Atlas Copco T3W Manual

ATLAS COPCO
IP Drilling Solutions
PART LIST
MODEL: T3W
S/N: US021250
II
ATLAS COPCO
IP Drilling Solutions
PART LIST
MODEL: T3W
S/N: US021250
r
Atlas Copco Drilling Solutions, LLC
2100 North First Street
Garland, Texas, 75040
(972)496-7400
Read the instruction manual before operating this equipment.

This manual contains important safety information.
Do not destroy this manual.
This manual must be available to the personnel who operate and maintain this machine.
The Distributor/Dealer serving the area in which your equipment
is working will be able to give you the
BEST and FASTEST SERVICE of Genuine Repla
cemen t Parts.
IMPORTANT:
Be sure the parts book which you are ordering parts from is the
parts book for the Drill needing the re-
placement parts! Each parts book is CUSTOM MADE to a specific
Drill. All parts books have a Drill SE-
RIAL NUMBER and MODEL DESCRIPTION on the header of each
parts page. All Drills have a SERIAL
NUMBER welded on the frame at the drilling end of the MAIN
FRAME or CHAS SIS.
YOU MUST USE THE CORRECT PARTS BOOK TO INSURE
CORRECT PARTS IDENTIFICATION.
Continuing Product Improvement and advancement of product design

which may not be reflected in this Parts/Service Manual. Produc may cause changes to your Drill
tion models may vary in some detail.
Drilling Solutions reserves the right to modify or make changes
without notice or obligation.
•
Parts Ordering Instructions
By giving complete information, you will enable us to fill your order

correctly and avoid
unnecessary delays!
When ordering Replacement Parts, specify:
1. Unit Serial Number

2. The Name of each part as listed
3. The Part Number as listed in your Partsbook.
4. Quantity of parts desired.
Refer all communications concerning this unit to our nearest Branch

Office, Distributor,
Dealer or Agent
•
•
WARNING IN THE MANUAL
CALIFORNIA PROPOSITION 65 INFORMATION

TO CALIFORNIA CUSTOMERS AND
TO CUSTOMERS SELLING DIESEL ENGINE EQUIPMENT
INTO OR FOR USE IN CALIFORNIA
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
birth defects and other reproductive harm.
• Frame/Chassis
Serial Number: US021250
T3W
57895211 FRAME, COMMONS

57391773 KIT,CAB SHEILD INSTL 2
57847990 FRAME INSTALLATION,T3W 4
57845356 SUPPORT,TOWER,T3W 6
5792r,174 TIE DOWN TOWER ASSY 10
57612020 INSTL,PLATFORM,STEEL,T3W 12
57846180 ROD BOX,INSTALLATION 14
57895237 BOX, TOOL, INST 16
57770919 TOOLBOX,T3W 18
58051830 KIT, SAFETY 20
22
Jacks
57866048 JACK INSTALLATION,T3W
26
• Cab/Console
57844649 CONSOLE INSTLN T3W
57843880 CONSOLE,T3W.ASM
52236932 VALVE, PRESSURE-REMOTE
57815516 POTENTIOMETER ASSM
57848269 COVER INSTAL,CONSOLE
32
36
46
48
50
• WARNING: This manual contains data SPECIFIC to the drilling rig with
serial number: US021250
page i
Derrick/Tower
T3W
•
54
57880650 TOWER ASSEMBLY,T3W 40K
60
57678971 SHEAVE & BEARING, ASSY
62
57843104 SHEAVE,LOWER
64
66
57843419 GUIDE ASSEMBLY,TRVLG
70
57679011 CARRIAGE SHEAVE ASM
72
57863193 VALVE,REGEN ASSEMBLY
74
57821209 VALVE,REGEN,DH
76
57918534 ROTARY HEAD ASM,SGL SPD
84
57040347 ROLLER ASSEMBLY
86
57818700 MOTOR MODULE 12.5 & 15
88
57596868 SWIVEL,YOKE ASM,25CM
90
57596942 SWIVEL,25CM,3"CPLG-STR
92
57699654 SUB,SPINDLE,4.5",2.88IF
94
57699647 RING,LOCKING,4 3/4"
96
57757312 PLUG,LIFTING-2.7/8 IF
98
57844391 CAROUSEL,4.5",6 ROD,20"
100
58042920 SLING,ROD HANDLING
•
102
57228249 WRENCH,BREAKOUT
104
57844011 TABLE,RETRACT
106
57309650 CYLINDER,HYDRAULIC
108
57039695 KIT,SEAL
110
57475626 SHIELD,DUST,FRONT,ASM
112
57124901 SHIELD ASM,DUST-BACK
114
57724346 CAROUSEL,INSTL,T3W
118
57494510 DRIVE ASSY-CAROUSEL
120
58043142 REDUCER,SPEED
122
58151358 MOTOR, HYDRAULIC
124
57874422 PIPING,CAROUSEL
126
57724395 LOADER,SINGLE ROD,4.5"
128
57293540 TOOL,ROD HANDLING
130
57866428 ROD SPINNER INSTA,4-1/2"
134
56258668 ROD SPINNER
136
57880874 WINCH,INSTALL,18K HE
142
57861254 BOOM,JIB ASSY
144
57425811 LINE,1 PART/18K WINCH
146
57860991 AUX JIB CONTROL INSTAL
page ii WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250
i
• Powerpack/Engine
T3W
57869257 ENGINE ELEC. INSTLN, T3W

152
57847279 ENGINE ASSY,W/IN-OUT BOX 160
57772675 ENGINE,C15,580HP@1800 T3 168
57600843 ELEC BOX ASSY,3406E 172
57740763 LUBRICATION,SYSTEM 174
57600843 ELEC BOX ASSY,3406E 176
57846792 INSTL,DRIVE SHAFT GAURD 178
57740763 LUBRICATION,SYSTEM 182
57752644 BATTERY,INSTL-2STRT,T3W 184
57714404 EXHAUST,W/SLNCR INSULTN 186
57765224 PIPING,RADIATOR 190
57847634 INSTALLATION,COOLER,T3W 194
57765075 COOLER,ASSEMBLY 200
57765034 PIPING,CHG AIR COOLER 206
Air Cleaners
• 57772659 CLEANER,AIR,T3W,1070,ASM
50616028 AIR CLEANER
Fuel System
57581605 TANK INSTL,FUEL ALUM
210
212
216
57784084 PIPING & FUEL COOLER 218
57902868 ETHER,C15,INSTALLATION 220
57903015 ETHER,KIT,CAT C15 224
57728289 PROHEAT,INST,T3W 228
57643827 HEATER,DIESEL FIRED 232
• WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250 page iii
Compressor/Air System
Table of Contents
T3W
•
57846768 COMP ASSY,1070 HR 2.5 240
36017549 AIREND - HR 2.5 244
57861841 ACTUATOR,HEATER 246
57863391 BOX,ELECTRICAL 248
57846842 PIPING,COC,T3W 250
57170821 VALVE, TEMPERATUREBYPASS 254
57847725 PIPING,COMP TO REC TANK 256
57847188 INSTALLATION,REC TANK,LP 258
57845877 RECEIVER TANK ASSY,LP 264
57847170 MANIFOLD,AIR,LP 270
57861841 ACTUATOR,HEATER 272
57863391 BOX,ELECTRICAL 274
57721003 PIPING,DRILL AIR,70K,350 276
57843799 PIPING,AIR,STD 278
57872327 PIPING,PNEU,W/CLUTCH 280
page iv WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: U5021250
•
T3W
Hydraulic System
57844672 PUMP DRIVE INSTALLATION
57816742 PUMP DRIVE ASSEMBLY 294
57818585 PUMP,145CC P3 296
57895138 PUMP,60CC P2 FAN 300
57799322 PUMP,P7,9A CONT 304
54407309 DRIVE SHAFT & BEARING 308
310
54416946 KIT,RETAINING RING
57052631 SERVO OUTPUT 312
314
54408612 HOLDDOWN,GEROTOR& BARREL
316
54408620 PORT BLOCK/HOUSING ASSY
318
54408638 HOUSING,END CAP
322
54408646 BARREL/SHAFT/CRADLE ASM
326
57306268 VALVE BLOCK ASSY
336
57821241 HOT OIL SHUT, DR REC
58235128 KIT,SPLIT FLANGE 338
57861015 HYDRAULIC TANK INSTALL 340
57818668 TANK,HYD,ASM 342
344
50805118 VALVE,CHECK
350
57880(19 PIPING,HYD,40K,T3W
352
57818825 VALVE ASSY,10-SPOOL
374
57818601 VALVE, 10-SPOOL M4-12
376
57860 ; 65 VALVE ASSY,2-SPOOL
578629(I MANIFOLD ASM,HRC 378
57863557 MAIN MANIFOLD ASSY 380
382
5781873/1 MANIFOLD, MAIN DEEP HOLE
5784-Q9,3i/1 MANIFOLD ASSY,RETURN 384
386
57849 )29 MANIFOLD ASSY,RETURN
388
57863540 MANIFOLD ASSY
390
57849125 CYLINDER INSTL,TWR RAISE
57847295 PIPING,TOWER 40K 392
394
57846123 PIPING,SUCTION
402
Electrical System
57863300 ELECTRICAL INSTALLATION
410
57863565 BOX,ELECTRICAL
414
57864332 WIRING,CONSOLE T3W
418
57728263 LIGHTS,NIGHT,T3WDH 50/70
420
57234072 LIGHT-TAIL MARKER
422
WARNING: This manual contains data SPECIFIC to the drilling rig with serial number
US021250 page v
T3W
Table of Contents
Options
428
57860223 WATER INJ,INST,BEAN 18
432
57847642 INJ ASSY,WTR,18 BEAN
436
58000357 WATER INJECTION MANIFOLD
438
57752388 LUBE,DHD,7GAL INSTL
442
57752370 LUBRICATOR,DHD,7GAL ASSM
448
57752362 LUBRICATOR,SUB ASM,7GAL
452
57352973 PUMP,DHD LUBRICATOR
Tools/Accessories
456
57917239 STANDARD TOOLS
458
50245281 GUN,BLOW-WITH 25' HOSE
460
57359523 KIT, 0-RING, HYDRAULIC
462
57155541 DECALS,SAFETY-T3W
466
57313975 MANUAL, SAFETY-T3W
468
•
470
57557001 DECALS,T3W
472
57923773 DECAL ASM,T3W,7600,LT
page vi WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250
•
Section A - Frame/Chassis
• WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250
page 1
T3W
57895211 FRAME, COMMONS
.
(MAINFRAME)
(CHASSIS)"
•
SEE OETAL
2
3
4
6
DETAIL A
DETAL B
D2657895211 REV 000
page 2 WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250
BOM 57.t9!;211 T3W
REF . PART NO. QTY UNIT DESCRIPTION

