with the shape of the piston head.
Max 50%
Old version
Not available 5. Check that the shaft surface in contact with the
shaft seal is in good condition; if grooved, corroded,
or otherwise damaged, the shaft should be replaced.
If play indicated in the figure is exceeded then re-

place all piston and ring assemblies in the unit. Never
replace individual worn piston and ring assemblies.
Max .0.2 mm

3ERIES& BI006823-00
Reassembly, Series F11-5 through The following valve plates are available (designation ap-
-150 pears on the nameplate):
M = Bi-directional, motor or pump operation
All parts should be thoroughly cleaned and lightly lubricated L = L.H. rotation, pump operation
with hydraulic fluid. Reassembly is carried out in reverse R = R.H. rotation, pump operation
order of disassembly. G = L.H. rotation, internal drain, motor operation
J = R.H. rotation, internal drain, motor operation
Caution: Follow directions for use of hydraulic fluid carefully. H = Bi-directional, motor operation, high pressure
Protect your hands and eyes from fluid. Fluid may also be Q = Bi-directional, motor operation, low noise
flameable.
1. Place the cylinder barrel housing in a vice as

shown. 3. The cylinder barrel retaining ring (does not apply
to Series F11-28 and -58) should be installed as
illustrated below. When installing the barrel in the
housing, the opening of the retaining ring should face
the housing cut-out as shown; the barrel has to be
pushed down to overcome the spring force of the
retaining ring.
Some resistance should be felt when trying to turn

the cylinder barrel by hand; if no resistance is felt, the
retaining ring must be replaced.
2. Install the valve plate making sure it is seated

properly in the housing; when installed correctly,
the visible face of the valve plate should appear as
shown.
M Q
Drain port
L G
Note
Regarding installation of needle bearings in

R H F11-110 and -150 cylinder barrels, refer to
page 16.
The internal drain valve plate G is shown from the back side 4. Series F11-28 and -58 utilize a leaf spring for bar-
of the plate. From the front, when installed, it looks the same rel hold-down. Install the cylinder barrel on the barrel
as the M plate. post, install the hold-down ring and the leaf spring,
and secure the spring with the locating pin.

BI006823-00 3ERIES&
5. Install the guide spacer (with new o-rings) to the 8. Locate the marked tooth of the shaft ring gear.
barrel housing; make sure one of the cut-outs is in
the position shown, and leave room for the split shim
between the spacer and the housing .
Cut out
Note
If the shaft assembly has been taken apart, refer to
"Reassembly, Series F11-250" for instructions.
6. Install the split shim as illustrated. Make sure the 9. Position the shaft/piston assembly over the
shim is properly located in the barrel housing recess. housing/barrel assembly as shown, so that the timing
Correct thickness of the shim should result in a gear marks of the ring gear and cylinder barrel are lined
backlash of .05 to .20 mm. If any part of the rotating up. Locate each piston into the corresponding, previ-
group has been replaced, it might be necessary to ously marked cylinder bore.
change to a shim of different thickness; backlash is
checked according to paragraph 12 (page 12).
10. If the timing marks don't match as illustrated,

carefully pull the shaft assembly out of mesh with the
ring gear and reposition correctly.
7. Two teeth on the cylinder barrel and one tooth on
the ring gear are marked to ensure that the pis-
tons are in line with the cylinder bores. Position the
cylinder barrel so that the markings are visible in the
spacer cut-out as shown, this assures correct timing
of the shaft and the cylinder barrel.
11. Install the bearing housing with a new shaft seal

on the shaft/bearing assembly, being careful not to
cut or otherwise damage the seal. Cross-torque the
cap screws according to specifications on page 3.

3ERIES& BI006823-00
12. Turn the shaft by hand to assure correct assembly. A

"clicking" noise generated when the shaft is rapidly turned
back and forth reveals that there is backlash between the
ring gear and the cylinder barrel. A "no noise" condition indi-
cates no backlash, and a thicker shim has to be installed.
The correct backlash should be .05 to .20 mm.
Reassembly, Series F11-250

1. If the shaft/bearing assembly has been taken apart,
5. Install the barrel housing and check through the drain
start the reassembly by installing the ring gear over the
port that the timing is correct. Cross-torque the cap screws
locating dowel pin. Press the cone of the large roller
bearing against the ring gear. Install the large bearing cup, according to specifications (page 3).
the spacer ring (note the position of the cut-outs), and the
small bearing cup. Press the small bearing cone onto the
shaft, but only so far that the spacer ring can still be moved
sideways easily.
6. Install new o-rings on the end cap; one o-ring is located

in the barrel post bore. Screw tool (without nut and bearing)
into the barrel post, and install the end cap over the tool
2. Install a new tab washer and tighten the lock nut gradu-
spindle against the block housing. Install the split shim as
ally until the spacer ring between the bearing cups is held
shown, making sure it is located correctly in the barrel hous-
firmly but not tight; you should be able to push the spacer
ing recess.
sideways with your thumbs as shown. Secure the nut with
one of the tabs of the washer.
Note
If the lock nut has been tightened too much as to allow the
spacer to be moved sideways, the bearings have to be
removed from the shaft and the assembly procedure started
over again.
3. Install a new shaft seal and push the shaft assembly into
the bearing housing. Install the pistons in the ball sockets.
4. If a new cylinder barrel is used, install the groove pins

that locate the bearing plate, the internal retaining ring, and
the needle bearings (refer to page 14). Install the barrel
post/bearing assembly in the cylinder barrel. Locate each 7. Install the nut/bearing of the tool on the spindle, and , by
piston into the corresponding, previously marked cylinder tightening on the nut,pull the barrel post partly into the end
bore, and position the cylinder barrel assembly on the ring cap. Install the three cap screws and tighten according to
gear as shown so that the timing marks are lined up. specification (page 3).

BI006823-00 3ERIES&
8. By further tightening on the nut, pull the block post

completely into the end cap; do not overtighten.
9. Remove the assembly tool. Install the cap screw that

secures the barrel post, and torque it to .40-.45 Nm; back
off 1/3 turn to obtain correct axial play. Push the seal cap
over the screw head.
10. Check the backlash through the drain port; correct back-
lash is .10-.30 mm. 1. Press the bearing to the bottom of the cylinder barrel
(dimension A).
Needle Bearing Installation 2. Install the second needle bearing on the drift pin and
press in place (dimension B).
F11-110, -150
F11-250:
Retaining
Ring
B
A
Series Dim. A Dim. B

mm mm
F11-110 56.0 4.5
F11-150 61.5 10.0

1. Press the needle bearing in place so that it just
touches the retaining ring.
2. The second needle bearing should be located

against the one previously installed.
Note
When installing the needle bearings, the marked end of the

cage should face agains the gears on the cylinder barrel.

BI006823-00
3ERIES&
Item Title
110 Barrel Housing Assy

121 Valve Plate 492 110
131 Hex Socket Plug
132 Seal Washer 491
211 Bearing Housing
221 O-Ring 131,132
222 O-Ring
233 Shaft Seal 121
236 Back-up Ring
237 Retaining Ring
311 Shaft 431
321 Flat Key 411
411 Cylinder Barrel
415 Needle bearing 436
431 Barrel Retaining Ring 438
436 Bearing Ring 439
438 Leaf Spring
439 Pivot Pin
221
440 Piston Assy
442 Piston Ring
451 Pin
452 Ring Gear 442
460 Taper Roller Bearing 440
464 Spacer Ring
470 Taper Roller Bearing
474 Lock Washer
222
475 Round Nut
486 Guide Spacer 488
488 Shim
486
491 Hex Socket Screw
451
311
321
452
460
464
470
474
475
211
233
236
237

BI006823-00 3ERIES&
Item Title
111 End Cap 429

131 Hex Socket Plug
132 Seal Washer 428
211 Bearing Housing 493
222 O-Ring
223 O-Ring
224 O-Ring 111
233 Shaft Seal 223
236 Back-up Ring 488
237 Retaining Ring
311 Shaft
321 Flat Key 491
411 Cylinder Barrel 481
413 Spring Pin
414 Retaining Ring
132
415 Needle Bearing 131
422 Spacer Sleeve
423 Barrel Spindle
424 Sliding Plate
426 Spacer Washer
427 Retaining Ring
428 Hex Socket Screw 413
429 Cap Plug
433 Disc Spring
440 Piston Assy
421
442 Piston Ring
451 Pin 411
452 Ring Gear
461 Taper Roller Bearing Cone
462 Taper Roller Bearing Cup 442
464 Spacer Ring 311 440
474 Lock Washer
475 Round Nut 451
481 Barrel Housing 452
488 Shim
321
491 Hex Socket Screw
493 Hex Socket Screw 461 224 422
462 423 425
464 414 433
470 415 426
471 427
475
211
233
236
237

Notes BI006823-00

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Hydraulic Cylinder Repair

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BI006823-00
Section 9
Hydraulic Rock Drill

Repair Section
Hydraulic Rock Drill 9-1

Notes BI006823-00
9-2 Hydraulic Rock Drill

BI006823-00
Model HPR4519/5123
Hydraulic Rock Drill
Service Manual
P/N 416421
3rd Edition
Bucyrus Mining Equipment, Inc.

3501 S. FM Hwy 1417 Denison, Texas 75020 USA
BI006823-00
PARTS ORDERING AND PRODUCT SUPPORT

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

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

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

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

3501 S. FM Hwy 1417, Denison, TX 75020
www.bucyrus.com
© 2010 Bucyrus International, Inc.

All Rights Reserved
BI006823-00
Introduction
HPR4519
This construction of HPR drills includes all the updates in the second generation rock drills, fewer
parts, no side rods, detachable remote charging accumulators, and more efficient hammer cycle. The
"45" drill is most effectively used in conjunction with 45 mm drill string. Drill hammer output is matched
to the drill string to provide the lowest cost of operation at optimum penetration. Most applications will be
associated with larger hole diameters, 3-4 in. (76-02 mm) in underground uphole and benching.
HPR5123
This construction of HPR drills includes all the updates in the second generation rock drills, fewer
parts, no side rods, detachable remote charging accumulators, and more efficient hammer cycle. The
"51" drill is most effectively used in conjunction with 51 mm drill string, but can be adapted to 45 mm.
Drill hammer output is matched to the drill string to provide the lowest cost of operation at optimum
penetration. Most applications will be associated with larger hole diameters, 3 1/2-5 in. (89-127 mm) in
benching.
Fig. i-1 HPR4519/5123 Hydraulic Rock Drill Main Components

Table of Contents BI006823-00
SECTION 1 SAFETY
Hazard Classification .............................................................................................................1-3
Safety Symbols on Drills.........................................................................................................1-4
Safety Information ..................................................................................................................1-7
SECTION 2 GENERAL MAINTENANCE

Start-Up Procedure.................................................................................................................2-2
Operating Tips ........................................................................................................................2-2
Operation & Maintenance .......................................................................................................2-2
Accumulator Pressures ..........................................................................................................2-3
Contamination ........................................................................................................................2-3
Major Repairs .........................................................................................................................2-3
General Maintenance Tips......................................................................................................2-3
Preventive Maintenance .........................................................................................................2-4
At the beginning of every shift: .............................................................................................2-5
Every Two Hours: .................................................................................................................2-5
Every Week or Every Time the Shank is Changed: ..............................................................2-5
Every 500 Hours or 3 Months: ..............................................................................................2-5
SECTION 3 TROUBLESHOOTING
SECTION 4 DRILL DISASSEMBLY AND INSPECTION

General Tips on Drill Overhaul ...............................................................................................4-2
Tools Required........................................................................................................................4-3
Special Tools ..........................................................................................................................4-4
Seal Installation Tool...............................................................................................................4-4
Special Tool List (Optional) .....................................................................................................4-5
HPR4519 Exploded View .......................................................................................................4-8
HPR5123 Exploded View .....................................................................................................4-12
General Information ..............................................................................................................4-17
Water Swivel Assembly - Removal .......................................................................................4-17
Water Swivel Housing - Repair .............................................................................................4-18
Chuck End Cover - Removal ................................................................................................4-19
Chuck Driver & Pinion Gear - Removal & Inspection ...........................................................4-20
Rotation Motor - Removal.....................................................................................................4-23
Rotation Housing - Removal from Cylinder ..........................................................................4-24
Inspection ...........................................................................................................................4-24
Drill Cylinder Components ....................................................................................................4-27
Backhead - Removal and Inspection ....................................................................................4-28
Cylinder - Internal Parts ........................................................................................................4-28
Hammer and Bushings - Removal and Inspection ...............................................................4-28
Shuttle Valve - Internal Parts ................................................................................................4-30
Shuttle Valve - Removal and Inspection ...............................................................................4-30
Accumulator - Internal Parts .................................................................................................4-34
Accumulator - Removal ........................................................................................................4-35
Accumulator - Disassembly and Inspection..........................................................................4-36
BI006823-00
Table of Contents
SECTION 5 DRILL ASSEMBLY

General Tips on Drill Overhaul ...............................................................................................5-2
Bolt Torque Specifications ......................................................................................................5-3
Cylinder - Internal Parts ..........................................................................................................5-4
Rear Cylinder Bushing and Backhead - Installation ...............................................................5-5
Hammer - Installation .............................................................................................................5-7
Front Cylinder Bushing - Installation.......................................................................................5-8
Cylinder - Internal Parts ..........................................................................................................5-8
Accumulator - Internal Parts .................................................................................................5-10
Accumulators - Assembly and Installation ............................................................................5-10
Shuttle Valve - Internal Parts ................................................................................................5-12
Shuttle Valve - Assembly ......................................................................................................5-13
Shuttle Valve - Installation ....................................................................................................5-14
Rotation Housing - Assembly ...............................................................................................5-16
Chuck Driver - Assembly ......................................................................................................5-21
Rotation Housing - Assembly ...............................................................................................5-22
Shank Installation .................................................................................................................5-25
Water Swivel - Assembly ......................................................................................................5-26
SECTION 6 CHARGING THE ACCUMULATORS

Charging the Accumulators ....................................................................................................6-2
Requirements .........................................................................................................................6-2
Charging Procedure ...............................................................................................................6-3
Checking the Accumulator Charge Pressure..........................................................................6-4
Accumulator Charge Kit..........................................................................................................6-6
SECTION 7 SPECIFICATIONS
Hydraulic Oils for Percussion Drills ........................................................................................7-2
Hydraulic Drill Rotation Unit Lubrication .................................................................................7-3
Grease Lubrication with a Hand Grease Gun.........................................................................7-3
Grease Specifications.............................................................................................................7-3
HPR4519 Wear Tolerances ...................................................................................................7-4
HPR5123 Wear Tolerances ..................................................................................................7-10
MAINTENANCE RECORD ...................................................................................................7-15
BI006823-00
Notes
BI006823-00
Section 1
Safety
Safety 1-1
Notes BI006823-00
1-2 Safety
BI006823-00
The Hydraulic Rock Drill is used in conjunction with the Jumbo or Track Drill, a heavy moving ma-
chine with a boom capable of extending its reach vertically and horizontally. Like all moving objects
and reach extending devices, there are potential hazards associated with its use. These hazards will
be minimized if the machine is properly operated, inspected and maintained. The operator's must read
this manual and have been trained to use the machine in an appropriate and safe manner. Non-English
speaking persons must have an interpreter explain all safety procedures in this manual. Should any
questions arise concerning the maintenance or operation of the drill or machine contact the manufac-
turer.
Safety Alert Symbol

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

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

in death or serious injury.

minor or moderate injury.

property or equipment damage.
Safety 1-3
Safety Sign Symbols on Drills BI006823-00

Safety Alert Symbol. Used to alert See Operator's Manual for instruc-
you to potential personal injury haz- tions. If you do not understand the
ards. Obey all safety messages that information the manuals, consult
follow this symbol to avoid possible your supervisor, the owner, or the
injury or death. manufacturer.
Entanglement Hazard. Death Keep clear of rotating drill steel and

or serious injury can result from drivelines. Switch off engine before
contact with rotating drill steel and performing service.
drivelines.
Entanglement Hazard. Rotating Keep away from fan and belt when
parts can cause personal injury. engine is running. Stop engine be-
fore servicing.
Explosion / Burn Hazard. Will Keep all open flames and sparks
cause death, burns or blindness away. Wear personal protective
due to ignition of explosive gases or equipment, including face shield,
contact with corrosive acid. gloves and long sleeve shirt.
READ MANUALS
Read all manuals prior to opera-
tion.
ous injury can result from the use of ergy starting aids. Engine equipped
ether or other high energy starting with grid heating system.
aids.
ous injury can result from the use ergy starting aids in compressor.
of ether or other high energy start-
ing aids.
Burn Hazard. Death or serious

injury can result from release of hot Keep away from flames.
pressurized liquids.
Relieve all pressure.
Allow to cool before performing ser-

vice on compressor.
1-4 Safety
BI006823-00
Safety Sign Symbols on Drills
Flying Object & Spray Hazard. Shut off live air at source, and re-
Death or serious injury can result lieve all pressure before removing
from release of pressurized liq- filler plug.
uids.
Flying Object Hazard. Serious Use guards.

injury or death can occur if drill is Keep in place.
operated without guards in place.
Flying Object Hazard. Serious Read and understand the proce-

injury or death can occur if track dures in the Operation and Main-
tension is adjusted improperly. tenance Manual before adjusting
track tension
Electrocution Hazard. Death or Maintain required clearance.

injury can result from contacting
electric power lines. See Table 1-1 in this manual.
Burn Hazard. Hot fluid under pres- Allow to cool before opening.
sure can scald.
Trip & Fall Hazard. Death or seri-

Keep off top of machine.
ous injury can result from tripping
and falling.
Fall Hazard. Death or serious injury Use the access system provided
can result from falling. when servicing the machine.
Safety 1-5
Safety Sign Symbols on Drills BI006823-00
Inhalation Hazard. Compressor Keep clear of compressor air dis-

discharge air is hazardous if inhaled. charge area.
Death or serious injury may result.
Injection Hazard. Escaping fluid Relieve pressure before disconnect-

under pressure can penetrate skin, ing hydraulic lines. Keep away from
causing serious injury. leaks and pin holes. Use a piece of
cardboard or paper to search for
leaks. Do not use hand.
Crush Hazard. Death or serious Keep clear of moving centralizer. Do

injury can result from contact with not actuate centralizer until person-
moving centralizer. nel are clear.
Crush Hazard. Death or serious Keep clear of moving machine.

injury can result from contact with
moving machine.
Crush Hazard. Death or serious Read and understand operator's

injury can result from contact with manual and all safety signs before
moving feed mast. attempting to remove feed mast
swing pin.
Drill Feed And Table Can Fall Always raise the drill feed and feed
causing serious injuries or death. table clear of all obstacles before
moving the machine. Raise them
high enough to allow for rough
ground or small hills.
Do Not allow anyone under the drill
feed or feed table unless machine
parts are not moving and are sup-
Caution. Do not use high pressure ported.
spray by electrical connections. Do Not attempt to repair a pivot
pin that has failed or has been
sheared.
1-6 Safety
BI006823-00
Safety Information
Before Operation
• Do study this manual and the machine's operation manual and fully understand the controls.
• Do be sure all safety guards are securely in place. Replace any damaged or missing guards.
• Do be sure all nameplates and decals pertaining to safety, operation, and maintenance are in place
and not damaged. Replace any damaged or missing nameplates or decals. Refer to decal locator
drawings in this section.
• Do be sure all personnel are clear of the machine and work area before starting the engine or operat-
ing the machine.
• Do be sure drill area is clear of all obstructions before operating machine.
• Do attach safety chain when using towbar.
• Do wear safety helmet, glasses and hearing protection when operating or working on machine.
• Do Not operate machine with:
• Hydraulic or air leaks.
• Damaged hydraulic hoses or fittings.
• Broken or damaged electrical wiring.
• Damaged or missing guards and shields.
• Damaged structural members.
• Worn or damaged mechanical parts.
• Damaged or missing fasteners.
• Broken, damaged, or malfunctioning controls.
Operation
• Do examine the surface before drilling to determine the possible presence of unfired explosives.
• Do provide sufficient ventilation when running the engine in an enclosed area. Exhaust gases contain
carbon monoxide, a deadly poison, which is colorless and odorless.
• Do keep work area clean and clear of mud, snow, ice, fluids, hand tools and other objects.
• Do raise the drill feed before moving the machine. Raise it high enough to allow for rough ground or
small hills. Drill feed can fall causing serious injury or death.
• Do wear seat belt and operate machine with door closed on cab machines.
• Do use PPE (personal protection equipment) appropriate for the conditions you are working in; e.g.
safety helmet, safety glasses, hearing protection, gloves, respirator.
• Do maintain minimum clearance from high voltage wires (see Table 1-1). Check with power
company and local regulations for specific guidelines and safety information.
• Do Not use the machine for any other purpose than what it was designed for.
• Do Not wear loose clothing or jewelry; keep clothing and hands clear of moving parts.
• Do Not travel on steep inclines, soft or unstable ground, or close to unsupported excavations.
• Do Not move boom or machine if it is in a potentially unstable position.
• Do Not stand directly under a boom or feed.
• Do Not drill into or near a "bootleg" hole or any hole that may contain explosives.
Safety 1-7
Safety Information BI006823-00
Maintenance
• Two people shall be present when performing service work, both being fully trained on safety issues.
One person shall supervise from the operator's position and have immediate access to an emergency
stop in all situations. Visual, audible or verbal communication signals shall be established and under-
stood by both persons.
• Do relieve pressure in the hydraulic or pneumatic systems before loosening connections or parts.
• Do use only proper tools to make repairs or adjustments.
• Do be sure of adequate lighting when performing service work at night.
• Do maintain a metal-to-metal contact between the fill nozzle and fuel tank when filling the fuel tank.
This will prevent sparks and the possibility of explosion.
• Do be sure each person is adequately trained to perform service and maintenance procedures.
• Do place a warning tag on starting controls to alert personnel that someone is working on the machine
and disconnect battery before making repairs or adjustments to machine.
• Do be sure machine and components are well supported before servicing or replacing parts.
• Do Not service, or perform maintenance, while machine is running, or capable of being started.
• Do Not hammer bit or drill steel. Use only proper tools to make repair or adjustments.
• Do Not weld or grind near oil, air, fuel lines, or batteries.
• Do Not smoke or use an open flame near batteries. Batteries can give off hydrogen which is a highly
explosive gas.
• Do Not direct high pressure cleaning agents or water on electrical connections.
Equipment Transfer
If all or part of the equipment is shipped to a new destination, always include a complete Operator's
Manual or a copy of the following topics:
• Safety Section
• Operation Instructions including:
Pre-Start Checks
Start-up Clearances from High Voltage Lines
After Start Checks Line Voltage Minimum Clearance
Shutdown Procedure 0 to 50 kv 10 ft (3 m)
Tramming Machine 50 to 200 kv 15 ft (4.6 m)
200 to 350 kv 20 ft (6.1 m)
350 to 500 kv 25 ft (7.6 m)
500 to 750 kv 35 ft (10.7 m)
750 to 1000 kv 45 ft (13.7 m)
Table 1-1 Minimum safe distances from high voltage lines.
1-8 Safety
BI006823-00
Section 2
General Maintenance
General Maintenance 2-1

BI006823-00
Operation and Maintenance
Start-Up Procedure
1. Install shank.
2. Torque all nuts and bolts (see Section 5 for torque values).
3. Check that connections are tight.
4. Charge Accumulators (see Section 6).
5. Lubricate Rotation unit.
6. Add drill steel and bit.
7. Position boom and feed.
8. Collar hole at reduced power level.
9. Increase to full power after reaching good rock.
10. Check hose vibration by touching hoses. This will be your future reference of "Normal" and "Exces-
sive" hose vibration.
11. Make frequent checks for leaks, loose fittings, bolts and nuts. Repair or replace immediately.
Operating Tips
• Observing proper operating procedures is an important consideration for keeping the drill running
longer and at optimum performance.
• Drill alignment is critical to extend the life of the drill steel, couplings, shank and hammer.
• Avoid overfeeding or underfeeding. Apply only enough feed pressure to keep the coupling tight
and the shank from bouncing. A visible bow in the drill string indicates too much feed pressure or
misalignment.
• Avoid overdrilling of bits. Change and sharpen bits frequently. Drilling with dull bits leads to bit fail-
ures, high coupling heat, shank and drill steel failures, drill rotation problems, and hammer failures.
• Loose or leaking hoses and loose bolts should be repaired as quickly as possible.
2-2 General Maintenance

BI006823-00
General Maintenance Tips
DO NOT attempt lubrication or service while the machine is running. Be sure the hydrau-
lic and pneumatic systems are not pressurized before loosening any connections or
parts.
Preventive maintenance is vital to personnel protection and lower operating costs. The HPR4519/5123
drills require regularly scheduled maintenance to keep them operating efficiently.
Accumulator Pressures
Check accumulator pressures only if excessive hose vibration (jumping of hoses) or a loss in penetra-
tion rate is noted. Frequent checking will destroy the charge valve seat. It also lowers the charge pressure
since gas is lost each time the valve is opened.
Contamination
The one overriding rule in maintaining hydraulic equipment is cleanliness. Prevention of contamination
in hydraulic fluid is the most important factor. Clean the exterior of all parts and hose connections before
removing. Cap or plug hydraulic and pneumatic connections after disassembly to prevent contamination
of the system.
Major Repairs
Drill overhaul and major repairs on the hammer, hammer bearings, accumulators, and valve assembly
is best performed in a clean, sheltered area to prevent contamination.

Preventive Maintenance BI006823-00
Fig. 2-1 Grease Fittings–Location on Rotation Housing

3 Places–Grease every two hours of drill operation.
Fig. 2-2 Grease Fitting–Location on Water Swivel

1 Place–Grease every two hours of drill operation.
1. Grease Relief Fitting

BI006823-00
Preventive Maintenance
Preventive maintenance is vital to personnel protection and lower operating cost. The HPR4519/5123
drills require regularly scheduled maintenance to keep them operating efficiently and to minimize down
time.
At the beginning of every shift

1. Torque rotation motor mounting bolts and drill mounting bolts (see Section 5).
2. Inspect shank for excessive thread wear.
3. Apply an EP2-High Temperature grease (we recommend Polytech PG55, P/N 312810, 14 oz. tube)
to the four grease fittings located at the front end of the drill (fig's. 2-1 and 2-2).
NOTE Grease will seep out of the grease relief fitting (fig. 2-2) when rotation housing is full of
grease.
4. Check for loose fittings, nuts and bolts.

5. Check for leaks.
6. Check hose vibration on high pressure and return line of oscillator by touching the hoses during
drilling. If vibration is excessive, repair or charge accumulators.
Every Two Hours

1. Apply an EP2-High Temperature grease (we recommend Polytech PG55, P/N 312810, 14 oz. tube)
to the grease fittings located at the front end of the drill (fig. 2-1).
2. Check for leaks, loose nuts and bolts.
Every Week or Every Time the Shank is Changed

1. Check for contamination or grease in the striking area between the shank and hammer. Investigate
cause and repair as required.
2. Visually inspect for wear on the chuck, thrust plate, shank bushing and shank.
Every 500 Hours or 3 Months

1. Remove Rotation Unit.
2. Check for contamination and grease in the striking area between the shank and hammer. If grease
or contamination is found, investigate cause and repair as required. Minimum required mainte-
nance is cleaning, replacement of shank seal and replacement of hammer seal.
3. Inspect hammer striking face for wear, chipping or cupping. Replace hammer if wear is more than
0.030 in. (0.8 mm), or if chipping or cupping is noticed.
4. Inspect hammer for seal wear or scoring. Replace if scoring is noticed or if wear is more than 0.003
in. (0.08 mm) in diameter.
5. Remove backhead, check for grease, contamination and corrosion. If grease or contamination is
found, clean area behind hammer seal and replace seal. If corrosion is found clean and reassem-
ble backhead using silicon sealant.
6. Inspect rotation parts for excessive wear and damage. Replace as required.

Notes BI006823-00

BI006823-00
Section 3
Troubleshooting
Troubleshooting 3-1
Troubleshooting BI006823-00
TROUBLESHOOTING
PROBLEM CAUSE REMEDY

Bit dull or missing carbides. Change bit.
Inadequate hole cleaning. Check compressor output.
Check piping for restrictions.
System pump unloading valve not Check valve function.

1. Penetration rate falls off
shifting to full on position.
quickly.
High pressure diaphragm has failed. Replace diaphragm and recharge to
30 - 40% of inlet pressure.
Feed pressure is set too low. Check and readjust feed pressure.
Overheated coupling will be evident
in this case.
Mechanical problem in feed system. Check for free and smooth travel of
drifter on feed.
3-2 Troubleshooting
BI006823-00
Troubleshooting
TROUBLESHOOTING

Main pump pressure has dropped off. Check and re-adjust pump pressure.
Inspect following parts and replace as

required:
Thrust Washer
Excessive wear in chuck end of
drifter. (will cause short stroking of Bearing Plate
hammer).
Chuck Driver
Check back of shank splines for wear.

2. Penetration rate falls off
over period of time.
Check case drain on rotation pump.
Leakage over 1GPM indicates pump
Hydraulic fluid temperature is too wear.
high. (See Oil Specifications in Sec-
tion 7) Drifter is being free oscillated for long
periods of time at high pressure.
Wrong hydraulic fluid for application

(see fluid specs).
Check hydraulic cooling system for

proper operation.
Supply pressure to drill may be set Check supply pressure to drill and
too low for rock conditions. adjust compensator as required.
Troubleshooting 3-3
Use only dry nitrogen for charging accumulators.
TROUBLESHOOTING

Over charging of accumulators. Steel Check inlet and outlet hydraulic pres-
plate in diaphragm will be damaged sure at backhead of drill with ystem
or cracked. at operating temperature. Charge
to 30 - 40% of these pressures (see
Section 5 of this manual).
High pressure valves leaking. Check valves and valve seats.
3. Frequent failure of Crack in accumulator cover plate. Inspect cover for cracks particularly
accumulator diaphragms. in the area of the bolt holes.
Covers improperly tightened. Tighten the six cover bolts to 280 ft.
lbs. and the four allen head bolts to
600 ft. lbs. on each accumulator.
Drill operated with accumulators un- Replace and charge to 30 – 40% of

charged or undercharged. the hydraulic pressures at the back-
head of the drill (see Section 5 of this
manual.).
NOTE A small quantity of grease on the sealing lip of diaphragm will help assure proper
sealing.
Soapy water and a brush can be used to locate external leaks in an accumulator.
A small quantity of never seize or grease is helpful on the threads when reinstalling
accumulator covers.
Always inspect the mating surfaces of the accumulator cover and base. Any burrs or
3-4 Troubleshooting
BI006823-00
Troubleshooting
TROUBLESHOOTING

Feed pressure too high (overfeeding). Adjust feed pressure according to
Drill rod coupling will get hot and start ground conditions. In very bad ground
to smoke if you are overfeeding. it may be desirable to drill in the
"collaring mode" (reduced feed and
hammer pressure).
Check function of feed override valve
to assure that the feed is not operat-
ing in override range.
4. Rotation becomes erratic or
Rotation binding or locking up. Check drifter for adequate lubrication.
slows down.
Rotation pump badly worn. Check pump case flow. Replace

pump as indicated.
Rotation valve compensator malfunc- Check compensator for sticking

tioning (single pump unit only). spool, bad relief poppet and seal or
broken springs.
Broken shank. Check for broken shank in front of

splines or in flushing swivel area.
Splines in chuck worn out. Replace chuck and shank bearing.

5. Rotation stops suddenly.
Rotation motor failure. Repair or replace motor.
Rotation pump failure. Check pump for pressure and flow.

Replace as required.
Troubleshooting 3-5
TROUBLESHOOTING
Front hammer seal or o-ring leaking. Check and replace seal and o-ring.
6. Hydraulic fluid leak at

If, on inspection, seal shows damage other than normal
front of cylinder. NOTE
wear, remove hammer and bearing and check for damage
to either. Replace bearing if it shows scoring or evidence
of side loading.
Rear hammer seal or o-ring leaking. Check rear seal and o-ring, replace
as required.
Damage or scoring to hammer or Disassemble drifter and inspect for
cylinder bushings. damage.
7. Fluid leak.
If a quantity of grease is found in the rear cavity or striking
NOTE
cavity, this indicates the seal in the thrust or bearing plate
has failed, this seal should be replaced at this time.
8. Shuttle valve plug leaking. O-ring damaged. Replace o-ring, use grease to install.
Exercise care to prevent cutting o-
ring when installing.
Shuttle valve sticking. Remove shuttle valve. Inspect all

parts for metal pick up or scoring.
9. Oscillator becomes erratic.
Polishing of the valve should be done with a very fine grit
NOTE
emery cloth (320). The corners on the large diameters of
the valve should not be rounded. A valve requiring exces-
sive polishing to clean up should be replaced.
3-6 Troubleshooting
BI006823-00
Troubleshooting
TROUBLESHOOTING
Erratic hydraulic supply pressure or Check hydraulic system.

flow.
9. Oscillator becomes erratic.
Hammer compensator malfunction Remove compensator. Check for
(on units with collaring mode). sticking or worn spool, broken springs
or bad o-rings.
Loss of hydraulic pressure. Check hydraulic system.
Broken hammer. Replace hammer.
10. Oscillator stops and will not If the hammer is broken between the cylinder bushings, a
NOTE serious fluid leak will be evident.
restart.
Hammer seized in cylinder bushing. Disassemble, inspect, repair.
Shuttle valve seized. Remove and inspect per Item 9.
Worn front end parts. Inspect rotation group:

11. Oscillator starts but stops Chuck Driver, Thrust Washer and
when feed thrust is applied. Bearing Plate.
Cooler core plugged. Steam clean cooler.
Cooler blocked internally. Check for blockage and clean.
Thermal mixing valve malfunctioning. Check temperature at inlet and both

12. Hydraulic systems over- outlets to determine hot oil path.
heating.
Drifter being free oscillated for long The drifter should not be free oscil-
periods of time. lated for extended periods of time,
only when necessary (to retract stuck
steel, etc.) a cool down period should
be allowed.
Troubleshooting 3-7
Notes BI006823-00
3-8 Troubleshooting
BI006823-00
Section 4
Drill Disassembly and Inspection
Drill Disassembly and Inspection 4-1