NOTES
001.0 57795593 2.0 EA MUD FLAP,ATLAS COPCO
002.0 57391773 1.0 EA KIT,CAB SHEILD INSTL See Page 4
003.0 95922894 8.0 EA NUT,HEX
004.0 95937413 8.0 EA WASHER,LOCK,HELICAL
005.0 95934592 8.0 EA CAPSCREW,HEX
006.0 95922233 8.0 EA WASHER,FLAT,WIDE
WARNING: This manual contains data SPECIFIC to the drilling rig with serial number:
US021250 page 3
BOM 57391773
57391773 KIT,CAB SHEILD INSTL

T3W
•
FRONT OF CAR
(TOP vIEW OF TRUCK)
1
2
3
NOTES;
I. APPLY FLOORING ADHESIVE
AS SHOWN TO RUBBER PAO
AND PLACE ONTO CHASSIS
ROOF AFTER WAITING TIME
PRESCRIBED BY ADHESIVE
MANUFACTURER.
2.APPLY A BEAD OF SEALANT

ALONG EDGE OF PAO TO
PREVENT WATER FROM
CONTACTING ADHESIVE.
3.SHIELD SHALL BE CUT TO MATCH

INDIVIDUAL CAB REOUIRMENTS
MANUFACTURED CAB DIMENSIONS
VARY PER CAB TYPE.
C2657391773 REV 003
T3W
REF. PART NO. QTY UNIT DESCRIPTION

NOTES
001.0 58054537 1.0 EA SHIELD
002.0 57391781 1.0 EA ADHESIVE,FLOOR
003.0 50700731 1.0 EA COMPOUND,SILICONE
WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250
page 5
T3W
BO'
24 •
5
22 I 3 3
6 8 A- 4 4 23 18
7 11
19 2
12 7
25 25
26
VIEW A
D2657847990 REV 006
T3W
57847990 FRAME INSTitt.. ATION,T3VV
D2657847990 REV 006
page 7
BOM 57847990
REF.
001.0
PART NO.
57844086
QTY
1.0
57847990 FRAME INSTALLATION,T3W
UNIT DESCRIPTION
EA WELDMENT,MAINFRAME,T3W
T3W
NOTES
•
57613978 1.0 EA - GUARD,HELPER SIDE,LG
57845356 1.0 EA - SUPPORT,TOWER,T3W See Page 10
95104147 2.0 EA - CAPSCREW,HEX

57272841 1.0 EA - PIN, WRENCH MTG.
95922902 2.0 EA - NUT,HEX,FINISHED,PLATED
95081667 2.0 EA - WASHER,FLAT,WIDE
95507612 1.0 EA - U-BOLT
58163536 1.0 EA - BRACKET
58035403 2.0 EA - CHAIN,ANCHOR
57575169 1.0 EA - PIN,CLAMPING BAR
95934576 4.0 EA - CAPSCREW
57874265 1.0 EA - BAR,FLAT
57756041 1.0 EA - HINGE,LH,T3DH
57756058 1.0 EA - HINGE,RH,T3W-DH
95279352 2.0 EA - FITTING,HYD
95922639 8.0 EA - LOCK WASHER,HELICAL SPRNG
95105243 8.0 EA - CAPSCREW
95316964 1.0 EA - FITTING,HYD
57524449 4.0 EA - STUD,WELD
57925174 2.0 EA - TIE DOWN TOWER ASSY See Page 12
57606147 1.0 EA - CHANNEL,ANCHOR
002.0 57765646 4.0 EA SHIM,SET
003.0 57765661 6.0 EA SHIM,SET
004.0 57492332 18.0 EA HUCKFIT COLLAR, 20
005.0 95105094 8.0 EA CAPSCREW,HEX
006.0 95941084 8.0 EA NUT,HEX,FINISHED,PLATED
007.0 57729683 18.0 EA HUCKBOLT
008.0 57439937 1.0 EA SUPPORT,MID JACKS 48
009.0 57765653 2.0 EA SHIM,SET,T3WDH
010.0 57492365 6.0 EA HUCKFIT LCKBLT, 16,35-45
011.0 57492324 14.0 EA HUCKFIT COLLAR, 16
012.0 57593766 2.0 EA SHIM,MID JACK
018.0 57797151 8.0. EA BOLT,HUCK-FIT,16X45
019.0 95934717 8.0 EA LOCKWASHER,SPRING,PLATED
020.0 57815912 0.0 EA SCREW,MACHINE HD
021.0 57815920 0.0 EA SCREW, MACHINE HD
• BOM 57E47990
REF. PART NO.

023.0 57847345
QTY UNIT DESCRIPTION
4.0 EA BAR
T3W
NOTES
024.0 57311128 2.0 EA BAR 1.75 X 3.5 X 6

026.0 95972246 12.0 EA WASHER, FLAT, PLATED
page 9
T3W
BO M
57845356 SUPPORT,TOVVER,T3W
D2657845356 REV 004
• BOM 57845356
REF.
001.0
PART NO.
57845372
QTY
2.0
UNIT DESCRIPTION
T3W
NOTES
EA SUPPORT,POST
002.0 57061061 2.0 EA BUSHING ASSY
57061053 1.0 EA - SLEEVE
58055062 1.0 EA - BUSHING
003.0 57845398 1.0 EA PLATE
004.0 57845406 2.0 EA BRACKET,TOWER SUPPORT
005.0 57845414 2.0 EA BRACKET,TOWER SUPPORT
006.0 57845422 2.0 EA PIN,TOWER RAISE CYL
007.0 58041187 2.0 EA BAR,LOCKING
008.0 95934733 4.0 EA WASHER,LOCK
009.0 95934584 4.0 EA CAPSCREW
015.0 57917528 1.0 EA HOOP, TOWER PIVOT HOSE
page 11
BOM
57925174 TIE DOWN TOWER ASSY

T3W
C2657925174 REV 000

F,792!074
T3W
57925174 T E DOWN TOWER ASSY

REF . PART NO. QTY UNIT DESCRIPTION NOTES
001.0 57925182 1.0 EA TIE DOWN, TOWER BOTTOM
002.0 57925190 1.0 EA TIE DOWN TOWER TOP
003.0 95105110 1.0 EA CAPSCREW
004.0 58186321 2.0 EA EAR
page 13
•
T3W
BOM 57612020
57612020 INSTL,PLATFORM,STEEL,T3W
12
13
0
o 0
page 14
TB57612020 REV 004
•
T3W
BC 7()
57612020 INS'TL,PLATFORM,STE.EL,T3VV
RE PART NO. QTY UNIT DESCRIPTION NOTES
001.c 57612038 2.0 EA PLATFORM,STEEL,COMPLETE
002.0 57612087 1.0 EA PLATFORM,CENTER,STEEL
003.0 57612079 2.0 EA STEP,STEEL
004.0 57612061 1.0 EA PLATE,MTG,VALVE,STEEL
007.0 95952560 8.0 EA CAPSCREW,HEX
008.0 95929006 4.0 EA CAPSCREW
009.0 95934303 4.0 EA WASHER,LOCK,PLATED
010.0 95929782 4.0 EA NUT,HEX,FINISHED
011.0 95902144 4.0 EA SCREW,SHOULDER
012.0 95207429 4.0 EA NUT,HEX JAM
013.0 95934741 4.0 EA WASHER,LOCK HELICAL
page 15
•
T3W
BOM 57846180
57846180 ROD BOX,INSTALLATION
D2657846180 REV 000
pack 1t WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250
• BOM 57846180
REF.
001.0
PART NO.
57585135
QTY
1.0
57846180 ROD BOX,INSTALLATION
UNIT DESCRIPTION
T3W
NOTES
EA ROD BOX
002.0 95930723 8.0 EA CAPSCREW,HEX
005.0 95922910 12.0 EA NUT,HEX,PLATED
006.0 95035457 3.0 EA SUB 95934386 CAPSCREW
007.0 95200093 3.0 EA WASHER,FLAT
010.0 95035432 2.0 EA CAPSCREW,HEX
011.0 57845802 1.0 EA BRACKET,ROD BOX
012.0 95035408 4.0 EA CAPSCREW,HX
013.0 95935003 4.0 EA WASHER,FLAT
014.0 95934683 4.0 EA LOCKWASHER,HELICAL SPRG
page 17
BOM 57895237
57895237 BOX, TOOL, INST

T3W
List Only
PENDING REV 000
T3W
BOM 57895237
REF. PART NO. QTY UNIT DESCRIPTION NOTES

001.0 57770919 1.0 EA TOOLBOX,T3W See Page 20
002.0 95930723 8.0 EA CAPSCREW,HEX
003.0 54573704 8.0 EA WASHER,BEVEL,SQ,PLATED
005.0 95922910 8.0 EA NUT,HEX,PLATED
page 19
•
T3W
57770919 TOOLBOX,T3W
D2657770919 REV 001
• BOM 57770919
REF.
001.0
PART NO.
57770927
1.0 EA BOX,T3W TOOLBOX
T3W
NOTES
002.0 57131732 1.0 EA DOOR

003.0 57451536 2.0 EA PIN, HINGE/TOOL BOX
005.0 54404520 2.0 EA LOCK,PADDLE
• WARNING: This manual contains data SPECIFIC to the drilling rig with serial number:
US021250 page 21
•
T3W
BONI
58051830 KIT, SAFETY
Truck Chassis illustration

is a representative picture.
Truck Safety Kit is

stored in cab.
B58051830 REV 001
p;i, ae 22 WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250
T3W
REF, PART NO. QTY UNIT DESCRIPTION NOTES

001.0 58051848 1.0 EA TRAY, FUSE
002.G 58051855 3.0 EA FLARE,EMERGENCY
003.0 58051863 1.0 EA KIT,FLARE,REFLECTOR
004.1 57073546 1.0 EA EXTINGUISHER,FIRE-2.5LB
WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250 page 23
•
THIS PAGE IS INTENTIONALY BLANK
•
•
Section B - Jacks
T3W
•
9
18
32
31 24 tTAL A 25
19
17
28
19
17
27
19
DETAIL Fit
17
TB2657866048 REV 000
page WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250
T3W
BUM 5'1866048
• A:•
-26
H 23
27,
28,
j 25
30
20
•
jl 1 17
29
TB2657866048 REV 000
•
T3W
BOM 57866048
27 28
28
16
14
9
SECTION C-C
12 13
- -
5EC-00N E-E 11
page 28
TB2657866048 REV 000
SECTION D-D
•
T3W
'0I0 66048

001.0 57692782 2.0 EA CYLINDER,HYD
57729980 1.0 EA - KIT,SEAL
57513293 2.0 EA - VALVE, COUNTERBALANCE
002.0 95201547 4.0 EA FITTING,LUBE
003.0 95093381 4.0 EA PIN,COTTER
004.0 95265088 4.0 EA PIN,HINGE
005.0 50033414 2.0 EA FOOT,JACK
50381904 1.0 EA - FOOT, CASTING
006.0 57428773 1.0 EA CAP,MID JACK L.H.
007.0 50218627 2.0 EA FOOT, JACK
008.0 95035432 12.0 EA CAPSCREW,HEX
010.0 57222713 2.0 EA COVER, JACK
011.0 57070278 2.0 EA NUT, JACK
012.0 57070286 2.0 EA BAR, FLAT
013.0 57222143 2.0 EA CAP,JACK
014.0 95934170 2.0 EA CAPSCREW,HEX
015.0 57428765 1.0 EA CAP,MID JACK R.H.
016.0 57692790 2.0 EA CYLINDER,HYD
57729998 1.0 EA - KIT,SEAL
57513293 2.0 EA - VALVE, COUNTERBALANCE
017.0 95650156 6.0 EA ADAPTER
018.0 57862427 2.0 EA FITTING,STR,060FSX08SAE
019.0 57319733 5.0 EA FITTING,STL,060FS X06SAE
020.0 57319618 1.0 EA FITTING,STR,060FS X06SAE
021.0 57464208 2.0 EA CLAMP,ASSY 3/4 -STACK
022.0 57447260 2.0 EA CLAMP ASSY, STAUFF3/4 OD
023.0 57381261 1.0 EA HOSE ASSY
024.0 57659633 1.0 EA HOSE ASSEMBLY
025.0 57785073 1.0 EA HOSE,ASSEMBLY
026.0 57849796 1.0 EA HOSE ASSY
029.0 57380776 1.0 EA HOSE ASSY
031.0 95209870 2.0 EA O'RING
032.0 57279648 2.0 EA O-RING,SEAL-LOK,-6
•
•
•
Section C - Cab/Console
page 31
•
T3W
BOM 57844649
MAINFRAME REF. --\\
TB2657844649 REV 000
• BONE 44649
T3W
SEE DETAL A
,-MAINFRAME REF.
:C
IO o
• TB2657844649 REV 000
BOM
57844649 CONSOLE INSTLN T3W

T3W
MAINFRAME REF.--
DETAIL A
TB2657844649 REV 000
T3W
BONI 57E04649

001.0 57843880 1.0 EA CONSOLE,T3W.ASM See Page 36
002.0 95920674 6.0 EA CAPSCREW,HEX
003.0 95922373 6.0 EA WASHER,FLAT
004.0 95077939 6.0 EA NUT
• WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250 page 35
T3W
63 60
59 62 59
60 61 40 58 56
58 56
93
59
74
72
99
D2657843880 REV 005
• BOM 57843880
57843880 CONSOLE,T3VV.ASM
T3W
• D2657843880 REV 005
•
T3W
BOM 57843880
page 38
D2657843880 REV 005
•
T3W
BOIlk °i/843880
90
a
0
46 46
35
ga: 52
46
45 44 44
SECTION A-A
D2657843880 REV 005
BON! 57843880
T3W
•
C
38
!J7
48
49
57
VIEW B-B
5 100
106 43 101
108
VIEW C-C
DETAIL D
D2657843880 REV 005
• EOM 57843880
T3W
83
78
80
8
104
103
77
-86
D2657843880 REV 005
BOM 57843880
T3W
D2657843880 REV 005
T3W
BOly, <843880

001.0 57843807 1.0 EA CONSOLE,WELDMENT
95937413 20.0 EA - WASHER,LOCK,HELICAL
95934766 2.0 EA - WASHER,LOCK,HELICAL
95104071 2.0 EA - CAPSCREW
95931564 18.0 EA - NUT,HEX,FINISHED
002.0 52236932 1.0 EA VALVE, PRESSURE-REMOTE See Page 46
003.0 57880684 1.0 EA HRC,W/BUTTON
004.0 57870560 1.0 EA HRC,STRT HANDLE
005.0 57147282 1.0 EA LAMP, FLOOD-70W HALOGEN
006.0 58059536 1.0 EA VALVE
008.0 57816993 2.0 EA TERMINAL,RING 22-18 AWG
009.0 58150103 1.0 IN CORD,14/2
011.0 57818684 1.0 EA CONTROL,3POS, S.FEED
012.0 95147674 3.0 EA ADAPTER
013.0 57818676 1.0 EA CONTRL,ROT,9A
014.0 57216699 1.0 EA VALVE, RELIEF
015.0 57179608 2.0 EA SWITCH,SPST/ON-OFF
016.0 57493868 1.0 EA THROTTLE,ELECTRONIC-CAT
017.0 57358855 1.0 EA PUSHBUTTON, 2-POSITION
57364010 1.0 EA - LED,24V AC/DC RED
018.0 56993678 1.0 EA SWITCH,KEY
019.0 52185832 1.0 EA SWITCH, PUSH BUTTON
020.0 57867301 1.0 EA POWERVIEW
021.0 57319725 2.0 EA FITTING,STL,040FS X04SAE
023.0 57895054 1.0 EA GAUGE,ENG OIL PRES, AC
024.0 57895047 1.0 EA GAUGE,ENG TEMP AC LOGO
025.0 57888364 1.0 EA GAUGE,4",400PSI AC
028.0 57895088 1.0 EA GAUGE,FUEL,AC LOGO
029.0 57491813 3.0 EA INDICATOR,24VOLT,RED
030.0 57084055 5.0 EA BREAKER,CIRCUIT-15 AMP
031.0 57895039 1.0 EA GAUGE,TACH,AC LOGO
033.0 57843898 1.0 EA PANEL,GAUGE,T3W
034.0 57843906 1.0 EA PANEL,NAMEPLATE VALVE
035.0 57379505 2.0 EA MANIFOLD,ALUM-ORING
038.0 57888265 1.0 EA NAM EPLATE,10-SPOOL
040.0 57843815 1.0 EA PIVOT,LIGHT
041.0 50625946 1.0 EA CONNECTOR,CORD GRIP
042.0 58147646 1.0 EA CONNECTOR
043,0 57157885 1.0 EA HOUSING, 4X6 LIGHT
044 0 95329975 3.0 EA ELBOW,90 DEG STRT THRD
•
T3W
BOM 57843880
045.0 95365078 1.0 EA CONNECTOR,STRT THRD