General Tips on Drill Overhaul BI006823-00
ALWAYS wear proper eye and foot protection.
DO NOT wear loose clothing that can get caught in rotating parts.
These general instructions will be helpful when using the overhaul and adjustment procedures outlined
on the following pages.
1. Cover all hydraulic or air openings with an appropriate dust cover whenever any hydraulic or air open-
ings are exposed. A clean part in a dirty opening does little good.
2. Carefully examine all filters for evidence of metal or rubber particles. Replace the filters as neces-
sary.
3. Before servicing the drill or any part of the hydraulic system, neutralize the pressure in the complete
hydraulic system.
4. Before reassembling hydraulic components, clean all metal parts in a nonflammable cleaning fluid.
Carefully lubricate all components with hydraulic fluid to aid in reassembly.
5. ALWAYS lubricate threaded fasteners before assembly, especially if parts have been cleaned with
solvent.
6. Thorough checks must be made of all components to be sure they are assembled properly according
to instructions. Do not drill until all checks have been made.
7. Frequent inspection of the drill is very good practice. A minor adjustment can many times prevent
costly repairs later on.
8. Maintenance of hammer, bearings, accumulators or valve assembly must be performed in a clean
and sheltered area.
9. Maintenance of chuck end or rotation assemblies may be performed on a mounted drill.
10. It is not necessary to bleed off nitrogen charge in accumulators unless maintenance is performed on
accumulator assemblies themselves.
11. To avoid damage to new parts, replace mating parts that appear worn.
NOTE All drill parts are manufactured with care and precision. Each part is heat treated for
strength and carefully inspected before and after assembly. Every step has been taken
to provide you with the quality product you expect. Eventually some parts or your drill
will become worn. The description of damaged parts in this section is general, and is
intended to help the service person in the field to service and repair the drill. It is not
meant to imply that all such parts will fail in the described manner, or that the damage
is due to faulty manufacture.
It is good practice to replace all seals when drill is being disassembled for rebuild. Refer
NOTE
to parts manual for seal kits.
4-2 Drill Disassembly and Inspection

BI006823-00
Tools Required
The following is a list of tools needed for disassembly and reassembly procedures:
• Open end/box end wrenches–7/16, 9/16, 3/4, 7/8, 1, 1 1/8, 1 5/16, 1 1/2 and 1 3/4.
• 3/4 drive torque wrench–600 ft. lb. (816 Nm)
• 3/4 drive sockets–3/4 (for allen wrench), 1 1/8, 1 1/2
• 1 7/16 box end–special for use with torque wrench
• 1/2 drive socket wrench and breaker bar
• Allen wrenches–3/8, 3/4 and 7/8
• Large snap ring pliers
• Spanner wrench (to turn rotation motor shaft when installing)
• Seal installation tool (optional–see page 4-4)
• Screwdrivers
• Soft face hammer or dead blow hammer
• Ball peen hammer
• Bronze drift (soft steel or aluminum)
• Clean rags
• Lubricating oil for reassembly
• Loctite® thread locking compound
• Loctite® 518 Gasket Eliminator
• Pipe thread sealant
• Anti-seize compound

BI006823-00
Special Tools
Seal Installation Tool Seal Installation Instructions

1. Place seal on flat surface with seal lip down.
2. Open tool so that center pin is outside the seal O.D.
and the handle pins are inside the I.D.
3. Rotate handles to deform seal (See above).
4. Install seal in groove from external end of bore.
5. Release pressure and remove tool.
6. With finger pressure, snap remaining part of seal into
groove.
Seal Size Part No.

1 1/2 in. I.D. to 2 in. I. D. V003878
Fig. 4-1 Seal Installation Tool 2 in. I.D. to 3 in. I.D. V003879
Special Tool List for HPR4519 Drill (Optional)

The following list of special tools will greatly aid in disassembly and assembly of the drill. These tools
may be purchased from the manufacturer. The following pages illustrate the tools and dimensions, so you
can make them yourself or have them made at a local machine shop.
Part Number Description

1420352 Driver–Used against the hammer to drive out front and rear cylinder bushings.
1411247 Driver–Used with insert set 1411245 to remove water swivel bushing.
1411245 Insert Set–Used with driver 1411247 to remove water swivel bushing.
1416210 Hex Bar–Used to remove and install allen head accumulator capscrews.
1421459 Puller–Used with 1421460 hammer to remove shuttle valve end cap.
1421460 Hammer–Used with 1421459 puller, to make slide hammer.
V003878 Seal Installation Tool–Used to install 1 1/2 in. I.D. to 2 in. I.D. seals.
410096 Complete HPR4519 Tool Kit–includes all tools listed above.

BI006823-00
Special Tools
Special Tool List for HPR5123 Drill (Optional)

The following list of special tools will greatly aid in disassembly and assembly of the drill. These tools
may be purchased from the manufacturer The following pages illustrate the tools and dimensions, so you
can make them yourself or have them made at a local machine shop.

V003878 Seal Installation Tool–Used to install 1 1/2 in. I.D. to 2 in. I.D. seals.
419010 Complete HPR5123 Tool Kit–includes all tools listed above.
Insert Dimensions in inches:

A 0.750
B 1.50
C 0.390
D 0.90
E 1.995
F 2.740
G 1.260
H 0.745
All dimensions ± 0.005
AISI 1040 Steel, Harden to 38–40 Rc
Fig. 4-1a 423884 Insert Set for HPR5123–Use with driver 1421457 to remove water swivel bushing.
Fig. 4-1b 1421457 Driver for HPR5123–Use with insert set 423884 to remove water swivel bushing.

BI006823-00
Special Tools
Fig. 4-2 1420352 Driver for removing front and rear cylinder bushings.
Insert Dimensions in inches:

A 0.63
B 1.25
C 0.390
D 0.90
E 1.750
F 2.365
G 0.760
H 0.803
All dimensions ± 0.005
AISI 1040 Steel, Harden to 38–40 Rc

Fig. 4-3 1411245 Insert Set for HPR4519–Use with driver 1411247 to remove water swivel bushing.
Fig. 4-3a 1411247 Driver for HPR4519–Use with insert set 1411245 to remove water swivel bushing.

BI006823-00
Special Tools
Fig. 4-4 Hex Bar (1416210)–Used to remove and install accumulator bolts.
Fig. 4-5 Puller (1421459)–Used with hammer 1421460.
Fig. 4-6 Hammer (1421460)–Used with puller 1421459.

BI006823-00
HPR4519 Exploded View
22
78
64
32
20
33
21
29
62
18
7
46
5
44
14
13
12
17
11
16
10
17
15
(412617-HM45EF)
(414257-HM38EF)
13
8
5
45
6
31
44
33
1
63
3
77
19
4
20
5
Fig. 4-7 HPR4519 Exploded View Drawing–Item num-

bers correspond with those on cross-section drawings.
71
(Ref. 407596 Rev. L Sheet 1 of 2)

BI006823-00
58
57
58
54
66
33
39
41
35
56
38
40
53
69
50
70
67
64
68
51
26
27
30
49
69
42
70
61
64
43
36
28
37
23 60
34
52
33
32
62
39
59
55
24
57
58
25

29

(Ref. 407596 Rev. L Sheet 2 of 2)

BI006823-00
Notes

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78 44390 2 ADAPTER-STR-10 MOR X 12 MJIC
77 39871 1 ADAPTER-CAPNUT-16 JIC
76 404227 1 ADAPTER, HYD, SOCKET HEAD PLUG, -04 ORB
75 320206 REF PLUG-1 NPT-GALVANIZED
74 409398 REF SOFT GOODS KIT
73 410096 REF TOOL KIT
72 408766 REF MOUNTING SPECIFICATIONS
71 326404 1 WIPER-ROD-DISOGRIN #006-024
70 61982 2 ADAPTER-REDUCER-16 FOR X 12 MJIC
69 333649 2 ADAPTER, STR.-16 MORING X 16 MJIC
68 317653 2 VALVE, HIGH PRESSURE
67 407920 1 O RING-1.38 X 1.63 X .13
66 7683 1 CAPSCREW-HEXHD-5/8-18UNF X 1 1/2LG-GR5
62 346964 2 PIN, DOWEL-.500 X 1.00
61 309610 1 O RING-2.25 X 2.5 X .125
60 407633 1 O RING-DISOGRIN-2.5 X 2.75 X .125
58 317645 5 WASHER-SPRING-BELLEVILLE-1.140 OD X .640 ID
56 407626 1 PLUG-VALVE
55 407625 1 CAP
54 407624 1 CAP
53 409401 1 RING, RETAINER
52 335705 1 RETAINING RING-HPR2
51 423533 1 VALVE, AUTOMATIC
50 407611 1 SEAT, VALVE
49 407610 1 HOUSING VALVE
48 333584 1 PLUG, VENT
47 320411 5 PLUG-PIPE-HEX SOCKET-1/4 NPT
46 319002 1 FITTING-GREASE
45 320573 1 FITTING, ALEMITE-VENT PLUG-1/8 NPT
44 319005 3 FITTING, GREASE
43 439369 2 DIAPHRAGM
42 332249 2 COVER, ACCUMULATOR-HPR2
41 332991 8 WASHER-SPRING-BELLEVILLE-1.496 OD X 1.063 ID
40 333026 8 CAPSCREW-SKTHD-1-14UNS X 2 LG
38 333038 16 CAPSCREW-HEXHD-3/4-16UNF X 2 7/8 LG-GR8
37 309606 2 O RING-5.00 X 5.25 X .125
36 335698 2 ACCUMULATOR BASE HPR2
35 42915 4 CAPSCREW-HXHD-1-14UNS X 2 3/4 LG-GR8
33 317656 18 WASHER, SPRING BELLEVILLE-2.00 OD. X 1.00 ID.
32 333037 10 NUT-LOCK-1-14UNS-NYLOCK
31 441899 4 CAPSCREW-HEXHD-1-14UNS X 14 LG-GR8
30 317634 1 SEAL-DISOGRIN #001-129-1.75 X 2.25 X .375
29 317635 2 SEAL-DISOGRIN #001-143-2 X 2.5 X .375
28 407594 2 O RING-DISOGRIN-3.25 X 3.5 X .125
27 406538 1 BACKHEAD
26 414966 1 BUSHING, REAR CYLINDER
25 414965 1 BUSHING CYLINDER FRONT
24 419656 0 HAMMER-SHORT STROKE
24 406862 1 HAMMER
23 406621 1 CYLINDER
22 414271 0 MOTOR-HYD-8.0 DISPL.-MAGNETO 4 BOTL MOUNT
22 420250 1 MOTOR-HYD-8.0 DISPL.-STD 4 BOLT MOUNT
21 42935 4 CAPSCREW-SKTHD-1/2-20UNF X 1 1/2 LG
20 317552 6 WASHER-SPRING-BELLEVILLE-.748 OD X .539 ID
18 326707 1 O RING-AS-159-5.00 X 5.188 X .094
17 317933 2 BEARING-ROLLER
16 406713 1 PINION-ROTATION HOUSING
15 406718 1 PLATE-WEAR
14 406756 1 PLATE-BEARING
13 406710 2 BUSHING-CHUCK DRIVER
12 406755 1 BUSHING-SHANK
11 406759 1 WASHER-THRUST
10 406711 1 CHUCK DRIVER
9 406758 1 CHUCK
8 406818 1 PLATE-THRUST
7 406697 1 ROTATION HOUSING
6 406760 1 CHUCK END COVER
5 326401 4 SEAL-DISOGRIN #001-133-1.75 X 2.375 X .375
4 309597 1 O RING-AS-233-2.875 X 3.125 X .125
3 42977 2 PIN-ROLL-3/8 X 3
2 406789 1 BUSHING-FRONT END
1 406787 1 HOUSING-WATER SWIVEL
ITEM PART NUMBER QTY. DESCRIPTION
BILL OF MATERIAL
Fig. 4-7 Exploded View Parts List

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77 31
29
28
28
24
11
23
12
20
22
12
2
21
10
15
16
17
18
28
10
9
25 27
(SHANK #359445)
19
11
27 26
14
2
60
50 43
1
4
2

8

3
(Ref. 412091 Rev. D Sheet 1 of 2)

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30 71
78
57
72 34
67
56
42
66
54
41
55
49 27
40
52
63
51
64
38
34 61
56
32
53
47
66
48
45
46
58
30 71
13
59
62
34 33 35
39
38
36
37
37

(Ref. 412091 Rev. D Sheet 2 of 2)

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Notes

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81 402492 0 MOUNTING SPECIFICATIONS
80 336725 0 TOOL KIT
79 341164 0 SOFT GOODS KIT
78 405677 1 CAP
77 42935 8 CAPSCREW-SKTHD-1/2-20UNF X 1 1/2 LG
75 320573 2 FITTING, ALEMITE-VENT PLUG-1/8 NPT
72 7711 4 CAPSCREW-HXHD-1-14UNF X 2 1/4 LG-GR5
70 335838 2 CAPSCREW-HXHD-1-14UNF X 10 LG-GR8
68 333584 1 PLUG, VENT
67 327582 1 O RING-3.0625 X 2.875 X .09375
66 333036 2 O RING-1.875 X 1.6875 X .09375
65 346429 1 RING, BACK-UP-2.50 ID. X 2.68 OD.
64 343961 1 O RING-2.6875 X 2.5000 X .09375
63 326020 1 RING, BACK-UP-2.3125 ID. X 2.482 OD.
62 343962 2 O RING-2.3125 X 2.5000 X .09375
61 333026 16 CAPSCREW-SKTHD-1-14UNS X 2 LG
59 405676 1 CAP
58 335705 1 RETAINING RING-HPR2
57 343380 1 CAP, PROTECTOR
56 406236 2 PLUG, RETAINER-HPR2
55 335702 1 AUTO VALVE
54 343378 1 SEAT, VALVE
53 343377 1 SEAT, VALVE
52 335699 1 HOUSING, VALVE
51 317653 4 VALVE, HIGH PRESSURE
50 319005 2 FITTING, GREASE
49 333038 32 CAPSCREW-HEXHD-3/4-16UNF X 2 7/8 LG-GR8
48 439369 4 DIAPHRAGM
47 332249 4 COVER, ACCUMULATOR-HPR2
46 309606 4 O RING-5.00 X 5.25 X .125
45 335698 4 ACCUMULATOR BASE HPR2
43 34059 1 ADAPTER, STR-3/8MPT X 1/4FPT
42 339817 1 BACKHEAD
41 317635 2 SEAL-DISOGRIN #001-143-2 X 2.5 X .375
40 341026 1 BUSHING, REAR CYLINDER
39 341027 1 HAMMER
38 318135 2 O RING-4.00 X 3.75 X .125
37 317687 2 SEAL U-CUP
36 341025 1 BUSHING-CYLINDER FRONT
35 333037 7 NUT-LOCK-1-14UNS-NYLOCK
34 332991 27 WASHER-SPRING-BELLEVILLE-1.496 OD X 1.063 ID
32 335688 1 CYLINDER-HPR2
31 317552 8 WASHER-SPRING-BELLEVILLE-.748 OD X .539 ID
29 98322 2 MOTOR-HYDRAULIC CHAR-LYNN
28 333035 6 NUT-LOCK-3/4-16UNF-NYLOCK-GR8
26 333034 4 CAPSCREW, HEXHD-3/4-16 UNF X 8 GR8
25 7697 2 CAPSCREW-HEXHD-3/4-16UNF X 3LG-GR5
24 410801 2 PLATE-ADAPTER-MOTOR
23 335686 1 HOUSING, ROTATION CONTROL
22 326707 1 O RING-AS-159-5.00 X 5.188 X .094
21 335685 1 BEARING PLATE
20 335684 2 PINION
19 335683 2 ADAPTER COVER
18 328051 1 CHUCK
17 328050 1 WASHER, THRUST
16 335682 1 SHANK BUSHING
15 335681 1 DRIVER, CHUCK
14 328052 1 THRUST PLATE
13 346964 4 PIN, DOWEL-.500 X 1.00
12 89714 4 BEARING-CYLINDRICAL ROLLER
11 333028 4 SEAL U-CUP
10 335680 2 BUSHING
9 335679 1 COVER-ROTATION
8 337767 1 BUSHING, SWIVEL
7 37407 2 ADAPTER-PLUG-16 MOR
6 319002 3 FITTING-GREASE
5 312092 1 RING, RETAINER-TRUARC-N5000-350
4 21133 2 O RING-3.25 X 3.50 X .125
3 333031 1 WIPER-ROD-2.00 DIA.
2 333027 4 SEAL U-CUP
1 337762 1 HOUSING, WATER SWIVEL
ITEM PART NUMBER QTY. DESCRIPTION
BILL OF MATERIAL
Fig. 4-8 Exploded View Parts List

Drill Disassembly BI006823-00
Fig. 4-9 HPR4519/5123 Major Components:

1. Water Swivel Housing 5. High Pressure Accumulator
2. Rotation Housing 6. Cylinder
3. Rotation Motor 7. Backhead
4. Low Pressure Accumulator 8. Shuttle Valve (Automatic Valve)

BI006823-00
Drill Disassembly
General Information
The drill is made up of three basic sections (fig. 4-9). From front to back they are:
• The Water Swivel
The swivel contains a bushing to guide the front of the shank as well as seals to direct the water into
the shank and to the bit.
• The Rotation Housing
The rotation mechanism is made up of the chuck driver assembly, rotation motor and the bearings
and bushings to support the drive components.
• The Cylinder/Backhead Area
The cylinder/backhead area contains the hammer and hammer bearings, the automatic valve com-
ponents and the high and low pressure accumulators. The cylinder is closed at the back by the back-
head.
NOTE For complete disassembly of the drill, discharge the accumulators first. See Section 6
for procedure.
Water Swivel Assembly–Removal

1. Using a 1 7/16 and 1 1/2 wrench, remove the four locknuts (32), spring washers (33) and capscrews
(32) that retain the water swivel.
2. Remove the swivel assembly (1).
3. Remove the shank and thrust plate (8).
Fig. 4-10 Water Swivel Housing Fig. 4-10a Chuck End Cover
1. Water Swivel Housing 31. Capscrew (4) 8. Thrust Plate
6. Chuck End Cover 32. Locknut (4)
7. Rotation Housing 33. Spring Washer (8)

BI006823-00
Drill Disassembly
Water Swivel Housing–Repair

Special Tools Required:
Check the seals and wiper for wear and replace as needed. All seals should be replaced during drill
overhaul.
Replacement of the bushing is necessary only if it is worn beyond the wear tolerance listed in Section 7.
To remove bushing (2):
1. Drive out roll pins (3).
2. Remove seal (5) from bushing (2).
3. Drive out bushing with the special tools listed above.
Place inserts (two halves) where seal (5) was removed. Place driver against inserts and drive out
bushing, or use a hydraulic press if available.
Fig. 4-11 Water Swivel Assembly (ref. 407596)

1. Housing, Water Swivel 4. O-Ring
2. Bushing 5. Seal (3)
3. Roll Pin (2) 71. Rod Wiper
NOTE Item numbers correspond with items on parts list.