046.0 95666996 5.0 EA PLUG,HEX HEAD,STRT THRD
048.0 58145392 1.0 EA RUBBER
58203035 2.07 SI - RUBBER
049.0 58038761 1.0 EA LEVEL
052.0 95365094 1.0 EA ELBOW,90DEG,STRT THRD
056.0 95928982 12.0 EA CAPSCREW
057.0 95893483 3.0 EA SCREW,#5-40UNCX.75LG
058.0 95934568 4.0 EA CAPSCREW,HEX
061.0 95920682 4.0 EA CAPSCREW,HEX
063.0 95922894 4.0 EA NUT,HEX
066.0 56935562 2.0 EA SCREW,CAP-M6 X 10 MM
067.0 52215415 2.0 EA SCREW
069.0
070.0
071.0
072.0
073.0
074.0
57845513
95958583
95446639
95922183
95922563
95958351
1.0
4.0
2.0
8.0
4.0
4.0
EA
EA
EA
EA
EA
EA
TUBE WELDMENT,CONSOLE
SCREW,ROUND HD
COUPLING
WASHER,FLAT
WASHER,LOCK
CAPSCREW
•
076.0 57433757 1.0 EA HOSE ASSY
078.0 57020729 1.0 EA HOSE ASSY
079.0 57864100 1.0 EA HOSE ASSY
081.0 57381188 1.0 EA HOSE ASSY
082.0 95083051 1.0 EA CONNECTOR
083.0 95293296 1.0 EA CONNECTOR,FEMALE
084.0 95371258 1.0 EA FITTING,HYD
085.0 57308959 1.0 EA FITTING,RNT,040FS X04SAE
087.0 95928982 4.0 EA CAPSCREW
090.0 57319782 8.0 EA FITTING,L90,040FS X06SAE
091.0 57895062 1.0 EA GAUGE,DISC TEMP AC LOGO
092.0 57477317 2.0 EA ADAPTER,1/4 ORS TO NPTF
093.0 57815649 2.0 EA KNOB,POTENTIOMETER
094.0 57815516 2.0 EA POTENTIOMETER ASSM. See Page 48 •
T3W
M !, -74.4:3810

095.0 57818692 1.0 EA CONTRL,4WAY,JIB
58004011 1.0 EA - RUBBER BELLOWS
096.0 57888232 2.0 EA GAUGE, 5000PSI, 2.5" AC
097.0 57888240 1.0 EA GAUGE, 200PSI, 2" AC
098.0 57888257 1.0 EA GAUGE, 400PSI, 3.5" AC
099.0 95239521 10.0 EA NUT,HEX
100.0 95069589 1.0 EA WASHER,FLAT
101.0 95104006 1.0 EA CAPSCREW
102.0 95104071 4.0 EA CAPSCREW
103.0 57861544 1.0 EA RECEPTACLE FEMALE 12PIN
104.0 57862377 1.0 EA RECEPTACLE,FEMALE 19PIN
106.0 57888513 1.0 EA NAMEPLATE,JIB MA1N/AUX
108.0 57097792 2.0 EA GROMMET, RUBBER
page 45
•
T3W
BOM 52236932
52236932 VALVE, PRESSURE-REMOTE
10
6
7
C2652236932 REV 001
• BOM 52236932
REF.
001.0
PART NO.
52155660
QTY
1.0
UNIT DESCRIPTION
T3W
NOTES
EA SPRING GUIDE,PISTON SEAL
001.0 57141905 1.0 EA HANDWHEEL, INDICATING
002.0 95017984 1.0 EA 0-RING
003.0 50798925 1.0 EA SPRING
004.0 52155686 1.0 EA CONE
005.0 50798891 1.0 EA SEAT
006.0 52249604 1.0 EA PISTON
007.0 52249620 1.0 EA SLEEVE
008.0 52249638 1.0 EA SPRING
009.0 52249646 1.0 EA BALL
010.1 52249588 1.0 EA KNOB, CONTROL
BOM 57815516
57815516 POTENTIOMETER ASSM.

T3W
•
5
6
A 7
.. -- ...
B
11
A
VIEW A-A
ROTATED 90 DEG CW
82657815516 REV 000
T3W
*1(
57815516 POTENTIOMETER ASSM.

001.0 57815656 1.0 EA POTENTIOMETER,EAR SYSTEM
002.0 57816936 1.75 FT WIRE,18AWG WHITE
003.0 57815623 1.0 FT TUBING,CONVOLUTED
004.0 57817009 3.0 EA MARKER,WIRE LASER PRNTBL
005.0 57678088 1.0 EA CONNECTOR,3 PIN
006.0 57678096 1.0 EA WEDGE,3 PIN
007.0 54530985 3.0 EA PIN,SIZE 16
•
T3W
BOM 57Ri •
AIRFRAME (REFI
page 50
ISO VIEW
D2657848269 REV 000
•
• BOM 57848269
REF PART NO.

001.0 57849374
1.0 EA COVER,CONSOLE
T3W
NOTES
002.0 50344530 1.0 EA PADLOCK

003.0 57860298 4.0 EA RIVET,BLIND
004.0 50822964 20.0 FT TAPE,SPONGE
•
•
•
Section D - Derrick/Tower
si
•
T3W
BOM 57880650
55
A-7, 1 ROTARY HEAD REF rc 56
76
86
61
N 86
DETAIL E
DETAIL N 76
page 54
D2657880650 REV 003
•
T3W
51
40
46
6
53
SECTION A-A
•
29
25
20
SECTION F-F
SECTION D-D
6
53
29
15 RH LI-1 16 30 23 5 22 58 L II "57 21 24 5 28 19 18 1 28
\ / / /
/
//4 \
\
\„ \
2/ 28 20 21 31 42 45
DETAIL M
D2657880650 REV 003
•
T3W
BUM '.1
57880650 TOWER ASSEMBLY,T3VV 40K
10 44
11 SECTION B-B
49 49
34
34
88 79
72
70 72
70
SECTION Z-Z
37 38
SECTION C-C
D2657880650 REV 003
page WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250
• BOM 57880650

T3W
;a te SEE DETAL
TOP HEAD ROLLER-z •- ROLLER
REF. STOP PLATE REF.
DETAIL T
36
35
------ 38 \ -SEE DETAL U
SEE CET& KJ
37
DETAIL X
36 59 44
89
90
36 84 85 87 38
DETAIL K
67 41
47
11 DETAL X 73
32
10
/1-CABLE PULLBACK ( RIGHT
- /
CABLE MUM (RIGHT)
CABLE PULLDON (LEFT)
•
CABLE PULLBACK (LEFT)
DETAIL P
D2657880650 REV 003
•
T3W
BOtin 51880650

001.0 57843070 1.0 EA DERRICK,WELDMENT,T3W-40K
002.0 57692766 1.0 EA CYLINDER,FEED 5"BORE
003.0 57863201 2.0 EA PLATE
005.0 95201547 4.0 EA FITTING,LUBE
010.0 58043001 2.0 EA NUT,LOCK
011.0 95094280 2.0 EA WASHER,FLAT
012.0 57843096 1.0 EA BAR,RETAINER
015.0 57427825 1.0 EA GUIDE ARM, UPPER RH FAB
016.0 57237539 1.0 EA ARM,ASSEMBLY
018.0 57351892 2.0 EA CYLINDER,AIR
57351942 1.0 EA - KIT,REPAIR 2B.NON CUSH
019.0 58036229 2.0 EA CLEVIS, ROD
020.0 58036179 6.0 EA PIN-CLEVIS
021.0 58036187 4.0 EA FORK,ADJ
022.0 58041807 2.0 EA LEVER
023.0 58035015 2.0 EA LEVER,SUB
024.0 57279176 2.0 EA ARM,RETRACT ACTUATOR
58035015 1.0 EA - LEVER,SUB
57279184 1.0 EA - TAB, ARM
025.0 57093510 4.0 EA PIN
026.0 58041757 4.0 EA BUSHING
027.0 58056425 4.0 EA KEY,SQUARE
028.0 95294112 8.0 EA PIN,COTTER
029.0 95267399 4.0 EA CAPSCREW
030.0 95266771 4.0 EA NUT,HEX
031.0 95201331 4.0 EA NUT,HEX JAM
032.0 95077707 2.0 EA NUT,HEX
033.0 57678971 2.0 EA SHEAVE & BEARING, ASSY See Page 60
034.0 57843088 2.0 EA GUARD,SHEAVE
035.0 57921637 1.0 EA ROPE,WIRE,22MM,SWAGED
036.0 57921637 1.0 EA ROPE,WIRE,22MM,SWAGED
037.0 58143348 55.0 FT WIRE ROPE-3/4 BULK
038.0 58143348 55.0 FT WIRE ROPE-3/4 BULK
039.0 57699761 1.0 EA PIN,CYLINDER
040.0 57843120 2.0 EA PIN WELDMENT
041.0 57709149 2.0 EA EYE,CABLE ANCHOR
•
042.0 57713141 2.0 EA CLEVIS,PIN
043.0 95077608 2.0 EA NUT,HEX STOP
044.0 57799975 1.0 EA CLAMP 5.75 O.D. FEED CYL
045.0 57713042 2.0 EA MOUNT CYLINDER, SHORT
• BM 5788(1650
REF.
046.0
PART NO.
57918781
QTY
4.0
UNIT DESCRIPTION
EA SPACER, SHEAVE
T3W
NOTES
047.0 58062985 6.0 EA CLAMP,CABLE-7/8

049.0 57843104 2.0 EA SHEAVE,LOWER See Page 62
051.0 95223582 2.0 EA RING,RETAINING
052.0 58041187 2.0 EA BAR,LOCKING
053.0 95920674 4.0 EA CAPSCREW,HEX
055.0 95920047 6.0 EA CAPSCREW/35A2A379Z1HR
057.0 58151325 1.0 EA ARM GUIDE
058.0 57427841 1.0 EA GUIDE ARM-LOWER FAB RH
059.0 57799983 1.0 EA SUPPORT,FEED CYL 5.75"OD
060.0 95972246 2.0 EA WASHER,FLAT,PLATED
061.0 50339001 1.0 EA PIN,CYLINDER
066.0 57843419 1.0 EA GUIDE ASSEMBLY,TRVLG See Page 66
067.0 58038910 20.0 EA WASHER,BELLEVILLE
•
070.0 95452066 28.0 EA WASHER,FLAT
072.0 95865937 28.0 EA CAPSCREW
075.0 57863193 1.0 EA VALVE,REGEN ASSEMBLY See Page 72
076.0 95920674 4.0 EA CAPSCREW,HEX
077.0 95104675 2.0 EA CAPSCREW
078.0 95105300 4.0 EA CAPSCREW
079.0 95242376 1.0 EA NUT,HEX JAM
080.0 95352415 2.0 EA WASHER,LOCK
082.0 57867368 1.0 EA ACTUATOR, ROTARY
083.0 56793599 6.0 EA CLAMP,CABLE-3/4
084.0 95002499 2.0 EA NUT,HEX JAM
085.0 95077699 2.0 EA NUT,HEX
087.0 58036534 2.0 EA ANCHOR,CABLE
58187121 1.0 EA - PLUG,SOCKET
58187139 1.0 EA - SOCKET ASSY
088.0 57876831 1.0 EA KEY
089.0 95081717 2.0 EA WASHER,FLAT
090.0 95505699 2.0 EA LOCK NUT,HEX
•
T3W
BOM 57678971
SECTION A-A
page 60
C57678971 REV 002
•
•
T3W
BOM 57678971