BI006823-00
Drill Disassembly
Chuck End Cover–Removal

Use a 3/4 wrench to remove the two hex head capscrews and spring washers (19 &20). After remov-
ing these two capscrews, lift off the rotation cover; you may need to pry the cover from the housing with a
screwdriver or tap with a deadblow hammer.
Fig. 4-12 Chuck End Cover

6. Chuck End Cover 19. Capscrew (2)
Fig. 4-13 Chuck End Cover Removal

6. Chuck End Cover 7. Rotation Housing

Chuck Driver and Pinion Gear–Removal and Inspection

1. Remove pinion gear (16) and chuck driver assembly (10).
2. Wash parts with clean solvent.
Fig. 4-14 Rotation Housing Assembly Fig. 4-15 Chuck End Cover Assembly
10. Chuck Driver 16. Pinion Gear 13. Chuck Driver Bushing
15. Wear Plate
17. Pinion Gear Roller Bearing
3. Inspect all parts for wear (see end of Section 7 for wear tolerances), pay particular attention to the
inside diameter of the chuck driver bushing (13); checking for excessive scoring and abrasion.
NOTE Excessive wear of chuck driver bushings causes shank misalignment and uneven wear
on hammer face.
4. Inspect pinion gear roller bearings (item 17, fig's. 4-15 & 4-16), remove with bearing puller if neces-
sary, remove wear plate (15). Do not try to remove front roller bearing by removing plug in chuck
end cover and driving against the back side of the wear plate with a punch. This usually results in
a broken wear plate.
Inspect the internal splines of the pinion gear where it mates to the rotation motor and replace if
splines are worn or damaged.
5. Inspect internal splines of chuck (9) for excessive wear. Inspect thrust washer (11) for wear and re-
place if wear from shank splines exceeds 0.030 in. (0.76mm).
NOTE If all other chuck driver parts are within acceptable wear tolerance, it is not necessary
to disassemble chuck driver to replace the thrust washer unless wear exceeds 0.040 in.
(1.27mm).
6. Inspect shank bushing (12) for wear. Insert a shank and check for excessive side play. Replace bush-
ing if excessive shank side play is evident. See Section 7 for wear tolerances.
7. If internal chuck driver parts need to be replaced, press out the shank bushing, thrust washer and chuck
from chuck driver (fig. 4-17). Do not reuse the thrust washer if wear exceeds 0.030 in. (0.76mm).
NOTE It is good practice to replace all seals when drill is being disassembled for rebuild.

BI006823-00
Drill Disassembly
8. Inspect bearing plate (14). Wear can be measued at the outer edge adjacent to the chuck driver bush-
ing. Replace if wear exceeds 0.027 in. (0.69 mm). See "Rotation Housing–Removal from Cylinder."
Fig. 4-16 Rotation Housing Assembly Fig. 4-17 Chuck Driver Assembly
13. Chuck Driver Bushing Shown in hydraulic press to press out
14. Bearing Plate internal parts.
Fig. 4-18 Chuck Driver Internal Parts

Fig. 4-19 Thrust Washer showing 0.030 in. (0.76 mm)
9. Chuck
wear from shank splines. DO NOT USE if wear is
11. Thrust Washer
0.030 in. (0.76mm) or more.
12. Shank Bushing

Rotation Housing–Internal Parts
6 15 17 16 46 17 7
29 22
45
8 9 13 10 11 13 12 14 5 18 48 47
Fig. 4-20 Rotation Housing Assembly (ref. 407596)

5. Seal 13. Chuck Driver Bushing (2) 29. Seal
6. Chuck End Cover 14. Bearing Plate 45. Vent Plug
7. Rotation Housing 15. Wear Plate 46. Grease Fitting
8. Thrust Plate 16. Pinion Gear 47. Hex Head Plug
9. Chuck 17. Roller Bearing (2) 48. Vent Plug
10. Chuck Driver 18. O-Ring
11. Thrust Washer 22. Rotation Motor
12. Shank Bushing
NOTE Item numbers correspond with items on parts list.

BI006823-00
Drill Disassembly
Rotation Motor–Removal
1. Use a 3/8 allen wrench to remove the four allen head capcrews and spring washers (20 & 21, fig.
4-21) that hold the rotation motor (22, fig. 4-21) to the rotation housing.
NOTE Generally the rotation motor is trouble free except for occasional shaft seal replacement.
We will not cover motor repair here as it is generally more economical to replace the mo-
tor than to repair it. Refer to parts manual for shaft seal kits
2. Remove pinion gear shaft seal (65, fig. 4-22). If you are doing a complete rebuild, replace all seals.
Fig. 4-21 Rotation Motor

20. Spring Washer (4) 22. Rotation Motor
21. Sockethead Capscrews (4)
Fig. 4-22 Rotation Housing

65. Pinion Gear Shaft Seal

BI006823-00
Drill Disassembly
Rotation Housing–Removal from Cylinder

Be sure rotation housing is supported. Using a 1 1/2 and 1 7/16 wrench, remove the six capscrews (34),
locknuts and spring washers (32 & 33) that hold the rotation housing to the cylinder (fig. 4-23). Separate
the rotation housing from the cylinder.
Inspection
Wash parts in clean solvent. Check bearing plate, chuck driver bushing and pinion gear roller bear-
ings for wear and replace as required. See Section 7 for wear tolerances. To inspect bearing plate refer to
fig. 4-16. Wear can be measued at the outer edge adjacent to the chuck driver bushing. Replace if wear
exceeds 0.027 in. (0.69 mm).
If bearing plate or chuck driver bushing needs to be replaced, they will have to pressed out using a
hydraulic press (fig. 4-24).
Fig. 4-23 Rotation Housing Removal Fig. 4-24 Rotation Housing

32. Locknut (6) Pressing out bearing plate and chuck
33. Spring Washer (6) driver bushing.
34. Capscrews (6)

BI006823-00
Drill Disassembly
Inspection
Check the oil vent plug (48) before installing, see fig. 4-25. Remove the cap from the vent plug and
clean the filter with solvent. Check to be sure the vent hole is open, see fig. 4-26.
The purpose of the oil vent plug is twofold:

• First, it acts as a breather, letting in cool air on the piston return stroke and allowing hot air to escape
on the piston forward stroke.
• Secondly, the vent plug acts as a tell-tale to let you know if the piston seal is leaking.
Two positions are provided for the vent plug location. The vent should always be at the lowest point
when drilling. The position as shown in fig. 4-25 would be for downhole drilling. For uphole drilling, switch
the vent plug (48) with the hexhead plug (47).
NOTE Grease present in the cavity behind the bearing plate means the bearing plate seal is
worn. If this is the case, be sure to remove and clean out the vent plug thoroughly and
install.
Fig. 4-25 Rotation Housing Vent Plug Fig. 4-26 Oil Vent Plug
47. Hex Head Plug 1. Cap 2. Filter
48. Oil Vent Plug

BI006823-00
Notes

BI006823-00
Drill Disassembly
ALWAYS discharge pressure in accumulators BEFORE any work is performed on the ac-
cumulators.
Drill Cylinder Components

The main components of the drill cylinder are shown in fig. 4-27. It is possible to perform service work
on the hammer, shuttle valve or backhead without discharging the accumulators.
DO NOT remove the accumulator covers without discharging the nitrogen gas first. Do this by opening
the high pressure valve (68) with an 11/16 wrench. The accumulator covers are held in place with four allen
head capscrews at the outside corners. Use a 3/4 allen wrench to remove.
The complete accumulator assembly may be removed from the drill cylinder without discharging the
accumulators. This is done by removing the eight hexhead capscrews, using a 1 1/8 socket wrench.
Fig. 4-27 Drill Cylinder Assembly

24. Hammer
27. Backhead
68. High Pressure Valve

Cylinder–Internal Parts
29 24
23 26 30
27
47
69 70 64
28
28 25
Fig. 4-28 Cylinder Assembly (ref. 407596)
NOTE Item numbers correspond with item on parts list.
23. Cylinder 28. O-Ring (2) 64. Capnut (2)

24. Hammer 29. U Cup Seal 69. Adapter (2)
25. Front Cylinder Bushing 30. U Cup Seal 70. Adapter-Reducer (2)
26. Rear Cylinder Bushing 47. Sockethead Plug
27. Backhead
Backhead–Removal and Inspection

Remove the four capscrews that hold the backhead to the cylinder, using a 1 1/2 socket wrench. Inspect
rear of cylinder and backhead for rust or oil. If rust is present, clean the mounting surface of the backhead
and apply a thin coat of Loctite® 518 sealant before installing, to prevent water from entering in. If oil is
present, the rear hammer seal or o-ring are leaking and need to be replaced.
Hammer and Bushings–Removal and Inspection

1. Push hammer forward until it seats against the front cylinder bushing. Place driver (1420352) against
rear face of hammer and drive out front cylinder bushing.
2. Push hammer back in until it seats against rear cylinder bushing. Place driver against front face of
hammer and drive out rear cylinder bushing.
3. Carefully slide the hammer and bushing out of the cylinder. Inspect hammer and bushing surfaces
for scratches and scoring. Light scratches can be cleaned up with crocus cloth. Replace hammer and
bushings if scratches or scoring are deep and can not be cleaned up with crocus cloth.

BI006823-00
Drill Disassembly
Fig. 4-29 Hammer showing normal wear.

Scratches and scoring can be cleaned up with crocus cloth.
4. Inspect hammer striking face for wear and cracks; replace if wear exceeds 0.040 in. (1 mm). See
Section 7 for wear tolerances. Check for wear on seal track area of hammer. Maximum wear on this
surface is 0.003 in. (0.08 mm).
NOTE It is recommended the hammer be replaced if wear on the striking face exceeds 0.040
in. (1 mm). Do not grind hammer face, as it is case hardened and you will grind through
to softer steel.
5. Inspect cylinder bushings for scratches and scoring. Cylinder bushings should fit tight in the cylinder
bore. See Section 7 for wear tolerances of inside diameter.
Fig. 4-30 Cylinder Bushing showing signs of cavitation (pitted area).
The cylinder bushing shown in fig 4-30 is showing signs of cavitation. The primary cause of this is im-
properly charged accumulators (either too high or too low) or return pressure is too low. This bushing can
be reused if the inside diameter is within specifications. However, take note of the warning sign and be
sure accumulators are charged properly (see Section 6). Accumulators should be charged to 30 - 40% of
line pressure. Check return pressure of the machine during actual drilling conditions, i.e. with drill hammer
and rotation ON, feed ON, compressor and dust collector ON. Gauge should read in the range of 50 psi to
150 psi (3.4 bar to 10.3 bar). Consult factory if return pressure is not in the specified range.

BI006823-00
Drill Disassembly
Shuttle Valve–Internal Parts
58 57 52 53 56 57 58
39 59 66 58
55 60 51 49 50 61 67 54
Fig. 4-31 Shuttle Valve - ref. 407596

39. Spring Washer 54. Cap 59. Capscrew
49. Valve Housing 55. Cap 60. O-Ring
50. Valve Seat 56. Valve Plug 61. O-Ring
51. Automatic Valve 57. Capscrew (4) 66. Capscrew
52. Retaining Ring 58. Spring Washer (5) 67. O-Ring
53. Retaining Ring
Shuttle Valve–Removal and Inspection

1420352 Driver–Use with socket to drive out valve housing.
1. Remove the two capscrews (57) that retain the left side dust cap using a 15/16 socket wrench and
remove the cap.

BI006823-00
Drill Disassembly
Shuttle Valve–Removal and Inspection (cont.)
NOTE If you are just inspecting the valve (51), it is not necessary to remove the valve housing
or the right side cap.
2. Remove the center capscrew (66) that retains the plug (56).
3. Remove the 3 piece retaining ring (53). It may be necessary to tap on the valve end cap slightly.
4. Use puller (1421459) with slide hammer (1421460) to remove valve end cap (50).
NOTE Have a pan ready to catch oil that will come out when valve end cap is removed.
Fig. 4-32 Shuttle Valve

50. Valve End Cap 53. Retaining Ring (3 piece)
Fig. 4-33 Shuttle Valve–Left Side Components

50. Valve End Cap 53. Retaining Ring (3 piece)
51. Valve 56. Plug
BI006823-00
Drill Disassembly
58 57 52 53 56 57 58
39 59 66 58
55 60 51 49 50 61 67 54

53. Retaining Ring

BI006823-00
Drill Disassembly
Shuttle Valve–Removal and Inspection

5. Carefully remove the valve (51) for inspection.
6. To remove the valve housing (49), first remove the center capscrew (59) and the two outer capscrews
(57). Remove the right side cap (55). Remove the retaining ring (52). If a press is available, press out
the valve housing (49). If a press is not available, place a socket over the end of the valve housing
so it rests near the outer edge of the shoulder. Drive out using hammer and driver (1420352).
7. Inspect bore of valve housing (49) for erosion or cavitation damage. Replace if damaged.
8. Inspect valve (51) for scoring and signs of cavitation (fig. 4-34). Replace if damaged, there must not
be any nicks, burrs or pitting on the valve. Cavitation is a sign of operating the drill with incorrect
accumulator charge pressure. The valve must slide freely in the valve housing. Light scratches or
scoring can be cleaned up by polishing with fine crocus cloth, but be careful not to round the edges
of the valve or the dashpot will be lost.
Fig. 4-34 Valve showing signs of cavitation

Accumulator–Internal Parts
43
37
68
40 41 36 40 41
38 39 38 39
42
Fig. 4-35 Accumulator Assembly (ref. 407596)

36. Accumulator Base 39. Spring Washer (8) 42. Accumulator Cover
37. O-Ring 40. Socket Head Capscrew (4) 43. Diaphragm
38. Hexhead Capscrew (8) 41. Spring Washer (4) 68. High Pressure Valve

BI006823-00
Drill Disassembly
ALWAYS discharge pressure in accumulators BEFORE any work is performed on the ac-
cumulators.
Accumulators–Removal
1416210 Hex Bar–Used to remove accumulator capscrews–3/4 in. hex X 4 in.
1. Remove safety cap from the high pressure valve (68) and carefully turn the valve counterclockwise
until you hear the nitrogen gas escaping. The valve should loosen easily, as it should never be torqued
more than 10 ft. lbs. (13.6 Nm) to avoid damage to the valve seat. Repeat this procedure for each
accumulator.
NOTE Loosen the 4 sockethead capscrews (40) on each accumulator before removing the eight
hex head capscrews that secure the accumulator to the drill. The sockethead capscrews
are torqued to 600 ft. lbs (816 Nm). Use the 3/4 in. hex bar (part no. 1416210) for this.
2. Remove the 8 hexhead capscrews (38) that hold each accumulator to the cylinder using 1 1/8 socket
wrench. Lift the accumulator straight away from the cylinder. There is a notch on each side of the
accumulator base to insert a screwdriver to pry the accumulator from the cylinder if it gets in a bind
Fig. 4-36 Accumulators

38. Hexhead Capscrews (8) 41. Spring Washer (4)
39. Spring Washer (8) 68. High Pressure Valve

Accumulators–Disassembly and Inspection

1. Do not remove high pressure valve (68) from accumulator unless it was damaged or leaking.
2. Remove the 4 sockethead capscrews and spring washers (40 & 41) that hold the accumulator cover
to the base and inspect the accumulator diaphragm for damage.
• If there is an imprint of the holes in the base on the metal plate of the diaphragm, it is an indication
of possible overcharging of the accumulator.
• Look for a pin hole in the diaphragm adjacent to the charging valve. This can be caused by inadequate
or no charge pressure (fig 4-39).
Fig. 4-37 Accumulator Cover

40. Sockethead Capscrew (4) 41. Spring Washer (4)
68. High Pressure Valve and O-Ring
Fig. 4-38 Accumulator Base

36. Accumulator Base
43. Diaphragm - note metal plate faces accumulator base.
NOTE Metal plate is no longer used on newer model drills.