001.0 57678989 1.0 EA SHEAVE,1 GROOVE
002.0 57667453 2.0 EA BEARING,SINGLE SPHERICAL
003.0 57700247 1.0 EA RING, SHEAVE INSERT
page 61
•
BOM 57843104
T3W
SEE DETAIL A
page 62
SECTION A-A
D2657843104 REV 000

DETAIL A
WARNING: This manual contains data SPECIFIC to the drilling

rig with serial number: US021250
•
T3W
843104

,
00 1.0 57843641 1.0 EA CLEVIS WELDMENT
002.0 57678971 1.0 EA SHEAVE & BEARING, ASSY See Page 64
003.0 57700312 2.0 EA SPACER
004.0 58041187 1.0 EA BAR,LOCKING
006.0 95920674 2.0 EA CAPSCREW,HEX
007.0 57843732 1.0 EA PIN WELDMENT,LOWER
•
T3W
BOM 57678971
SECTION A-A
•
C57678971 REV 002
T3W
=r,1 h 1b78971
QTY UNIT DESCRIPTION NOTES

REF. PART NO.
001.0 57678989 1.0 EA SHEAVE,1 GROOVE
002.0 57667453 2.0 EA BEARING,SINGLE SPHERICAL
003.0 57700247 1.0 EA RING, SHEAVE INSERT
number: US021250 page 65

WARNING - This manual contains data SPECIFIC to the drilling rig with serial
•
BOM 5784 ;,11!f T3W
11
page 66
D2657843419 REV 003
•
T3W
BOtO 4.419
E DETAIL El
DETAIL C
SEE DETAIL A
•
SECTION A-A
2 6
r ipr
-ML
it
viv
•
DETAIL A
DETAIL Ell
DETAIL C
D2657843419 REV 003
US021250 page 67
WARNING - This manual contains data SPECIFIC to the drilling rig with serial number:
BOM 57843419

T3W
•
3
15
10
•
8
page 68
D2657843419 REV 003
WARNING: This manual contains data SPECIFIC to the drilling rig with
serial number: US021250
•
T3W
itrjiVi 57843419
PART NO. QTY UNIT DESCRIPTION NOTES

REF.
001.0 57843625 1.0 EA CARRIAGE WLDMT,TRAVELING
57843633 2.0 EA - PLATE,TRAVELING SHEAVE
57679011 2.0 EA CARRIAGE SHEAVE ASM See Page 70
002.0
003.0 57700379 1.0 EA PIN WLDMT,TRAVEL.SHEAVES
57700361 1.0 EA - BOSS,PIN
57700304 1.0 EA - PIN,TRAVELING SHEAVES
004.0 57700353 1.0 EA SHIM,25 GA.
005.0 57700346 1.0 EA SHIM,15 GA.
006.0 57700320 3.0 EA SPACER,TRAVELING
007.0 57700296 1.0 EA SPACER,TENSIONER
008.0 57700221 8.0 EA SHIM
009.0 57734204 4.0 EA PAD,WEAR-TRAVEL SHEAVES
010.0 57699670 2.0 EA NUT,JAM
011.0 57737132 2.0 EA PLATE,SIDE,CABLE GUIDE
012.0 57737140 2.0 EA BAR,LONG,CABLE GUIDE
•
013.0 57737157 2.0 EA BAR,SHORT,CABLE GUIDE
014.0 57737165 4.0 EA SPACER,INNER,CABLE GUIDE
015.0 57737173 4.0 EA SPACER,OUTER,CABLE GUIDE
016.0 58041187 1.0 EA BAR,LOCKING
017.0 95209409 20.0 EA WASHER,LOCK
018.0 95920674 2.0 EA CAPSCREW,HEX
019.0 95157731 20.0 EA CAPSCREW,HEX HEAD
021.0 95077608 8.0 EA NUT,HEX STOP
022.0 95929097 4.0 EA CAPSCREW,HEX
023.0 50344605 8.0 FT WIRE,LOCK
• WARNING: This manual contains data SPECIFIC to the drilling rig with serial
BOM 57679011 T3W
57679011 CARRIAGE SHEAVE ASM
DETAIL A
SEE DETAIL A
SECTION A-A
C57679011 REV 000

page 70
T3W
BO', ',76/9011
001.0 57679029 1.0 EA SHEAVE, 2 GROOVE

002.0 57700262 2.0 EA BEARING,TAPERED ROLLER
003.0 57700270 2.0 EA SEAL, NILOS RING
004.0 57700213 1.0 EA SPACER,INNER RACE
005.0 57818221 2.0 LB GREASE,RONEX-HD
page 71
•
BOM 5713 , T3W
page (z
3
D2657863193 REV 001

WARNING: This manual contains data SPECIFIC to the drilling rig with serial
number: US021250
•
T3W

001.0 57821209 1.0 EA VALVE,REGEN,DH See Page 74
002.0 95280541 1.0 EA FITTING,HYD
003.0 57167454 2.0 EA FITTING,STR,200FS X2OSAE
008.0 95735346 1.0 EA FITTING,HYD
T3W
'i I
57821209 VALVE,REGEN,DH
110 130
120
110 130
100
( 120 )
0v El
SFT
5000 PSI SFE
(1 30. 2)
—
RI
SE T 6)
—1 500 0 PS I c. SFR
(130. I)
^
(-) R2
0 E2
J
I
y
FFR RP [FE
D2657821209 REV 002

T3W
B(:M < ts21209

100.0 57844714 1.0 EA MANIFOLD BLOCK
110.0 57844722 2.0 EA VALVE, 3 WAY
120.0 57844730 1.0 EA VALVE,CHECK
130.0 57844912 2.0 EA VALVE,COUNTER BALANCE
•
T3W
BOM 57918534
90
88 89
95
28
'87
59 70
56 71
54
71 '63 96
86 -- 40
28 75
32
36
97 89 90
•
31
27 43
17 -
16 75- 35 34
24 93
59 ------ 34 ,87
n=
60 V*. 95
1.*-4. 37
fr- \ 2019 32
33 44 ‘4, \ 45 32
25' 6 28
37 70
32
•
RA
40K SWIVEL SHOWN FOR REF
D2657918534 REV 001
• BOM 57918534

T3W
89
88
90
95
\
28
87
59
70
56 71
54
71-„, 63 96
86,„
28 ---- — 40
32
75
97-, 89
31 36 9p
27 —
— 43
17 34
16 75 35 93
24
87
59/ 041- 14r 34
14414 95
60 37
4' 1 :4
\ 5 20 9 32 _32
33 28
34 / 25 26
37 —70
32 40
63
97
-28
43
1
33
31
70K SWIVEL SHOWN FOR REF 38
D2657918534 REV 001
•
T3W
BOM 57918534
28
B
85 B
34
95
89
RISER PLATE DETAIL
27
32
24 32 19 32 28
32
32
28
27
43
36 -11
35 :IN
20
I
30
r
34
25 37
32 37 32
D2657918534 REV 001
T3W
D2657918534 REV 001
page 79
•
T3W
BOM 57918534
58 59 61
60- ----j--
57
97
31 31
97
•
27
75 54
75
22 43
21 21
SECTION C-C
page 80
40K SWIVEL SHOWN FOR REF
D2657918534 REV 001
•
T3W
tZt
11~-
59 61
58 (L
I
60 70
57 54
71 91
56-- 54
•
40
86
63 98
97 97
31 31 99
27-
100
75
,, 43
22 z„
.-- 21 SECTION C-C
21
23
24
33
34 \ '31 '31
37 38
32 38
• 70K SWIVEL SHOWN FOR REF