BI006823-00
Drill Disassembly
Accumulators–Disassembly and Inspection
Fig. 4-39 Accumulator Diaphragm–note small hole at 12 o'clock position

caused by undercharging or loss of charge pressure.
NOTE Older model drills may have a metal plate in the center of the diaphragm.
MOLDED PART NUMBER

AND MFG. DATE CODE
THIS SIDE TOWARDS COVER
Fig. 4-40 Accumulator Diaphragm–Part Number

and Manufacturing Date Code Towards the Cover
Side

Notes BI006823-00

BI006823-00
Section 5
Drill Assembly
Drill Assembly 5-1

General Tips on Drill Overhaul BI006823-00
ALWAYS wear proper eye and foot protection.

ALWAYS wear gloves when handling frozen parts.
DO NOT wear loose clothing that can get caught in rotating parts.
NOTE It is good practice to replace all seals when drill is being disassembled for rebuild. Refer
to parts manual for seal kits.
These general instructions will be helpful when using the overhaul procedures outlined on the following
pages.
1. Cover all hydraulic or air openings with an appropriate dust cover whenever any hydraulic or air open-
ings are exposed. A clean part in a dirty opening does little good.
2. Carefully examine all filters for evidence of metal or rubber particles. Replace the filters as neces-
sary.
3. Before servicing the drill or any part of the hydraulic system, neutralize the pressure in the complete
hydraulic system.
4. Before reassembling hydraulic components, clean all metal parts in a nonflammable cleaning fluid.
Carefully lubricate all components with hydraulic fluid to aid in reassembly.
5. ALWAYS lubricate threaded fasteners before assembly, especially if parts have been cleaned with
solvent.
6. Thorough checks must be made of all components to be sure they are assembled properly according
to instructions. Do not drill until all checks have been made.
7. Frequent inspection of the drill is very good practice. A minor adjustment can many times prevent
costly repairs later on.
8. Maintenance of hammer, bearings, accumulators or valve assembly must be performed in a clean
and sheltered area.
9. Maintenance of chuck end or rotation assemblies may be performed on a mounted drill.
10. It is not necessary to bleed off nitrogen charge in accumulators unless maintenance is performed on
accumulator assemblies themselves.
11. To avoid damage to new parts, replace mating parts that appear worn.
5-2 Drill Assembly

BI006823-00
Bolt Torque Specifications
Procedure No. 1-87 REVISION A
Torque Values: Bolts, Screws and Studs (Lubricated or Plated)
Tolerance Values in all cases to +5 % - 0 % of the Value listed below.
Note: K = .15 for plated or lubricated fasteners.
Nominal SAE Grade 5 ASTM A-449 SAE Grade 8
Diameter Tightening Torque Ft. Lbs. Tightening Torque Ft. Lbs.
(Nm) Newton meter (Nm) Newton meter
1/4 6 (8.2) 9 (12.2)
5/16 13 (17.7) 18 (24.5)
3/8 23 (31.3) 33 (44.9)
7/16 35 (47.6) 55 (74.8)
1/2 57 (77.5) 80 (108.8)
9/16 82 (111.5) 115 (156.4)
5/8 113 (153.7) 159 (216.2)
3/4 200 (272) 282 (383.5)
7/8 322 (437.9) 455 (618.8)
1 also UNS 483 (656.9) 681 (926.2)
UNC 1-1/8 596 (810.6) 966 (1313.8)
1-1/4 840 (1142.4) 1363 (1853.7)
1-3/8 1102 (1498.7) 1786 (2429)
1-1/2 1462 (1988.3) 2371 (3224.6)
1-3/4 1714 (2331)
2 2576 (3503.4)
2-1/4 3768 (5124.5)
2-1/2 5155 (7010.8)
2-3/4 6996 (9514.6)
3 9231 (12554.2)
1/4 7 (9.5) 10 (13.6)
5/16 14 (19) 20 (27.2)
3/8 26 (35.4) 37 (50.3)
7/16 40 (54.4) 60 (81.6)
1/2 64 (87) 90 (122.4)
9/16 91 (123.8) 128 (174.1)
5/8 127 (172.7) 180 (244.8)
UNF 3/4 223 (303.3) 315 (428.4)
7/8 355 (482.8) 502 (682.7)
1 528 (718.1) 746 (1014.6)
1-1/8 668 (908.5) 1083 (1472.9)
1-1/4 930 (1264.8) 1509 (2052.2)
1-3/8 1254 (1705.4) 2034 (2766.2)
1-1/2 1645 (2237.2) 2668 (3628.5)
1-3/4 1879 (2555.4)
2 2857 (3885.5)
UN 2-1/4 4127 (5612.7)
2-1/2 5726 (7787.4)
2-3/4 7693 (10462.5)
3 10064 (13687)
Drill Assembly 5-3

Drill Assembly BI006823-00
29 24
23 26 30
27
47
69 70 64
28
28 25

5-4 Drill Assembly

BI006823-00
Drill Assembly
BE SURE that the area where the drill is being assembled is kept clean and free of dust
and dirt. Keep plenty of clean rags on hand. Wipe all parts clean and lightly oil internal
parts and seals as they are assembled.
Rear Cylinder Bushing and Backhead–Installation

Refer to fig. 5-1 for assembly and item number reference.
1. Install the u cup seal (30) in the rear cylinder bushing (26). Note the u cup side of the seal faces
inward. The seal is easier to install with the tool shown in fig. 5-2 and as listed in the tool list at the
beginning of this section. If the tool is not available, you can use long nose pliers and fold the seal
into a "C" shape to install as shown below.
Seal Installation:
Fold seal as shown and insert into groove
then expand seal into place.
Fig. 5-2 Rear Cylinder Bushing–Seal installation

30. U Cup Seal
Drill Assembly 5-5

Rear Cylinder Bushing and Backhead–Installation (cont.)

2. Install o-ring (28) on rear cylinder bushing (26). Lubricate o-ring and cylinder bore before installing
bushing (fig. 5-3).
3. Install rear cylinder bushing into cylinder as far as it will go by hand, then drive in until shoulder is
flush with cylinder, using a dead blow hammer (fig's. 5-4 and 5-5).
4. Apply a thin coat of Loctite® 518 sealant to mounting surface of backhead. Apply anti-seize compound
to the 4 backhead capscrews. Install backhead with the four 1-14 UNS capscrews and spring wash-
ers, using a 1 1/2 socket wrench. Torque per specifications on page 5-3.
Fig. 5-3 Rear Cylinder Bushing Fig. 5-4 Rear Cylinder Bushing
28. O-Ring Install carefully by hand as far as it will go.
Fig. 5-5 Rear Cylinder Bushing

Seat with dead blow hammer.
5-6 Drill Assembly
BI006823-00
Drill Assembly
Hammer–Installation
1. Lubricate inside of rear cylinder bushing with hydraulic oil, then stand hammer up and lubricate with
hydraulic oil before installing (fig. 5-6).
2. Carefully slide hammer into cylinder (refer to fig. 5-1 for correct installation) until resistance is felt
(about 3/4 of the length). Rotate hammer to coat seals with oil and check for concentricity, then push
hammer in the rest of the way.
Fig. 5-6 Hammer

Lubricate with hydraulic oil before installing.
Drill Assembly 5-7

29 24
23 26 30
27
47
69 70 64
28
28 25

Front Cylinder Bushing–Installation

Refer to fig. 5-1 for assembly and item number reference.
1. Install the u cup seal (29) in the front cylinder bushing (25). Note the u cup side of the seal faces
inward. The seal is easier to install with the tool shown in fig. 5-7 and as listed in the tool list at the
beginning of Section 4. If the tool is not available, you can use long nose pliers and fold the seal into
a "C" shape to install as shown below.
Seal Installation:
5-8 Drill Assembly

BI006823-00
Drill Assembly
2. Install o-ring (28) on front cylinder bushing (25). Lubricate o-ring and cylinder bore with hydraulic oil
before installing bushing.
3. Lubricate inside of front cylinder bushing with hydraulic oil. Carefully install over hammer and into
cylinder as far as it will go by hand, then drive in until shoulder is flush with cylinder, using a dead
blow hammer.
Fig. 5-8 Front Cylinder Bushing–O-Ring Installation

28. O-Ring
Fig. 5-7 Front Cylinder Bushing

Seal installation
29. U Cup Seal
Fig. 5-9 Front Cylinder Bushing–Installation
Drill Assembly 5-9

BI006823-00
Drill Assembly
Accumulator–Internal Parts
43
37
68
40 41 36 40 41
38 39 38 39
42
Fig. 5-10 Accumulator Assembly (ref. 407596)

36. Accumulator Base 39. Spring Washer (8) 42. Accumulator Cover
37. O-Ring 40. Sockethead Capscrew (4) 43. Diaphragm
38. Hexhead Capscrew (8) 41. Spring Washer (4) 68. High Pressure Valve
Accumulators–Assembly and Installation

1416210 Hex Bar–Used to install accumulator capscrews–3/4 hex X 4 in.
1. Be sure all parts are clean before assembly, refer to fig. 5-10.
2. Put a thin coat of hydraulic oil on the outside edge of the diaphragm (43) and install in accumulator
base (36) with the part number and manufacturing date code towards the cover side..
3. Install accumulator cover and apply anti-seize compound to the threads of the 4 allen head capscrews
that hold the cover to the base. Install capscrews and spring washers. Tighten capscrews using the
3/4 X 4 in. hex tool (part no. 1416210), but final torque will be done with accumulators installed on
drill.
4. If the high pressure valve (68) was removed, install a new valve. Valve comes with o-ring, be sure to
lubricate o-ring. Tighten valve to 10 ft. lbs. (13.6 Nm) max. Do not overtighten (fig 5-11).
5-10 Drill Assembly

BI006823-00
Drill Assembly
5. Turn accumulator over, apply vaseline or grease to o-ring (37) and install accumulator on drill. The
vaseline will keep the o-ring in place when installing on drill.
6. Install the accumulators so the charge valve faces to the rear of the drill. This makes for easier access
to the valves for checking and charging. Apply anti-seize compound to the threads of the 8 3/4-16 UNF
grade 8 capscrews that hold the accumulator to the drill. Install capscrews (38) and spring washers
(39). Torque the hexhead capscrews and the four 1-14 UNC grade 8 allen head capscrews according
to chart on page 5-3.
Fig. 5-11 Accumulator–shown inverted Fig. 5-12 Apply anti-seize compound to threads
37. O-Ring–install with vaseline or grease before installing accumulators.
Fig. 5-13 Accumulators

38. Hexhead Capscrews (8) 40. Sockethead Capscrews (4) 68. High Pressure Valve
39. Spring Washer (8) 41. Spring Washer (4)
Drill Assembly 5-11

58 57 52 53 56 57 58
39 59 66 58
55 60 51 49 50 61 67 54

53. Retaining Ring
5-12 Drill Assembly

BI006823-00
Drill Assembly
Shuttle Valve–Assembly
Refer to fig. 5-14 for assembly. Torque all capscrews per specifications on page 5-3.
1. Clean all parts in solvent and lubricate with hydraulic oil.
2. Check fit of valve (51) in valve housing (49). Valve should slide easily in and out of valve housing, if
not, polish the valve surfaces with crocus cloth until valve slides easily. Be careful not to round the
edges of the valve or the dashpot will be lost.
3. Lubricate and install o-ring (60) into groove in bore on right side of cylinder. Lubricate and install o-
ring (61) into groove in valve housing. Install valve housing from left side of cylinder with small hole
facing up (fig. 5-17). Be careful not to damage o-rings. Tap housing with soft faced driver on the outer
diameter of the housing until shoulder is flush with cylinder on left side (fig. 5-18).
Fig. 5-15 O-Ring Installation into Cylinder Fig. 5-16 Lubricate Valve Housing Bore
60. O-Ring
Fig. 5-17 Valve Housing Installation Fig. 5-18 Valve Housing Installation
Note 12 o'clock position of small hole. Drive in until shoulder is against cylinder.
61. O-Ring
Drill Assembly 5-13

BI006823-00
Drill Assembly
Shuttle Valve–Installation
4. Install snap ring (52) onto valve housing. Make sure it is seated all the way in the groove (fig. 5-19).
Fig. 5-19 Retaining Ring Installation

52. Retaining Ring
NOTE Install R.H. cap first, so when the center capscrew is tightened, it will pull the shoulder
of the valve housing against the cylinder on the left side.
5. Install right side cap (55) with the two 5/8-18 capscrews (57) and spring washers (58).
Install the 3/4-16 UNF capscrew (59) and spring washer (39).
6. Install lubricated valve (51) into valve housing, small diameter first. The small diameter end is on the
end nearest the four holes in the valve.
7. Lubricate and install o-ring (61) on valve end cap (50). Install lubricated valve end cap into valve
housing as far as it will go. Seat lightly against shoulder of valve housing.
8. Install the 3-piece retaining ring (53) in the groove and install plug (56). Install spring washer (58) and
the 5/8-18 UNF capscrew (66). Torque capscrew before installing left side cap (54).
9. Install left side cap (54) with two 5/8-18 capscrews (57) and spring washers (58).
This completes the shuttle valve installation. Be sure to torque all capscrews according to specifica-
tions on page 5-3.
5-14 Drill Assembly

BI006823-00
Drill Assembly
Fig. 5-20 Shuttle Valve–Left Side Components

50. Valve End Cap 53. Retaining Ring (3-piece)
51. Valve 56. Plug
Fig. 5-21 Valve End Cap Installation Fig. 5-22 Retaining Ring Installation
50. Valve End Cap
53. 3 Piece Retaining Ring
Drill Assembly 5-15

Rotation Housing–Internal Parts
6 15 17 16 46 17 7
29 22
45
8 9 13 10 11 13 12 14 5 18 48 47

5. Seal 11. Thrust Washer 17. Roller Bearing (2) 45. Vent Plug
6. Chuck End Cover 12. Shank Bushing 18. O-Ring 46. Grease Fitting
7. Rotation Housing 13. Chuck Driver Bushing (2) 22. Rotation Motor 47. Hexhead Plug
8. Thrust Plate 14. Bearing Plate 29. Seal 48. Vent Plug
9. Chuck 15. Wear Plate
10. Chuck Driver 16. Pinion Gear
Rotation Housing–Assembly
NOTE The assembly procedures that follow are for a complete rebuild of the rotation housing
assembly. In some cases a complete teardown and rebuild is not required. If unit was
not completely disassembled, use only the procedures that apply to your situation.
1. Install the grease relief fitting (45) using pipe thread sealant, see fig. 5-23.
2. Install the three grease fittings using pipe thread sealant. There are two 1/4 NPT grease fittings
(44) and one 1/8 NPT grease fitting (46), see fig. 5-24.
5-16 Drill Assembly

BI006823-00
Drill Assembly
3. Check the oil vent plug (48) before installing, see fig. 5-25. Remove the cap from the vent plug and
clean the filter with solvent. Check to be sure the vent hole is open, see fig. 5-25a.
The purpose of the oil vent plug is twofold:
• First, it acts as a breather, letting in cool air on the piston return stroke and allowing hot air to escape
on the piston forward stroke.
• S e c o n d l y, t h e v e n t p l u g a c t s a s a n i n d i c a t o r o f p i s t o n s e a l l e a k a g e .
Two positions are provided for the vent plug location. The vent should always be at the lowest point
when drilling. The position as shown in fig. 5-25 would be for downhole drilling. For uphole drilling,
switch the vent plug (48) with the hexhead plug (47).
Grease present in the cavity behind the bearing plate means the bearing plate seal is
NOTE
worn. If this is the case, be sure to remove and clean out the vent plug thoroughly and
install.
Fig. 5-24 Rotation Housing Grease Fittings Fig. 5-25 Rotation Housing Vent Plug
44. Grease Fitting, 1/4 NPT 47. Hexhead Plug
46. Grease Fitting, 1/8 NPT 48. Oil Vent Plug
Fig. 5-25a Oil Vent Plug

1. Cap 2. Filter
Drill Assembly 5-17
Rotation Housing–Assembly (cont.)

4. Install the chuck driver bushing (13) into the chuck end cover, using an arbor press if available.
5. The wear plate (15) is the same on both side and can be installed either way. With the wear plate
installed, press the pinion gear roller bearing (17) into the chuck end cover.
Fig. 5-26 Chuck End Cover Assembly

13. Chuck Driver Bushing
15. Wear Plate
Fig. 5-27 Bearing Plate
5. Seal
18. O-Ring
6. Install seal (5) into bearing plate (14) with lip of seal facing away from side with o-ring groove. Coat
o-ring (18) with Loctite® 518 and place in o-ring groove on back side of bearing plate. The Loctite®
518 will keep the o-ring from falling out when the bearing plate is pressed into the rotation housing.
NOTE Before pressing bearing plate into rotation housing, be sure to remove all nicks or burrs
with a file. It is a good idea to line up one of the three grease grooves with one of the
grease fittings. In this way you will be able to tell if the bearing plate has turned in the
housing on the next inspection. If the bearing plate has turned, it is an indication that the
chuck driver bushing has turned also, possibly due to lack of lubrication. If the bearing
plate has turned, then the o-ring (18) needs to be replaced.
7. Press bearing plate (14) into housing, being careful that the o-ring (18) does not fall out of the groove.
To check this, insert a feeler gauge (fig. 5-28a) from the back of the rotation housing. It will be easiest
to make a gauge, by placing a 0.002 in. or 0.003 in. piece of shim stock on the end of a long bolt as
shown in fig. 5-28a. You should not be able to insert the feeler gauge behind the bearing plate. If the
feeler gauge does go under the bearing plate, it means the o-ring has come out of the groove. The
bearing plate will then have to be pressed out and installed again.
5-18 Drill Assembly

BI006823-00
Drill Assembly
Fig. 5-28 Rotation Housing with Bearing Plate Installed

14. Bearing Plate
Fig. 5-28a Checking Bearing Plate Installation–viewed from back of rotation housing.
14. Bearing Plate
8. When satisfied that the bearing plate is installed correctly, press in the chuck driver bushing (item
13, fig. 5-23) until it is flush with the bearing plate. You are now ready to assemble the chuck driver
components.
Drill Assembly 5-19

BI006823-00
Drill Assembly
6 15 17 16 46 17 7
29 22
45
8 9 13 10 11 13 12 14 5 18 48 47

5. Seal 11. Thrust Washer 17. Roller Bearing (2) 45. Vent Plug
6. Chuck End Cover 12. Shank Bushing 18. O-Ring 46. Grease Fitting
7. Rotation Housing 13. Chuck Driver Bushing (2) 22. Rotation Motor 47. Hexhead Plug
8. Thrust Plate 14. Bearing Plate 29. Seal 48. Vent Plug
9. Chuck 15. Wear Plate
10. Chuck Driver 16. Pinion Gear
9. Assemble the chuck driver components as follows: (refer to fig. 5-23 and following photo's).
A. Press shank bushing (12) into chuck driver (10).
B. Press thrust washer (11) into chuck driver with the chamfered surface facing shank splines.
C. Press chuck (9) into chuck driver. Check to see that the chuck is below the surface of
the chuck driver. A good way to do this is to lay a straight edge across the front sur-
face of the chuck driver and shine a flashlight from behind the straightedge, check to
see if you can see light under the straightedge (fig. 5-32).
5-20 Drill Assembly

BI006823-00
Drill Assembly
Chuck Driver–Assembly
Fig. 5-29 Chuck Driver Assembly Fig. 5-30 Chuck Driver Assembly
12. Shank Bushing 11. Thrust Washer
Fig. 5-31 Chuck Driver Assembly–Installing Chuck (9) Fig. 5-32 Chuck Driver Assembly–Check Chuck Instal-
lation
Drill Assembly 5-21

BI006823-00
Drill Assembly

10. Install pinion gear seal (65) with lip of seal facing in (fig.'s 5-23 & 5-33).
11. Apply a thin coat of Loctite® 518 sealant around the machined surface of the cylinder where the rota-
tion housing bolts to it (fig. 5-34). Use a hoist to position the rotation housing to mount to the cylinder
(fig. 5-35). Apply anti-seize compound to capscrew threads (fig. 5-36) and install the six 1-14 UNC
capscrews (34), spring washers (33) and locknuts (32), see fig. 5-37. Torque capscrews according to
specifications on page 5-3.
Fig. 5-33 Rotation Housing Fig. 5-35 Rotation Housing–positioned to mount to cyl-
65. Pinion Gear Shaft Seal inder
Fig. 5-36 Apply Anti-Seize compound to threads of cap-

screws.
Fig. 5-34 Apply Locktite® 518 to mounting surface of

cylinder.
5-22 Drill Assembly

BI006823-00
Drill Assembly

12. Coat inside of rotation housing and rotation cover with plenty of grease (fig. 5-38). Also, coat bearing
surfaces of pinion gear and chuck driver. Refer to grease specifications in Section 7.
13. Install chuck driver assembly with chuck facing forward. Carefully install pinion gear (16) with long
shaft (splined end) facing toward rotation motor, be careful not to damage seal (fig. 5-38).
Fig. 5-37 Rotation Housing Installation

32. Locknut (6)
33. Spring Washer (6)
34. Capscrew (6)
Fig. 5-38 Rotation Housing–grease well before installing Fig. 5-39 Rotation Housing–Install Pinion Gear after install
chuck driver and pinion gear. ing chuck driver.
16. Pinion Gear
Drill Assembly 5-23


14. Install rotation motor (22), using four 1/2-20 UNF sockethead capscrews (21) and four spring washers
(20). Torque capscrew according to specifications on page 5-3.
Fig. 5-40 Rotation Motor

20. Spring Washer (4) 22. Rotation Motor
15. Install chuck end cover (6) with the two 1/2-20 UNF capscrews (19) and spring washers (20). Torque
per specifications on page 5-3.
Fig. 5-41 Chuck End Cover Installation

6. Chuck End Cover 19. 1/2-20 UNF Capscrews (2)
7. Rotation Housing 20. Spring Washers (2)
5-24 Drill Assembly

BI006823-00
Drill Assembly
Shank Installation
If you are installing a new shank, be sure to remove the rust prevention coating on the
NOTE
bearing and seal surfaces, using steel wool or fine sandpaper (fig. 5-42). If this is not done,
the coating will build up on the seals, causing them to heat up and wear out rapidly.
16. Grease bearing surfaces and shank splines and install shank. Install thrust plate (8) over shank so it
rests against the chuck driver. The trust plate is the same on both sides and can be installed either
way. This completes the rotation housing assembly. You are now ready to assemble and install the
water swivel housing.
Fig. 5-42 Remove rust prevention coating from bearing Fig. 5-43 Grease bearing surfaces of shank.
surfaces of shank.
Fig. 5-44 Install Shank and Thrust Plate

8. Thrust Plate
Drill Assembly 5-25

Water Swivel–Assembly
3 2 1
REF. SHANK
71
3 4
5
Fig. 5-45 Water Swivel Assembly (ref. 407596)

1. Housing, Water Swivel 4. O-Ring
2. Bushing 5. Seal (3)
3. Roll Pin (2) 71. Rod Wipe
[Not shown in this view]
1. Install the three seals (5) as shown in fig. 5-45. This job is made easier with the use of the Seal Instal-
lation Tool No. V003878. If this tool is not available, you can use long nose pliers and fold the seal
into a "C" shape to install and then expand into seal groove as shown below.
Seal Installation:
2. Install o-ring (4) in bottom of water swivel housing bore before pressing in bushing. Grease the bush-
ing (2) before pressing into water swivel housing (fig. 5-46).
3. Install front wiper seal (71) and grease fitting (44) if it was removed previously.
4. Install roll pins (3), by driving in with a hammer and then use a punch to countersink below the surface
of the water swivel housing.
5-26 Drill Assembly

BI006823-00
Drill Assembly
Fig. 5-46 Water Swivel Bushing Installation

2. Bushing
5. Seal–lip of seal faces out.
Fig. 5-47 Water Swivel Bushing

Installing with a hydraulic press
Fig. 5-48 Water Swivel Housing - Installing Roll Pins

3. Roll Pin (2)
44. Grease Fitting 1/4 NPT
71. Wiper Seal
Drill Assembly 5-27

BI006823-00
Drill Assembly
Fig. 5-49 Water Swivel Housing Installation

1. Water Swivel Housing 31. Capscrew (4)
6. Chuck End Cover 32. Locknut (4)
5. Install water swivel housing assembly (1) to chuck end cover (6). Install the four 1-14 UNS capsrews,
eight spring washers (33) and four locknuts (32). Torque capscrews to specifications on page 5-3.
This completes the drill assembly. Be sure to charge the accumulators before putting the drill into ser-
vice. Do a final bolt torque check after drill is mounted on the feed.
5-28 Drill Assembly

BI006823-00
Section 6
Charging the Accumulators
Charging the Accumulators 6-1

BI006823-00
Fig. 6-1 Accumulator Charging Set-up

Charge/Check Gauge installed on low pressure accumulator.
Requirements
1. Nitrogen filled tank.
2. Pressure regulator with proper fittings to hook to nitrogen tank and receive charging hose.
3. Charging hose, with proper fittings, to connect to charging and checking gauges. Hose should be
long enough to reach drill and tank (approximately 6–8 ft).
4. One 300 PSI (20.7 bar) gauge assembly with proper fittings to connect to low pressure accumula-
tor valve and to the charging hose.
5. One 2000 PSI (138 bar) gauge assembly with proper fittings to connect to high pressure accumula-
tor valve and to the charging hose.
NOTE The fittings, gauges and hose are supplied with the Drill Charge Kit shown on page
6-6.
6-2 Charging the Accumulators

BI006823-00
Charging Procedure
NOTE BE SURE to charge both high pressure and low pressure accumulators.
The high pressure accumulator is charged to 30 - 40% of the supply pressure and the
low pressure accumulator is charged to 30 - 40% of the return pressure.
The 30% pressure is achieved with the drill cold prior to any drilling. The 40% pres-
sure is when the drill is at operating temperature of 140oF (60oC).
Measure the pressures during actual drilling conditions with drill hammer and rotation
on, feed on, compressor and dust collector on.
1. Connect pressure regulator to nitrogen tank and tighten.

2. Connect the 2000 PSI (138 bar) checking and charging gauge assembly to the high pressure ac-
cumulator. (The high pressure accumulator is located right side of the drill, viewed from rear.)
3. Connect charging hose to pressure regulator and tighten. If the regulator is not being used for any
other service, it is advisable to leave this connection intact permanently.
4. Connect the charging hose to the high pressure gauge assembly.
5. Check and make sure the valve on the pressure regulator is in the OFF position. The regulator
valve should be backed out.
6. Turn the handle on the nitrogen tank counterclockwise until the tank pressure is shown on the pres-
sure regulator gauge.
7. Open the accumulator valve on the high pressure accumulator, counterclockwise all the way until it
stops.
8. Turn the valve handle on the pressure regulator slowly clockwise until the 2,000 PSI (138 bar)
gauge on the checking and charging gauge assembly reads 30 - 40% of the hydraulic pressure at
the inlet port of the drill (the high pressure port is on the right side as viewed from the rear).
9. Close (clockwise) the accumulator valve on the high pressure accumulator until it is snug (10 ft.
lbs.).
10. Close off the nitrogen tank by turning the handle clockwise until it is tight. Back out the regulator
valve (counterclockwise).
11. Disconnect the charging hose and gauge assembly from the accumulator valve.
12. Charge the low pressure accumulator (located on the left side of the drill, viewed from rear), in the
same manner, using the 300 PSI (20.7 bar) charging and checking gauge assembly. The gauge
should read 30 - 40% of the hydraulic pressure at the return port of the drill.

Checking the Accumulator Charge Pressure BI006823-00
DO NOT remove accumulator covers from hydraulic drills before completely

bleeding off the gas charge in the accumulators.
The high and low pressure accumulators must be properly charged during machine setup and prior to
drilling the initial round. Check accumulator pressures only if excessive hose vibration or loss in penetra-
tion rate is noted.
The procedure for checking the high and low pressure accumulators is the same. However, use the
2,000 PSI (138 bar) checking and charging gauge for the high pressure accumulator. The high pressure
accumulator is located on the right side of the drill. Use the 300 PSI (20.7 bar) gauge for the low pressure
accumulator located on the left side of the drill (viewed from rear).
NOTE Some charge pressure is lost to the gauge during the checking process. To check for
a gas leak, brush soapy water on charge valves and accumulator covers.
To Check Charge Pressure

1. Connect the appropriate checking and charging gauge to the accumulator; use 2,000 PSI (138 bar)
gauge for the high pressure accumulator, use 300 PSI (20.7 bar) gauge for low pressure accumula-
tor.
2. Open the valve on the accumulator counterclockwise all the way until it stops.
3. Read accumulator charge pressure. Correct accumulator charge pressure is 30 - 40% of the
hydraulic pressure at the inlet port to the drill. The correct low pressure accumulator charge is 30
- 40% of the hydraulic pressure at the return port of the drill. Refer to graphs on next page for quick
reference. See note below.
NOTE Check pressures during actual drilling conditions, i.e. drill hammer and rotation on,
feed on, compressor and dust collector on.
4. Close the accumulator valve clockwise all the way until it stops. Tighten snugly (10 ft. lbs. max.).
5. Remove the test gauge and replace the accumulator valve safety caps.

BI006823-00
Checking the Accumulator Charge Pressure
SUPPLY (HIGH PRESSURE) ACCUMULATOR
3000
(206.9) •
DRILL OPERATING PRESSURE–PSI (BAR)
The graphs shown here are based

2500
(172.4) • on the following calculation:
Accumulator charge pressure =
.30 X operating pressure.
2000
(138) •
1500
(103.4) •
1000
(69) •
500
(34.5) •
150 300 450 600 750 900
(10.3) (20.7) (31) (41.4) (51.7) (62)
SUPPLY (HIGH) ACCUMULATOR CHARGE PRESSURE–PSI (BAR)
RETURN (LOW PRESSURE) ACCUMULATOR

280 (19.3)
260 (17.9)
DRILL RETURN PRESSURE–PSI (BAR)
240 (16.6)
•
220 (15.2) •
200 (13.8) •
180 (12.4) •
160 (11) •
140 (9.7)
•
120 (8.3)
•
100 (6.9)
•
80 (5.5)
•
60 (4.1)
•
40 (2.8)
•
20 (1.4)
•
0
0 6 12 18 24 30 36 42 48 54 60 66 72 PSI
(0.4) (0.8) (1.2) (1.7) (2.1) (2.5) (2.9) (3.3) (3.7) (4.1) (4.6) (5) (BAR)
RETURN (LOW) ACCUMULATOR CHARGE PRESSURE–PSI (BAR)

Accumulator Charge Kit BI006823-00
9 11 13
5
8
ALL COMPONENTS TO BE ASSEMBLED

USING LOCTITE "PST" PIPE SEALANT
OR EQUIVALENT.
9 12 5
5
8
Fig. 6-2 1HPR781X (316120) Charge Kit–includes all item listed below
ITEM QTY PART NO. DESCRIPTION

1* 1 318150 FILLER, FOAM
2* 1 318148 CASE, KIT
3* 1 318147 INSTRUCTION SHEET
4 1 317961 ASSEMBLY, HOSE
5 3 317959 CONNECTOR, SWIVEL
(one per gauge, one on hose)
6 2 317958 VALVE, BLEEDER
7 2 317947 VALVE ASSEMBLY, TANK
8 2 317943 ADAPTER, SPECIAL
9 2 353906 NIPPLE, PIPE
10 * 1 317846 BOTTLE, NITROGEN
11 1 317845 GAUGE, PRESSURE, 0–300 PSI
12 1 317844 GAUGE, PRESSURE, 0–2000 PSI
13 1 317783 REGULATOR, PRESSURE
* NOT SHOWN

BI006823-00
Section 7
Specifications
Specifications 7-1
Hydraulic Oils for Percussion Drills BI006823-00
In general, oils recommended or approved by hydraulic pump manufacturers are suitable for operat-
ing hydraulic percussion drills. Optimum viscosity in a temperature stabilized system is 150 to 300 SUS
(extended range is 500 SUS) for continuous operation.
The following oils meet the requirements:
ISO EQUIVALENT OIL TYPE OPTIMUM RANGE EXTENDED RANGE

ISO 150/220 Mobil DTE 19M Between 175oF and 135oF 115oF (46.14oC)
(79.4oC and 57.2oC)
ISO 100 Mobil DTE 18M Between 145oF and 115oF 100oF (37.8oC)
(62.7oC and 46.1oC)
(43.3oC and 26.7oC)
If stabilized system temperatures have not been established, the oil can be selected based on antici-
pated ambient temperature range.
AMBIENT OPERATING OIL SELECTION ISO EQUIVALENT

TEMPERATURE
90oF (32.2oC) or higher DTE 19M or equivalent ISO 150/220
32oF to 90oF (0oC to 32.2oC) DTE 18M or equivalent ISO 100
–20oF to 32oF (–28.9oC to 0oC) DTE 15M or equivalent ISO 46
Under –20oF (–28.9oC) Consult Factory
These selections assume "normal operating conditions" as expected in quarry or quarry-like opera-
tions. Pioneering and secondary drilling normally result in a lower than average operating temperature;
the necessity to drill out of the hole to remove stuck steel, as found in badly broken ground, will result in
higher than normal operating temperatures.
NOTE Since the determining factor for safe and efficient operation is the viscosity of the oil,
final selection for the oil (or changing the oil) should be based on the stabilized oil
temperature in your specific drilling application.
In addition to the viscosity at stabilized oil temperature, we also have to consider viscosity at start-up
conditions.
Limitations are cavitation of the pumps and sluggish controls, and extended warm-up periods that
may be required to avoid pump cavitation and to provide adequate control. Oils with high viscosity index
(above 120) are better able to cover a wide range of temperatures. Oils with lower viscosity index may
need more frequent change of oil based on ambient temperature or may require an oil heater to improve
start-up conditions
In general, cold starts may be made at a temperature of at least 30oF (16.9oC) warmer than the pour
point of the fluid. All cold starts should be made at low pressure, low flow, and low speed.
7-2 Specifications
BI006823-00
Hydraulic Drill Rotation Unit Lubrication
Grease Lubrication with a Hand Grease Gun

Every drill has a primary and one or more secondary lubrication points. The primary lubrication point is
the one lubricating the thrust plate and the shank splines. Secondary lubrication points are for pinion bear-
ings and swivel bearings. For best performance and reliability, use only high pressure, high temperature
grease such as:
PG55–Part No. 312810 (14 oz. tube)

Petro Canada Supreme EP2
BP/Sohio Super Bearing Guard EP2
Primrose 327 Armor Plate with Moly-D
Frequency
At the beginning of each shift, fill rotation cavity with grease until grease comes out of the grease relief
or grease gun gets tight. Then, lubricate every 2 hours with 5 to 8 "shots" out of a hand grease gun.
Grease Specifications
Depending on the problems encountered in specific applications, the grease specification of different
manufacturers should be compared.
Drop Point ASTM D2265; Preferably 500o F (260o C) or higher.