D2657918534 REV 001
•
T3W
BOM 57918534

001.0 58182767 1.0 EA BOX, TOPHEAD
002.0 57217234 2.0 EA PINION, INPUT-TOPHEAD
003.0 57187213 1.0 EA GEAR, OUTPUT
004.0 95306296 4.0 EA BEARING
005.0 57274474 2.0 EA BEARING, ROLLER-TAPER
006.0 58035064 2.0 EA SLEEVE
007.0 58035171 2.0 EA SEAL, OIL
008.0 58035189 2.0 EA SEAL, OIL
009.0 58035072 1.0 EA V-RING
010.0 58152729 1.0 EA BAR,SQUARE
011.0 58035056 1.0 EA RING,FLINGER
012.0 57274482 2.0 EA HOUSING, SEAL-ROTARYHEAD
013.0 95104204 8.0 EA CAPSCREW,HEX
014.0 57274516 1.0 EA SPINDLE, MAIN-ROTARYHEAD
015.0 57490849 1.0 EA SHALE TRAP
)16.0 57318743 16.0 EA WASHER, FLAT-HARDENED
.117.0 95309829 16.0 EA CAPSCREW,FLANGED 12 PT
019.0 58042235 1.0 EA PLATE, COVER
020.0 95920674 10.0 EA CAPSCREW,HEX
021.0 57040024 2.0 EA PIN,POWERHEAD
022.0 95086559 2.0 EA 0-RING
;123.0 95013702 8.0 EA CAPSCREW,HEX SOCKET HEAD
324.0 58214461 2.0 EA GUARD, HOSE
025.0 95934592 4.0 EA CAPSCREW,HEX
026.0 50817428 1.0 EA CLAMP, HOSE
'127.0 57167959 2.0 EA FITTING,BRT,120FS X12SAE
028.0 57907875 3.0 EA ADAPTER
029.0 95086849 2.0 EA O'RING
030.0 58042581 1.0 EA PLUG,PIPE
034.0 57167934 3.0 EA FITTING,L90-120FSX12SAE
035.0 95037446 1.0 EA BUSHING,PIPE
036.0 58044512 1.0 EA BREATHER
037.0 59923482 2.0 EA FITTING,L90,12 OFS
038.0 59921056
•
2.0 EA FITTING,L90,6 OFS
040.0 57344731 1.0 EA HOSE ASSY
045.0 58042334 1.0 EA GAUGE,SIGHT
054.0 57845190 1.0 EA WELDMENT,RISER PLATE
056.0 57495368 1.0 EA HOSE ASSY
T3W
B ,M ')/918534

057.0 57040164 8.0 EA SHIM, TOPHEAD
058.0 58034950 4.0 EA WASHER,ROLLER
059.0 57040347 4.0 EA ROLLER ASSEMBLY See Page 84
060.0 95468633 4.0 EA CAPSCREW
061.0 57040149 4.0 EA WASHER, THRUST
062.0 57274490 1.0 EA SHIM SET, BEARING ADJUST
063.0 57329948 1.0 EA HOSE ASSY
071.0 57864258 1.0 EA HOSE ASSY
081.0 95934733 8.0 EA WASHER,LOCK
084.0 95469037 2.0 EA PLUG,JIC -20
085.0 59924019 2.0 EA FITTING,REDU 12X060FS
086.0 57344731 1.0 EA HOSE ASSY
088.0 95748562 2.0 EA FITTING, HYD
090.() 57940009 1.0 EA HOSE,ASSEMBLY
091.0 95285904 1.0 EA KEY-SQ
093.0 57871774 1.0 EA FITTING,HYD
095.0 95317848 1.0 EA NIPPLE,PIPE
096.0 57174070 3.0 EA FITTING,L90,200FS X2OSAE
097.0 59918557 2.0 EA TEE,BRT -06
098.0 95651378 3.0 EA CAP SCREW
099.0 58057274 3.0 EA LOCKNUT
•
T3W
BOM 57040347
57040347 ROLLER ASSEMBLY
111
11111.11*
1
sarArAisrArAvArarAwi
50r AVIV:AMR
Mo.
02657040347 REV 001

page 84 WARNING' This manual contains data SPECIFIC to the drilling rig with serial number: US021250
T3W
30w, 67040347

001.0 57040032 1.0 EA ROLLER,MACH
002.0 95201547 1.0 EA FITTING,LUBE
003.0 57040156 1.0 EA BUSHING
T3W
BOM 57818700
57818700 MOTOR MODULE 12.5 & 15 r
page 86
D2657818700 REV 000
•
T3W

94171873 2.0 EA MOTOR,HYDRAULIC
58212697 1.0 EA - SEAL KIT
58212705 1.0 EA - SEAL KIT
0O !J 57186728 2.0 EA MOTOR, HYD,12.5"
58212697 1.0 EA - SEAL KIT
58212705 1.0 EA - SEAL KIT
•
T3W
BOM 57596868
C2657596868 REV 001
•
T3W
BOIVI 57596868
57596868 SWIVEL,YOKE ASM,25CM

001.0 57487605 2.0 EA TRUNNION PIN
57554925 8.0 EA - NUT
57554933 8.0 EA - COTTER PIN
57554941 8.0 EA - STUD
002.0 57596942 1.0 EA SWIVEL,25CM,3"CPLG-STR See Page 90
003.0 57404881 1.0 EA YOKE-ASSY FOR 25CMSWIVEL
57487605 2.0 EA - TRUNNION PIN
57554925 8.0 EA -NUT
57554933 8.0 EA - COTTER PIN
57554941 8.0 EA - STUD
57486375 2.0 EA - BUSHING
004.0 57486375 2.0 EA BUSHING
005.0 95934659 4.0 EA CAPSCREW,HEX
006.0 95934733 4.0 EA WASHER,LOCK
•
Serial Number: U5021250
T3W
BOIVf 5 7 596942
1
27
26
19
20
21
22
24
25
18
C2657596942 REV 001
T3W
BOM 57596942

001.0 57595605 1.0 EA BONNET,SWIVEL W/3"CPLG
002.0 57487514 4.0 EA CAPSCREW W/LOCK WASHER
003.0 57438384 1.0 EA 0-RING
004.0 57409237 1.0 EA GLAND, PACKING
005.0 57439341 1.0 EA PACKING-SWIVEL
006.0 57409252 1.0 EA RING, LANTERN
007.0 57409260 1.0 EA PACKING SEAT RING
008.0 57409286 1.0 EA SLINGER, MUD
009.0 57416620 2.0 EA SEAL, HOUSING
010.0 57487563 2.0 EA CAPSCREW
012.0 57487571 1.0 EA HOUSING, BEARING
013.0 57487589 1.0 EA SEAL BOX, LOWER
015.0 57418808 1.0 EA BEARING NUT
016.0 57487423 1.0 ST SETSCREW,ADJ. NUT
•
017.0 57487449 1.0 EA SET SCREW
018.0 57494619 1.0 EA 0-RING, 25CM-233
019.0 57409278 1.0 EA WASHPIPE
021.0 57438376 1.0 EA 0-RING
022.0 57486375 2.0 EA BUSHING
024.0 57487431 1.0 EA BEARING, SPINDLE
025.0 57419996 1.0 EA LOWER SUB
026.0 57487555 1.0 EA PACKING BOX
027.0 57658833 1.0 EA 0-RING
028.0 57438418 2.0 EA BEARING CUP
029.0 57438400 2.0 EA BEARING CONE
•
T3W
BOM 57699654
57699654 SUB,SPINDLE,4.5",2.88IF
4—NOT SHOWN
5—NOT SHOWN
page 92
TB2657699654 REV 005
•
T3W
IV; 5199654
57699654 SUB,SPINDLE,4.5",2.88IF

001.0 57699613 1.0 EA SUB,UPPER,3 1/2"
002,0 57699621 1.0 EA SUB,LOWER, 4-1/2X2.881F
003.0 57699647 1.0 EA RING,LOCKING,4 3/4" See Page 94
004.0 57757312 1.0 EA PLUG,LIFTING-2.7/8 IF See Page 96
005.0 57556565 1.0 EA THREADLOCK
•
T3W
BOM 57699647
57699647 RING,LOCKING,4 3/4".
page 94
C2657699647 REV 001
•
T3W
4,47
57699647 RING,LOCKING,4 3/4"

001.0 µ 57272551 1.0 EA RING,TAPERED
002.0 57272569 1.0 EA RING, TAPERED
003.0 57699639 2.0 EA RING, SPLIT, 4 3/4"
004.0 95939948 16.0 EA WASHER,LOCK,HELICAL SPRG
005.0 95055117 8.0 EA CAPSCREW,AH
•
T3W
BOM 57757312
57757312 PLUG,LIFTING-2.718 IF
HOIST PLUG BAIL
HOIST PLUG BODY
ZERK
TB2657757320 REV 004
page 96 WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: U5021250
•
T3W
BOM 57757312

001.0 58056029 1.0 EA BEARING,THRUST
002.0 58056037 2.0 EA RACE,BEARING
•
T3W
BOM
57844391 CAROUSEL,4.5",6 ROD 20"
List Only
LIST REV 000
page 98 WARNING: This manua► contains data SPECIFIC to the drilling rig with serial number: US021250
• BOM 57844391
REF.
001.0
PART NO.
57602963
QTY
1.0
57844391 CAROUSEL,4,5",6 ROD,20"
UNIT DESCRIPTION
EA CAROUSEL,6X4.5 DIA. ROD
T3W
NOTES
58039454 6.0 EA - SPRING,

002.0 57863268 1.0 EA WRENCH,UPPER B0,4.5"
003.0 57033508 1.0 EA SLING,ROD
58042920 1.0 EA - SLING,ROD HANDLING See Page 100
57322364 1.0 EA - SHACKLE, CHAIN
56932551 1.0 EA - LINK,MASTER
004.0 57494049 1.0 EA ROD STOP, 4.5 PIPE
005.0 95934451 4.0 EA CAPSCREW,HEXHEAD,PLATED
007.0 95934733 4.0 EA WASHER,LOCK
008.0 57228249 1.0 EA WRENCH,BREAKOUT See Page 102
009.0 58035320 1.0 EA GUIDE,4.5 ROD
010.0 57490831 1.0 EA WIPER,ROD- 4.5 DIA.ROD
011.0 57844011 1.0 EA TABLE,RETRACT See Page 104
•
012.0 58063231 1.0 EA HOLDER
013.0 57724346 1.0 EA CAROUSEL,INSTL,T3W See Page 114
014.0 58047101 1.0 EA WRENCH, LOWER
58036575 1.0 EA - WRENCH
58036583 1.0 EA - EAR,MOUNTING
015.0 57874422 1.0 EA PIPING,CAROUSEL See Page 124
•
T3W
BOM 58042920
58042920 SLING,ROD HANDLING
page 100
BRO-T-1098-A REV 003
•
T3W
BOM 58042920
REF. PART NO, QTY UNIT DESCRIPTION NOTES