Load Carrying Ability
Timken test ASTM D2509; Preferably 50 LBS (22.7 Kg) or higher.
4-Ball EP Test ASTM D2596; Preferably 440 LBS (200 Kg) or higher.
Water Washout ASTM D1264; Preferably 1% or lower.
Specifications 7-3
HPR4519 Wear Tolerances BI006823-00
MAXIMUM WEAR
PART NUMBER DESCRIPTION DIMENSION (REPLACE)
406758 Chuck Internal splines worn to a point
406710 Chuck Driver Bushing I.D. : 6.020 in. (152.9 mm) max. (uninstalled)
I.D. : 6.014 in. (152.8 mm) max. (installed)
406755 Shank Bushing I.D.: 1.770 in. (45 mm) max.
406759 Thrust Washer Thrust face worn 0.040 in. (1 mm) max.
406818 Thrust Plate Plate Width 0.700 in. (17.8 mm) min.
0.020 in. (0.51 mm) max. wear on chamfer
Plate can be turned over and re-used until center is
peaked.
406756 Bearing Plate Plate width 1.020 in. (25.9 mm) min.
406789 Water Swivel Bushing I.D.: 1.775 in. (45 mm) max.
414965 Front Cylinder Bushing I.D.: 2.0035 in. (50.9 mm) max.
414966 Rear Cylinder Bushing I.D.: 1.7525 in. (44.5 mm) max.
406862 Hammer 0.040 in. (1 mm) max. wear on hammer face
0.003 in. (0.08 mm) max. wear on seal track area
NOTE A good rule of thumb: Add 0.001 in. (0.03 mm) for every 1 in. (25.4 mm) diameter for
press fit parts.
Drawings are not to scale.
SPLINES MAY BE
WORN TO A POINT
6.020”
(152.91 mm)
MAX DIAMETER
CHUCK–406758
CHUCK DRIVER BUSHING–406710

Uninstalled dimension shown
6.014 in. (152.8 mm) max. installed
7-4 Specifications
BI006823-00
HPR4519 Wear Tolerances
1.770” DIA
(45 mm)
SHANK BUSHING–406755
MAX WEAR ON 1.785

DIA
THIS FACE 1.790
.040” (1.02 mm)
1.000
0.999
THRUST WASHER–406759
Specifications 7-5
BI006823-00
.700”
(17.78 mm)
MIN
MAX WEAR ON
EACH FACE
.020” (.51 mm)
REPLACE WHEN
CENTER COMES
TO A PEAK
THRUST PLATE–406818
1.020”
(25.91 mm)
MIN
BEARING PLATE–406756
7-6 Specifications
BI006823-00
1.775”
(45.09 mm)
MAX
DIAMETER
WATER SWIVEL BUSHING–406789
2.0035”
(50.89 mm)
MAX
DIAMETER
FRONT CYLINDER BUSHING–414965
Specifications 7-7
BI006823-00
Notes
7-8 Specifications
BI006823-00
1.7525”
(44.51 mm)
MAX
DIAMETER
REAR CYLINDER BUSHING–414966
.040” (1 mm) MAX WEAR ON FACE

DO NOT GRIND FACE
CHECK FOR CRACKS CHECK SEAL TRACK AREA FOR WEAR
MAX .003 (.08 mm) ON DIAMETER
9.335” MIN
(237.11 mm)
HAMMER–406862
Specifications 7-9
MAXIMUM WEAR
PART NUMBER DESCRIPTION DIMENSION (REPLACE)
406717 Chuck Internal splines worn to a point
406710 Chuck Driver Bushing I.D. : 6.020 in. (152.9 mm) max. (uninstalled)
I.D. : 6.014 in. (152.8 mm) max. (installed)
406712 Shank Bushing I.D.: 2.020 in. (51.31 mm) max.
406719 Thrust Washer Thrust face worn 0.040 in. (1 mm) max.
406819 Thrust Plate Plate Width 0.700 in. (17.8 mm) min.
0.020 in. (0.51 mm) max. wear on chamfer
Plate can be turned over and re-used until center is
peaked.
406714 Bearing Plate Plate width 1.020 in. (25.9 mm) min.
406790 Water Swivel Bushing I.D.: 2.030 in. (51.56 mm) max.
406520 Front Cylinder Bushing I.D.: 2.2535 in. (57.24 mm) max.
406521 Rear Cylinder Bushing I.D.: 1.9400 in. (49.28 mm) max.
406552 Hammer 0.040 in. (1 mm) max. wear on hammer face
0.003 in. (0.08 mm) max. wear on seal track area
NOTE A good rule of thumb: Add 0.001 in. (0.03 mm) for every 1 in. (25.4 mm) diameter for
press fit parts.
Drawings are not to scale.
SPLINES MAY BE
WORN TO A POINT
6.020”
(152.91 mm)
MAX DIAMETER
CHUCK–406717
CHUCK DRIVER BUSHING–406710

Uninstalled dimension shown
6.014 in. (152.8 mm) max. installed
7-10 Specifications
BI006823-00
2.020” MAX
(51.31 mm)
SHANK BUSHING–406712
MAX WEAR ON
THIS FACE 2.035
DIA
.040” 2.040
(1.02 mm)
1.000
0.999
THRUST WASHER–406719
Specifications 7-11
.700 (17.78 mm)

MIN
MAX WEAR ON
EACH FACE
.020” (51 mm)
REPLACE WHEN
CENTER COMES
TO A PEAK
THRUST PLATE–406819
1.020” (25.9 mm)

MIN
BEARING PLATE–406714
7-12 Specifications
BI006823-00
2.030” MAX
(51.56 mm)
WATER SWIVEL BUSHING–406790
2.2535” MAX
(57.24 mm)
FRONT CYLINDER BUSHING–406520
Specifications 7-13
1.9400” MAX
(49.28 mm)
REAR CYLINDER BUSHING–406521
9.335” (237.11 mm)

MIN LENGTH
.040” (1 mm) MAX WEAR ON FACE CHECK SEAL TRACK AREA FOR WEAR
DO NOT GRIND FACE MAX .003” (.08 mm) ON DIAMETER
CHECKS FOR CRACKS
HAMMER–406522
7-14 Specifications
BI006823-00
Maintenance Record
WORK WORK
DATE HOUR METER MAINTENANCE PERFORMED PERFORMED AUTHORIZED
BY BY
Specifications 7-15
Maintenance Record BI006823-00
WORK WORK
BY BY
7-16 Specifications
BI006823-00
Maintenance Record
WORK WORK
BY BY
Specifications 7-17
BI006823-00
Maintenance Record
WORK WORK
BY BY
7-18 Specifications
BI006823-00
Section 10
Lubrication and
Maintenance
BEFORE attempting to operate or service this machine, read and understand the warn-
ings and cautions listed in Section 1.
Lubrication and Maintenance 10-1

BI006823-00
Notes
10-2 Lubrication and Maintenance

BI006823-00
Hydraulic Oils for Percussion Drills
In general, oils recommended or approved by hydraulic pump manufacturers are suitable for operat-
ing hydraulic percussion drills. Optimum viscosity in a temperature stabilized system is 150 to 300 SUS
(extended range is 500 SUS) for continuous operation.
The following oils meet the requirements:
ISO EQUIVALENT OIL TYPE OPTIMUM RANGE EXTENDED RANGE

ISO 150/220 Mobil DTE 19M Between 175oF and 135oF 115oF (46.14oC)
(79.4oC and 57.2oC)
(62.7oC and 46.1oC)
(43.3oC and 26.7oC)
If stabilized system temperatures have not been established, the oil can be selected based on antici-
pated ambient temperature range.
AMBIENT OPERATING OIL SELECTION ISO EQUIVALENT

TEMPERATURE
90 F (32.2oC) or higher
o DTE 19M or equivalent ISO 150/220
32oF to 90oF (0oC to 32.2oC) DTE 18M or equivalent ISO 100
–20oF to 32oF (–28.9oC to 0oC) DTE 15M or equivalent ISO 46
Under –20oF (–28.9oC) Consult Factory
These selections assume "normal operating conditions" as expected in quarry or quarry-like opera-
tions. Pioneering and secondary drilling normally result in a lower than average operating temperature; the
necessity to drill out of the hole to remove stuck steel, as found in badly broken ground, will result in higher
than normal operating temperatures.
NOTE Since the determining factor for safe and efficient operation is the viscosity of the
oil, final selection for the oil (or changing the oil) should be based on the stabilized
oil temperature in your specific drilling application.
In addition to the viscosity at stabilized oil temperature, we also have to consider viscosity at start-up
conditions.
Limitations are cavitation of the pumps and sluggish controls, and extended warm-up periods that
may be required to avoid pump cavitation and to provide adequate control. Oils with high viscosity index
(above 120) are better able to cover a wide range of temperatures. Oils with lower viscosity index may
need more frequent change of oil based on ambient temperature or may require an oil heater to improve
start-up conditions
In general, cold starts may be made at a temperature of at least 30oF (16.9oC) warmer than the pour
point of the fluid. All cold starts should be made at low pressure, low flow, and low speed.

BI006823-00
Lubrication and Inspection
Recommended Engine Oils

The following oils are recommended by Caterpillar:
• Caterpillar Diesel Engine Oil (DEO) 10W-30 - preferred
• Caterpillar Diesel Engine Oil (DEO) 15W-40 - preferred
• API CH-4 multigrade oil - acceptable
• API CI-4 multigrade oil - acceptable
• API CG-4 multigrade oil - acceptable
Lubricant Viscosities for Ambient Temperatures

o o
Oil Viscosity Min F Max Min C Max
SAE 0W-20 -40 50 -40 10
SAE 0W-30 -40 86 -40 30
SAE 0W-40 -40 104 -40 40
SAE 5W-30 -22 86 -30 30
SAE 5W-40 -22 122 -30 50
SAE 10W-30* 0 104 -18 40
SAE 10W-40 0 122 -18 50
SAE 15W-40 15 122 -9.5 50
* SAE 10W-30 is the preferred viscosity grade when the ambient
temperature is above 0oF (-18oC) and below 104oF (40oC)
NOTE Since the determining factor for safe and efficient operating is the viscosity of the oil,
final selection for the oil (or changing of the oil) should be based on the stabilized oil
temperature in your specific drilling application.
To avoid unnecessary machine repairs, keep the following in mind when handling fuel and lubricants:
• Clean grease fittings with a clean cloth before greasing.
• Keep all fuels and lubricants stored in clean and tightly sealed containers.
• Keep filler caps clean of dust and oil.
• Replace filters inside a shop or when no dust is in the air.
• Never reuse paper filters.
• Wash metal parts of filters with clean oil. Do not wipe the parts with a cloth.
• Keep dirt and dust from entering any fluid system.
• Keep the fuel storage containers and system filled.
• Watch for metal filings on any magnetic drain plugs. Filings are a sign of internal component wear
or misadjustment. If the source can be determined and repaired as a part of scheduled mainte-
nance, costly down time can be avoided later.
• Ensure that clean fuel of correct grade for winter/summer is used.

BI006823-00
General Hydraulic System

The hydraulic system is filled at the factory with Chevron AW MV ISO 100. Any other oils used, must
meet the specifications listed on page 10-3.
Diesel fuel or kerosene used as dilutants for cold weather operation are not recommended, as they are
not sufficiently refined products.
Do not use any fire resistant fluids or non-petroleum oils without consulting the manufacturer.
Keeping the hydraulic oil clean is by far the most effective method to help provide long hydraulic system
component life with minimum downtime.
Adding hydraulic oil to the tank is one source of contamination. Insure the oil added is clean, and do
not let any dirt or water fall into the fill spout, etc. when adding oil.
The second, and larger cause of contamination is can occur any time hydraulic fittings or hoses are
disconnected. Never leave any open path for contamination to get into the oil. Always cap and plug any
open fittings, hoses, etc., with clean fittings.
Daily Operational Checklist

In addition to the daily scheduled maintenance listed in the Maintenance Schedule, several mechanical
checks should be added to ensure long, safe and trouble-free operation.
Each day the minimum items to be checked include:
• All daily interval hours checkpoint items.

• Check underside. Look for broken or loose hoses. If dripping fuel, hydraulic oil or coolant is evident,
do not continue until leak is found and corrected.
• Check that tracks are tensioned properly. Clear any rocks, mud or snow from tracks to prevent
overtensioning or other damage.
• Check for clean, tight battery connections. Check that the battery is fully charged. With the ignition
switch in the ON position, the battery voltage reading should indicate 24–25 volts. When the engine
is running, the voltage should increase slightly to indicate alternator charging.
• Look for loose or missing bolts. Replace all missing bolts and tighten loose bolts. Tighten bolts per
torque specification in this section unless otherwise stated in the Parts List.
• Lubricate chuck end of drill every 2 to 3 hours during drilling.
• Look for excessive play due to worn wear pads on the boom, drill and feed.
• Check fill caps, tank covers and dipstick. They should be in place and seated properly.
• Check the engine intake and exhaust clamps, be sure they are tight to prevent damage to the tur-
bocharger.
• Check the radiator coolant level by oscillating machine forward and removing radiator cap. Do not
remove if engine is hot.
• Drain water from fuel/water separator.

BI006823-00
BE SURE all bolts are tight and not damaged. Pay particular attention to critical areas,
such as; feed mounting, boom pivot, boom mounting, drill mounting slide or any areas
where loose bolts could cause a component to fall and cause injury.
Bolt Maintenance
Check torque on bolts after first 50 hours of machine operation. Retorque any bolts that are less than
the specified value as listed in the Bolt Torque Specifications sheet at the end of this section or as specified
on the assembly drawing. Pay particular attention to critical mounting areas, such as; feed mounting, boom
pivot, boom mounting, drill mounting slide, or any areas where loose bolts could cause a component to fall
and cause injury or machine damage. Refer to drill service manual for bolt maintenance on drill.
Periodically inspect bolts for damage and replace as necessary. Check torque and retorque as re-
quired.
Safety Sign Maintenance

Replace any missing or damaged safety signs. Keep operator safety in mind at all times. Use mild
soap and water to clean safety signs. Do not use solvent-based cleaners as they may damage the safety
sign material.
Refer to Section 1 for safety sign locations on the machine.
Hydraulic Drill Accumulator Charge Pressure–Check Monthly

• The drills used on the machine are the HPR4519 and the optional HPR5123. Some machines are
equipped with the HPR1H-ATW drill.
• The drill accumulator's must be charged with dry nitrogen before drilling.
• Check accumulator charge pressure monthly. Each time charge pressure is checked, a little charge
pressure is lost, therefore don't check any more than necessary.
• If drill hoses vibrate excessively, this is an indication that charge pressure is low, and must be
checked and recharged.
• Refer to Service Manual Drill Section for correct procedure for checking and charging accumula-
tors. Or, refer to Charging Instructions that comes with Drill Charge Kit.

BI006823-00
Maintenance Schedule
Interval
Hours Service Points Service or Maintenance Lubricant Capacity
Every Drill Chuck End Lubricate and Inspect PG55 Grease, P/N 312810
2 Hours (see Drill Service Manual) 14 oz. tube
Engine Oil Check Level - Refill as required *SAE 15W-40 32 Qt. / 30 L
Caterpillar C9 See "Recommended Engine Oils"
in this section.
Engine Coolant Check Level - Refill as required Water/Permanent Anti-Freeze 12 Gal./ 45.4 L
50:50 Ratio
Every Engine Fuel/Water Separator Check. Drain if required
10 Hours Hydraulic Oil Check Level - Refill as required Chevron AW MV ISO 100 *107 Gal. / 405 L
or
Air Compressor Oil Check Level - Refill as required *Chevron ATF 7 Gal./ 26.5 L
Daily
Engine Air Filter Check - Clean or Change if required
Air Compressor Air Filter Check - Clean or Change if required
Hydraulic Oil Filters Check Indicators - Change if re-
quired
Radiator / Oil Cooler Check - Clean if required
Case Drain Filter Initial Change at 24 hours, thereafter every 500 hours
Batteries Check Level - Refill as required
Track Chain Tension Check and Adjust as required NLGI No. 2 Grease
Drill Slide Wear Pads Check and Adjust as required
Every
Feed Table Wear Pads Check and Adjust as required
50
Feed Table Pivot Pin Check End Play (0.005 in. max.) Torque Retaining Cap Bolts to 282 ft. lbs. (384 Nm)
Service
Dust Collector Filters Check - Replace as required P/N 419090
Hours
Detergent "Y" Strainer Check - Clean as required
Track Drive Gearcase Oil Check Level - Refill as required *HD 80W-90 Gear Oil 4.8 Qts./ 4.5 L
Engine Oil Drain Oil and Replace *15W-40 32 Qt./ 30 L
Engine Oil Filter Replace P/N V012941
Engine Fuel Filter Replace P/N V001775
Engine Belts / AC Belts Check and Adjust
Every Fuel Tank Drain Water and Sediment
250 Engine Coolant Conditioner Replace P/N 1405131 2 Qts. / 1.9 L
Service Feed Motor Gearcase Check Level, Refill as required *HD 80W-90 Gear Oil 17 Oz. / 503 ml
Hours Track Drive Gearcase Oil Initial Change, then every 1500 *HD 80W-90 Gear Oil 4.8 Qts./ 4.5 L
hours
Compressor Air Receiver Pres- Check and Adjust
sure
Dust Collector Air Filters Replace P/N 419090
Canopy Hinges Lubricate SAE 30 wt Oil
Hydraulic Rock Drill Check for loose bolts
Engine Air Filter Replace P/N 1156422 (P), 1156421 (S)
Compressor Air Filter Replace P/N 1157641 (P), 1405631 (S)
Every Compressor Oil Drain Oil and Replace *Chevron ATF 7 Gal. / 26.5 L
500 Compressor Oil Filter Replace P/N 1157245
Service Hydraulic Oil Filters Replace P/N 99703
Hours Case Drain Filter Replace P/N 1157245
Feed Table Bushing Check and Replace (if necessary)
Every 1200 Engine Fuel/Water Separator Drain and Replace P/N V007584
Service Hours Fan Hub Inspect
Every 1500 Track Drive Gear Case Oil Drain Oil, Flush and Replace *HD 80W-90 Gear Oil 4.8 Qts./4.5 L
Service Hours Every 12 months
Engine Coolant Replace Water/Permanent Anti-freeze 50:50 12 Gal. / 45.4 L
Every ratio
2400 Hydraulic Oil Drain and Replace *Chevron AW MV ISO 100 107 Gal. / 405 L
Service Compressor Oil Separator Replace
Hours Element
Feed Gear Case Oil Drain and Replace *HD 80W-90 Gear Oil 17 Oz./503 ml
* Normal Factory Fill

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Grease Points
Service Location Lube Points Frequency Notes
Hydraulic Rock Drill 4 Every 2 hours PG55 grease
Centralizer 4 Daily * 2 cylinder clevis
Feed Chain Sprockets 2 Daily * 1 upper, 1 lower
Feed Drive Sprocket 2 Daily *
Positioner 4 Daily *
Boom Pivot 3 Daily * attaches to mainframe
Boom Swing Cylinder 3 Daily * 2 clevis, 1 pivot pin
Boom Lift Cylinder 2 Daily * each clevis
Feed Swing Cylinder 2 Daily * each clevis
Feed Extend Cylinder 2 Daily * each clevis
Feed Dump Cylinder 3 Daily * 2 mounting blocks, 1 clevis
Rod Wrench 5 Daily * 3 wrench, 2 cylinder clevis
Rod Rack Driveline 6 Daily * 3 couplings, 3 bearings ( 1 ea. lower,

middle, upper)
Lower Rod Rack 5 Daily * 4 rollers, 1 rod lock pin
Upper Rod Rack 5 Daily * 4 rollers, 1 rod lock pin
Hose Reel 1 Monthly PG55 grease or equivalent
Mainframe Lube 10 Weekly * See Fig. 10-1
Dust Collector Swing Pin 2 Bi-Monthly *
Engine Fan Drive Bearing 1 250 hours or Special Purpose Grease (SPG)
6 months See Fig. 10-2
* NLGI No. 2 Grease

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Grease Points
Fig. 10-1 Mainframe Lube Points (Viewed from Front of Machine)

Right Track Left Track
1. Oscillation Cylinder Top 6. Oscillation Cylinder Top
2. Oscillation Cylinder Bottom 7. Oscillation Cylinder Bottom
3. Inner Frame Track Pivot 8. Inner Frame Track Pivot
4. Middle Frame Track Pivot 9. Middle Frame Track Pivot
5. Outer Frame Track Pivot 10. Outer Frame Track Pivot
Fig. 10-2 Engine Fan Drive Bearing Lube Fitting

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Engine Oil Filter
BEFORE attempting to operate or service this machine, read and understand the
warnings and cautions listed in Section 1.
SHUT DOWN machine and relieve pressure before attempting lubrication or service.
AVOID prolonged and repeated skin contact with used engine oil. Prolonged and
repeated contact with used oil can cause serious bodily injury. Use only authorized
waste disposal facilities to dispose of used engine oil and other lubricants.
The engine oil filter (fig. 10-3) is the spin-on type. To replace:
1. Shutdown engine and clean area around filters.
2. Spin off and properly discard used oil filter (1). Use caution to avoid burns from hot oil. Clean
mounting base and be sure old gasket is not stuck to base.
3. Lubricate the gasket on the new filter with engine oil. Spin on the new filter, tighten 3/4 of a turn
further after the filter gasket makes contact with filter base.
4. Add oil through fill tube (2). Check oil level with dipstick (3).
Fig. 10-3 Rear View of Machine

1. Oil Filter
2. Oil Fill Tube
3. Oil Dipstick

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Engine Fuel Filter
The engine fuel filter (fig. 10-4) is a spin-on filter located on the right side of the engine. To replace:
1. Shutdown engine, clean area around the filter, flange.
2. Spin off and discard the old filter (1) and rubber gasket. Clean mounting base and be sure old gas-
ket is not stuck to base.
3. Lubricate the filter gasket with clean diesel fuel, or oil.
4. Spin on a new filter, tightening 3/4 turn after the gasket has contacted the base.
5. If necessary, open the fuel priming pump valve (2) by unscrewing the handle and then pump to
prime the system. Screw handle back on tight.
Fuel/Water Separator
Drain water from fuel water separator daily (fig. 10-5).

3. Fuel/Water Separator

1. Fuel Filter
2. Fuel Priming Pump
3. Fuel/Water Separator

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Engine Air Cleaner Filter
DO NOT clean the safety element. The safety element should be replaced once a year
or sooner, if required.
The engine air cleaner should be cleaned when the service indicator (fig. 10-7) indicates the filter is
clogged (check daily or every 10 hours). There is a service window on the indicator that will gradually turn
red as the filter restriction increases to a maximum of 30" of H20. After cleaning the filter, reset the service
window to green by pressing the rubber diaphragm on top of the service indicator.
To replace or clean the engine air cleaner filter:

1. Shutdown the machine.
2. Undo the clamps and remove the filter cover.
3. The primary and safety element are a press fit inside the housing. Carefully move the primary ele-
ment from side to side and slide the element from the air cleaner housing to avoid dislodging dust
from element when removing. Be careful not to knock the element against the side of the housing.
Check condition of element, if you see a streak of dust on the clean air side, it is an indication of a
poor seal. Check seal area of housing for foreign material or damage.
4. Remove safety element in the same manner.
5. Clean the inside of the housing and vacuator valve with a clean cloth.
6. Clean the primary element (up to 6 times) with water, household detergent or compressed air. Do not
use more than 40 PSI (2.8 bar) water or 90 PSI (6.2 bar) air.
7. Install new safety element (if need be) and primary element. Push all the way in and be sure the ele-
ments are seated against the back of the housing. Install cover and secure with clamps.
Fig. 10-7 Engine Air Filter Indicator
Fig. 10-6 Right Rear of Machine

1. Engine Air Cleaner Filter
2. Dust Collector

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Compressor Air Cleaner Filter
DO NOT clean the safety element. The safety element should be replaced once a year
or sooner, if required.
Check filter daily or every 10 hours. To replace the compressor air cleaner filter:
1. Shutdown the machine.
2. Loosen the wingnut and remove the filter cover. Clean inside of filter cover with a clean cloth.
3. Unscrew the wing nut and carefully slide the primary element from the air cleaner housing to avoid
dislodging dust from element when removing. Be careful not to knock the element against the side
of the housing. Check condition of element, if you see a streak of dust on the clean air side, it is an
indication of a poor seal. Check housing for foreign material or damage.
4. Clean the inside of the housing with a clean cloth.
5. Install safety element (if removed) and primary element and secure with wingnuts. Reinstall filter
cover.
Fig. 10-8 Compressor Air Filter
Fig. 10-9 View From Front of Machine

1. Filter Cover
2. Dust Collector

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Compressor Oil Filter
BEFORE attempting to operate or service this machine, read and understand the warn-
ings and cautions listed in Section 1.
SHUTDOWN machine and relieve pressure before attempting lubrication or service.
Allow compressor to cool down and stabilize at least 5 minutes before starting any
work.
Use recommended oil type only; do not mix different oils.

Dispose of waste oil according to local regulations regarding handling of waste oil.
1. Remove filter element with filter wrench. Have a cloth handy to catch any oil that may drain from
filter. Clean mounting base and be sure old filter gasket is not stuck to base.
2. Lubricate sealing ring on new filter element with clean oil.
3. Screw on new filter element and tighten by hand only.
4. Check oil level in Air Receiver Tank (fig. 10-11).
5. Add oil as required through filler neck (fig. 10-10). Normal factory fill is Chevron ATF.
Fig. 10-10 Compressor Oil Filter Fig. 10-11 Air Receiver Tank Sight Gauge
1. Oil Filter (Check Daily)
2. Oil Filler Neck
3. Air Receiver Tank

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Hydraulic Fluid Fill Pump and Filter
RELIEVE all pressure before attempting service or maintenance procedures to this

machine.
DO NOT attempt any service or maintenance procedures while the machine is running.
To Add Hydraulic Fluid
1. Shutdown the engine and wait for pressure to relieve.

2. Be sure to use correct type of fluid. Refer to maintenance chart in this section or machine mainte-
nance records for correct oil type. Do not mix different oil types. Always store oil in clean contain-
ers.
3. Clean any dirt from around oil container opening and fill pump connection (3). Connect pump hose
to hydraulic oil container.
4. Pump handle to draw oil out. Oil passes through filter (1) before going into tank. Fill to proper level
on tank gauge (4).
5. Start the engine and bring the system to full pressure. Recheck fluid level on gauge. If more fluid
needs to be added, shut down machine and add more oil.
6. Check oil level daily. Change filter annually.
Fig. 10-12 Right Rear View of Hydraulic Tank

1. Hydraulic Oil Filter
2. Oil Fill Pump
3. Oil Inlet
4. Oil Level and Temperature Gauge

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Hydraulic Return Filter Indicators
If indicator ring is in the Bypass (orange) zone, DO NOT OPERATE MACHINE until
filter(s) is changed.
There are two (2) hydraulic filter indicators located

on the hydraulic oil return filter housings (fig. 10-13).
Both indicators should be checked daily.
Normal operation is the indicator ring in the Clean

(green) zone. If the indicator ring (fig. 10-14) falls into
the Change (yellow) zone, the filter(s) must be changed.
Otherwise, replace the filters at 500 hours.
Fig. 10-13 Top of Hydraulic Tank

1. Hydraulic Oil Return Filters
2. Filter Indicators
Fig. 10-14 Hydraulic Oil Indicator Zones

BI006823-00
Coolant System
DO NOT check coolant level when coolant is hot.
KEEP AWAY from rotating fan and belts.
DO NOT wear jewelry or loose fitting clothing when working around machinery.
Check the radiator, hydraulic oil and compressor

oil coolers (fig. 10-15) daily. Clean out any accumula-
tion of dirt, leaves and other debris that would block air
flow through the coolers and cause overheating of the
engine.
Check coolant level through sight glass (fig. 10-16)

daily. Add 50/50 mix of water/anti-freeze to shunt tank to
proper level if required.
Fig. 10-15 Left Rear View of Machine

1. Radiator/Oil Coolers
2. Radiator Shunt Tank
Fig. 10-16 Radiator Shunt Tank

1. Shunt Tank
2. Coolant Sight Glass
3. Radiator Cap/Coolant Fill Neck

BI006823-00
Bolt Torque Specifications
Procedure No. 1-87 REVISION A
Torque Values: Bolts, Screws and Studs (Lubricated or Plated)
Tolerance Values in all cases to +5 % –0 % of the Value listed below.
Note: K = 0.15 for plated or lubricated fasteners.
Nominal SAE Grade 5 ASTM A-449 SAE Grade 8
Diameter Tightening Torque Ft. Lbs. Tightening Torque Ft. Lbs.
(Nm) Newton meter (Nm) Newton meter
1/4 6 (8.2) 9 (12.2)
5/16 13 (17.7) 18 (24.5)
3/8 23 (31.3) 33 (44.9)
7/16 35 (47.6) 55 (74.8)
1/2 57 (77.5) 80 (108.8)
9/16 82 (111.5) 115 (156.4)
5/8 113 (153.7) 159 (216.2)
3/4 200 (272) 282 (383.5)
7/8 322 (437.9) 455 (618.8)
1 also UNS 483 (656.9) 681 (926.2)
UNC 1-1/8 596 (810.6) 966 (1313.8)
1-1/4 840 (1142.4) 1363 (1853.7)
1-3/8 1102 (1498.7) 1786 (2429)
1-1/2 1462 (1988.3) 2371 (3224.6)
1-3/4 1714 (2331)
2 2576 (3503.4)
2-1/4 3768 (5124.5)
2-1/2 5155 (7010.8)
2-3/4 6996 (9514.6)
3 9231 (12554.2)
1/4 7 (9.5) 10 (13.6)
5/16 14 (19) 20 (27.2)
3/8 26 (35.4) 37 (50.3)
7/16 40 (54.4) 60 (81.6)
1/2 64 (87) 90 (122.4)
9/16 91 (123.8) 128 (174.1)
5/8 127 (172.7) 180 (244.8)
UNF 3/4 223 (303.3) 315 (428.4)
7/8 355 (482.8) 502 (682.7)
1 528 (718.1) 746 (1014.6)
1-1/8 668 (908.5) 1083 (1472.9)
1-1/4 930 (1264.8) 1509 (2052.2)
1-3/8 1254 (1705.4) 2034 (2766.2)
1-1/2 1645 (2237.2) 2668 (3628.5)
1-3/4 1879 (2555.4)
2 2857 (3885.5)
UN 2-1/4 4127 (5612.7)
2-1/2 5726 (7787.4)
2-3/4 7693 (10462.5)
3 10064 (13687)

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Maintenance Record
WORK WORK
BY BY

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Maintenance Record
WORK WORK
BY BY

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Maintenance Record
WORK WORK
BY BY

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Maintenance Record
WORK WORK
BY BY

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Maintenance Record
WORK WORK
BY BY

BI006823-00
Maintenance Record
WORK WORK
BY BY

© 2012 Caterpillar All Rights Reserved. CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow,”
the “Power Edge” trade dress as well as corporate and product identity used herein, are trademarks of
Caterpillar and may not be used without permission.
Printed in U.S.A.

MD5075 Hydraulic Track Drill Service Manual

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Product and Dealer Information

Product Identification Number

Engine Model/Serial Number

Compressor Model/Serial Number

Undercarriage Model/Serial Number

Rotary Drive Model/Serial Number

Pump Drive Model/Serial Number

Rock Drill Model/Serial Number

Customer Equipment Number

Dealer Equipment Number

Dealer Contact Phone Number Hours

Caterpillar Global Mining LLC

Technical Parts Support + 1.903.415.4021

MAINFRAME AND TRACKS .....................................................................................SECTION 2

POWER TRAIN ..........................................................................................................SECTION 3

HYDRAULIC AND ELECTRICAL SYSTEMS ............................................................SECTION 4

AIR SYSTEM .............................................................................................................SECTION 5

BOOM AND FEED ASSEMBLIES .............................................................................SECTION 6

PRESSURE SETTINGS AND ADJUSTMENTS ........................................................SECTION 7

VENDOR SERVICE INFORMATION .........................................................................SECTION 8

HYDRAULIC ROCK DRILL REPAIR .........................................................................SECTION 9

LUBRICATION AND MAINTENANCE .....................................................................SECTION 10

Drill Serial No. :

Date Drill Delivered :

Specifications are subject to change without notice.

Before Starting Engine, Study Operator's Manual

California Proposition 65 Warnings

The following warning applies to equipment supplied with lead-acid batteries:

Fig. i-1 Right Side View of R30C

Fig. i-2 Left Side View of R30C

Fig. i-3 Top View of R30C

Fig. i-5 Boom Mounted Angle Indicator

Fig. i-4 Lower Boom/Feed

Fig. i-6 Valve Locations

Fig. i-7 Manifold Locations

Fig. i-10 Hose Reel

Safety Alert Symbol

Safety Alert Symbol

Indicates an imminently hazardous situation which, if not avoided, will result in

Indicates a potentially hazardous situation which, if not avoided, could result

Indicates a potentially hazardous situation which, if not avoided, may result in

Indicates a potentially hazardous situation which, if not avoided, may result in

Potential Hazard Prevention

Entanglement Hazard. Death Keep clear of rotating drill steel and

Burn Hazard. Death or serious

Relieve all pressure.

Allow to cool before performing ser-

Potential Hazard Prevention

Flying Object Hazard. Serious Use guards.

Flying Object Hazard. Serious Read and understand the proce-

Electrocution Hazard. Death or Maintain required clearance.

Trip & Fall Hazard. Death or seri-

Potential Hazard Prevention

Inhalation Hazard. Compressor Keep clear of compressor air dis-

Injection Hazard. Escaping fluid Relieve pressure before disconnect-

Crush Hazard. Death or serious Keep clear of moving centralizer. Do

Crush Hazard. Death or serious Keep clear of moving machine.

Crush Hazard. Death or serious Read and understand operator's

Machines Without Enclosures

Refer to Figures 1-1 to 1-4 for locations

(Ref. 431329 rev. C)

Safety Sign Maintenance

Fig. 1-1 Right Side of Machine