001.0 58056169 1.0 EA HANDLE-ROD HANDLINGSLING
002.0 58056177 1.0 EA GUIDE,TOP-ROD SLING
003.0 58056185 1.0 EA TUBE,GUIDE-6 ID
004.0 58168360 1.0 EA ROPE,WIRE,5/16 X 16'5
58168352 16.42 FT - WIRE ROPE
005.0 58060161 2.0 EA THIMBLE,WIRE ROPE-5/16
006.0 58060187 6.0 EA CLAMP,CABLE-5/16
•
T3W
BOM 57228249
57228249 WRENCH,BREAKOUT
5
7
9
page 102
D57228249 REV 003
•
T3W
BOM .57228249

001.0 57361412 1.0 EA WRENCH, BREAKOUT-IMPROVED
002.0 58158445 1.0 EA ARM ASSY
003.0 58158429 1.0 EA ARM ASSY
004.0 57345316 1.0 EA CYLINDER, HYDRAULIC
57350035 1.0 EA - KIT,SEAL - CYLINDER
005.0 95328530 1.0 EA PIN,HINGE-1,DIAX1.13GRP
006.2 95228037 1.0 EA PIN,HINGE
007.' 95081709 4.0 EA WASHER,FLAT
008.0 95201547 2.0 EA FITTING,LUBE
009.2 95093399 4.0 EA PIN,COTTER
010.0 95208971 2.0 EA FITTING,LUBE-90 DEG
011.0 95356853 2.0 EA ELBOW,90 DEG STRT THRD
012.0 95228029 1.0 EA PIN,GRIP
013.0 95033940 1.0 EA PIN,ROLL
T3W
BUM
TABLE RETRACT
10 9
SECTION A.A
16
DETAL A
VIEW EI-13
TB2657844011 REV 001
T3W
d Ms 5M44011

001.0 57843740 1.0 EA PLATE,BREAKOUT-WELDMENT
002.0 95265088 1.0 EA PIN,HINGE
003.0 57309650 1.0 EA CYLINDER,HYDRAULIC See Page 106
004.0 95279493 2.0 EA ELBOW,90 DEG MALE
005.0 52262029 1.0 EA PIN
006.0 57128886 1.0 EA BUSHING
007.0 57032690 2.0 EA SUPPORT
008.0 58054602 2.0 EA BAR, SPACER
009.0 57475626 1.0 EA SHIELD,DUST,FRONT,ASM See Page 110
010.0 57124901 1.0 EA SHIELD ASM,DUST-BACK See Page 112
011.0 57714701 1.0 EA BUSHING,20"TABLE
012.0 57600959 1.0 EA PLATE,SWING,20" OPEN
013.0 57575102 1.0 EA BOSS,HINGE
014.0 57575094 1.0 EA BOSS,PIVOT
015.0 54402821 2.0 EA BEARING,SELF LUBE
016.0 58235672 1.0 EA GUSSET
017.0 58041302 1.0 EA GUSSET
018.0 57351900 1.0 EA CYLINDER,AIR
57351959 1.0 EA - KIT,REPAIR 2B,CUSHION
019.0 58036229 1.0 EA CLEVIS, ROD
020.0 58036542 1.0 EA PIN,BREAKOUT WRENCH
021.0 58047101 1.0 EA WRENCH, LOWER
58036575 1.0 EA - WRENCH
58036583 1.0 EA - EAR,MOUNTING
•
T3W
BOM
57309650 CYLINDE.R,HYDRAULIC
1 —Seal Kit
16 —Seal Kit
C2657309650 REV 003
page WARNING This manual contains data SPECIFIC to the drilling rig with serial number: 08021250
T3W
BOM 57309650
REF PART NO. QTY UNIT DESCRIPTION NOTES

001.0 57039695 1.0 EA KIT,SEAL See Page 108
003.0 57242554 1.0 EA LOCKNUT
004.0 57012684 3.0 EA SCREW, SET
005.0 57012676 3.0 EA PLUG, NYLON
007.0 57326795 1.0 EA O'RING
008.0 57326803 2.0 EA U-CUP
009.0 57224081 1.0 EA 0-RING
010.0 57224099 1.0 EA RING, BACK-UP
011.0 57326811 1.0 EA U-CUP
012.0 57224123 1.0 EA WIPER
013.0 57242596 1.0 EA HEADCAP
014.0 57242604 1.0 EA HEAD
015.0 57326829 1.0 EA PISTON
•
T3W
57039695 KIT,SEAL
page 108
E57039646 REV 000
WARNING: This manual contains data SPECIFIC to the drilling dg with serial number: US021250
•
• BOM 57039695
REF.
007.0
PART NO.
57326795
1.0 EA O'RING
T3W
NOTES
008.0 57326803 2.0 EA U-CUP

009.0 57224081 1.0 EA 0-RING
010.0 57224099 1.0 EA RING, BACK-UP
011.0 57326811 1.0 EA U-CUP
012.0 57224123 1.0 EA WIPER
•
T3W
BOM 57475626
ft''- A
L
01-- -4* -
SECTION A—A
CTH-F-636 REV 002
T3W
BOM 57,175626
001.0 57475618 1.0 EA DUST SHIELD-FRONT
002.0 58035510 1.0 EA RUBBER,FRONT
58203035 2804.0 SI - RUBBER
003.1 95934816 11.0 EA CAPSCREW,HEX
006.1 95922324 11.0 EA WASHER,FLAT,NARROW
007.0 58159377 1.0 EA BRACE
•
T3W
BOM 57 tt49e
57124901 SHIELD ASM,DUST-BACK
4
5
6
7
page 112
C2657124901 REV 003
•
•
T3W
BONS 57124901

001.0 57124919 1.0 EA FRAME,DUST SHIELD BACK
002.0 57124927 1.0 EA RUBBER,BACK
58203035 1248.0 SI - RUBBER
003.0 57124935 1.0 EA BRACE,DUST SHIELD BACK
004.0 95934816 13.0 EA CAPSCREW,HEX
007.0 95922183 13.0 EA WASHER,FLAT
•
T3W
BOM 577247
57724346 CAROUSEL,INS►TL,T3W
iA
72
V 12
(CAROUSEL)
49 —11
ra
1/./ZY/
gMMIIM
B
4..
0
82
D2657724346 REV 003
page 114 WARNING. This manual contains data SPECIFIC to the drilling rig with serial number. US021250
T3W
•
72
9
10
VIEW A-A
D2657724346 REV 003
•
T3W
BOM
57724346 CAROUSE ,INSTL,T3W
VIEW B-B
D2657724346 REV 003
page 11E WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250
T3W
003 0 57494510 1.0 EA DRIVE ASSY-CAROUSEL See Page 118
004.0 58041310 2.0 EA RETAINER
005.0 95934659 1.0 EA CAPSCREW,HEX
006.0 95934733 1.0 EA WASHER,LOCK
007,0 95081667 1.0 EA WASHER,FLAT,WIDE
008.0 58145939 1.0 EA SUPPORT
58043225 1.0 EA - SUPPORT
58043290 1.0 EA - BUSHING
009.0 95378626 5.0 EA CAPSCREW
010.0 95081865 5.0 EA WASHER,LOCK
011.0 58041989 2.0 EA PAD, WEAR
58216391 1.5 IN - BAR, NYLON-3-3/4
012.0 95201547 1.0 EA FITTING,LUBE
049.0 58123100 1.0 EA ASSY SUPPORT
58036336 1.0 EA - BUSHING
58043159 1.0 EA - SUPPORT
95201547 1.0 EA - FITTING,LUBE
40 072.0 50344(305 2.0 FT WIRE,LOCK
082.0 95041034 1.0 EA ELBOW STREET
•
T3W
BOM 57494510
57494510 DRIVE ASSY-CAROUSEL
15 7
17
14
14
•
11
10
C57494510 REV 004
• BOM 57494510
REF.
001.0
PART NO.
58043142
QTY
1.0
UNIT DESCRIPTION
EA REDUCER,SPEED
T3W
NOTES
See Page 120
004.1 58151358 1.0 EA MOTOR, HYDRAULIC See Page 122
005.2 95104014 4.0 EA CAPSCREW
006.0 95081865 4.0 EA WASHER,LOCK
009.0 58039207 2.0 EA BRACKET, MOUNTING
013.0 57267528 1.0 EA ADAPTER
57351108 1.0 EA - COUPLING ASSY
57351116 1.0 EA - ADAPTER
58194960 1.0 EA - GASKET
58227661 1.0 EA - SEAL,OIL
95067906 6.0 EA - CAPSCREW
014.0 56953045 1.0 EA GASKET
•
015.0 95033601 1.0 EA PLUG,PIPE,SQ HEAD
016.1 95220976 1.0 EA ELBOW-90DEG,EXT/INT NPT
017.0 95934733 2.0 EA WASHER,LOCK
•
T3W
BOM 58043142
58043142 REDUCER,SPEED
TBRO-P-1357 REV 006
page 120 WARNING This manual contains data SPECIFIC to the drilling rig with serial number: US021250
•
T3W
BOM 58643142

002.0 58226630 1.0 EA COVER
004.0 58194911 1.0 EA GEAR
010.0 58194903 1.0 EA HUB,GEAR
012.0 57731739 2.0 EA KEY,SHAFT
013.0 57731747 1.0 EA KEY,SHAFT
014.0 58194929 1.0 EA SHAFT
016.0 58194937 1.0 EA GEAR,WORM
019.0 58194945 2.0 EA BEARING,BALL
020.0 58194952 1.0 EA BUSHING
026.0 58192915 1.0 EA GASKET
0271 58194960 2.0 EA GASKET
031.0 58227661 2.0 EA SEAL,OIL
033.0 58192923 2.0 EA BUSHING
034.0 95087045 2.0 EA 0-RING
•
T3W
BOM 58151358
58151358 MOTOR, HYDRAULIC
BTH-H-279 REV 002
T3W
BOM 57874422
57874422 PIPING,CAROUSEL •
D-1
SEE DETAIL-C
SEE DETAIL-A -- 7
\\s„..
Li
FROM PORT 'CI" (TONER) (DRIVE ASST-CAROUSEL)
(COUNTER BALANCE VALVE) 5
R -0 PORT •IEV
•
•
-• )CAROUSEL DRIVE)
4 TO PORT 'A'
;CAROUSEL DRIVE)
rAs
4 V,,r).-•
t
E3 FROM PORT •C2*
(COURIER BALANCE VALVE;
FROM PORT 'A*
6 FROM PDRT
(10 SPOOL VALVE) 110 SPOOL VALVE)
DETAL-C
1I0 SPOOL VAIVEI TO PORT 'VZ"
(COUNTER BALANCE VALVE)
6
(NUN FRAME)--
TO PORT 'VI'
!COUNTER BALANCE VALVES
SECTION D-D
DETAL-A
page 124
D2657874422 REV 000

•
T3W
000.0 57250276 1.0 EA KIT, SEAL
000.0 58003989 1.0 EA SEAL KIT-MOTOR
000.0 59643718 1.0 EA KIT,SEAL
001.0 50491729 4.0 EA SCREW, CAP-5/16 X 7/8
004.0 52188851 1.0 EA FLANGE, MOUNTING
007.0 52188885 1.0 EA RACE, BEARING
008.0 56001118 1.0 EA BEARING, MOTOR
009.0 52188893 1.0 EA KEY,WOODRUFF
010.0 52188901 1.0 EA SHAFT, OUTPUT
012.0 59671081 1.0 EA HOUSING
013.0 50669027 1.0 EA DRIVE SHAFT
014.0 59671107 1.0 EA PLATE, SPACER
018.0 50998145 1.0 EA CAP, END
028.0 50998103 1.0 EA PLUG
T3W
EiOM 57874422

001.0 57273716 1.0 EA VALVE, COUNTER BALANCE
002.0 95943668 2.0 EA CAPSCREW,HEX
005.0 57363350 1.0 EA HOSE ASSY
• WARNING. This manual contains data SPECIFIC to the drilling rig with serial number: US021250 page 125
•
T3W
BOM 57724395
inn 7
page 126
TB2657724395 REV 004
•
T3W
X7'724395

001.0 57724387 2.0 EA PLATE,PIVOT,T3W-70K
002.1 57421034 1.0 EA PIN RETAINING
57209520 1.0 EA - PLATE, RETAINING
003.0 57326738 1.0 EA WELDMENT ROD LOADER
58061367 1.0 EA - HANDLE-SLIP
004.0 95920674 4.0 EA CAPSCREW,HEX
006.0 57277790 1.0 EA WASHER,THRUST
007.0 57293540 1.0 EA TOOL,ROD HANDLING See Page 128
008.0 57420309 2.0 EA BEARING-SPHERICAL
009.0 95201547 2.0 EA FITTING,LUBE
010.0 57742421 1.0 EA PIN,RETAINING,LOWER
•
T3W
BOM 57293540
57293540 TOOL,ROD HANDLING
page 128
TB2657293540 REV 006
WARNING. This manual contains data SPECIFIC to the drilling rig with serial number: US021250
•
• BOM 51293540
REF. PART NO.

002.1 57438491
1.0 EA STOP,PLUG
T3W
NOTES
005.0 57296956 1.0 EA PLUG

006.0 57297228 1.0 EA SPRING, COMPRESSION
•
T3W
BOM 57866428
A
1
- • ....) 4
<.. "1"-le----' '5 ,•>4" ....-- -''''
'''....------ -'"..- •-ft
":•••>•-- --4,---
---.^... -..---
,,-- 1'
-...„„„ --... t• ......1 tillI t
..„1,,.. ' • . ....„.
k... ''',...... ...„. ..... ' . • q:-..„
...••
-.S... .A.'" •;:.,„ .....--.7„ -AZ....-.., , ri . • .
t....,-- . I
- .... --.••-•-. --..-..:\,>,.. s-..:.; ..1;
-.... - -,
. '`• „._ ..- ..... \:\
---... : ---:.... f ----- i -I
--... ••••.. 4,
..
• ---:.---1 ,
-....„
-....
.,„,...1
... -____,....„
' ,......
c ;i
•• 1 I ......_ '5' .
. . .4 \-------
-A...!•----,... • ....;
'''..-<-...*--..-„, - cr.,. .4r .' l ':-1 •
----"' ----.',..--> • , .. ,,,, . , •-•:-........- . i
.,....---••..„ \\.., Nte- ° '
. „..::... *... 1041'..i
:.v,
..
'....„ •
---....,_..
-.-•
11--- 5 .
. . -.......
. "
--"----..._ 10`.,.. 1)•
\ \ \\''\'‘ \. ''''' -.•,.-- --.:-..,,.-. .1
...„........„, -----,- . -teal',
- -'E'
- `•••••-• .6:At;
-... ....., ...,. _
‘:lis ........ 0
\ .1.I. /1.'-- .---, •-:„.\ .*---r .,,
....;\
.\• . it ...,<- _...
„/„,...".1 \-•
\ il
g 1
/ „.7
...„.
•
10
11
7
6 8
5
II, • • •.•
• ii , 1•11-
asp_ .1 Jt.l.tyffirfF
,
1,.. ±,1 ,1E,
11.A. hal -
r.
' •
. o
2 -
It •
•
YEW D-D
3
TB2657866253 REV 001
• BOM 57866428
=
T3W
• 15
16
VIEW A-A
26
DETAIL F
TB2657866253 REV 001
•
T3W
BOM 57866428
12
27
SECTION C-C
13
27
VIEW E-E
TB2657866253 REV 001
•
T3W
BOM 57866428

001.0 56258668 1.0 EA ROD SPINNER See Page 134
002.0 57549479 1.0 EA BASE, PIVOT
003.0 57549487 1.0 EA PIN, ROD SPINNER
004.0 57549495 1.0 EA COLLAR, ROD SPINNER
005.0 95935151 1.0 EA CAPSCREW
006.0 95922894 1.0 EA NUT,HEX
008.0 57849366 1.0 EA STUD,WELD 1/2-13X1.00
009.0 95445664 1.0 EA CLAMP,HOSE
010.0 95209409 1.0 EA WASHER,LOCK
012.0 95371258 1.0 EA FITTING,HYD
013.0 95263380 2.0 EA FITTING,HYD-NPT/JIC
015.0 95426235 1.0 EA REDUCER, 0-RING
016.0 57644163 1.0 EA FITTING
• 024.0
026.0
027.0
57866436
57866436
57097891
1.0
1.0
1.0
EA
EA
EA
HOSE ASSY
HOSE ASSY
HOSE ASSY
•
T3W
BOM 56258668
35
19,20
8,10
10,17 7 33
18 24,25
36
22 15
16
33
21 11,
12
16 8,10 3 11,12
16 16
26
18 10,17
22 21 8,10 9,10
C2656258668 REV 002
page 134 WARNING This manual contains data SPECIFIC to the drilling rig with serial number US021250
T3W
,R668
56258668 ROD SPINNER

00 57567190 3.0 EA ROLLER,ROD SPINNER
002 ( 57567182 1.0 EA SPINNER,KNURLED
003.( 54634878 1.0 EA MOTOR
54634886 1.0 EA - KIT,SEAL,MOTOR
004.0 57913303 1.0 EA CYLINDER
006.0 57785651 1.0 EA PLATE,ROLLER MOUNTING
007.0 57785669 1.0 EA PLATE,SPINNER MOUNTING
040.0 57548182 2.0 EA VALVE,FLOW CONTROL
•
T3W
BOM 57880874
28
5
•
-
\
SEE DETAIL A
D2657880874 REV 002
T3W
BONI 57880874
• 57880874 WINCH,INSTALL,18K HE
e"1 , e7. 2171%

7' 1-;
—4— --I :1
4 _ _
62- 19'
I SWING
it
24
7 VIEW A-A
36
37
38
19
• VIEW C-C
D2657880874 REV 002
•
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D2657880874 REV 002
•
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BORN 57880874
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33
35
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D2657880874 REV 002
•
T3W
BO M 57880874
DETAIL F
•
27
page 140
DETAIL 0
D2657880874 REV 002
•
T3W
P:
57880874 WINCI4,INSTAI..L,i8K HE
001.0 57880866 1.0 EA WINCH,18K,HIGH EFF
002.0 95105110 4.0 EA CAPSCREW
003.0 95750543 4.0 EA WASHER,PLAIN
007.0 57412181 1.0 EA ADAPTER FLANGE SAE 20
008.0 57861254 1.0 EA BOOM,JIB ASSY See Page 142
57511255 1.0 EA - SEAL KIT
010.0 57440356 1.0 EA WASHER, THRUST
011.0 57408700 1.0 EA BUSHING
012.0 95201547 1.0 EA FITTING,LUBE
013.0 57129835 1.0 EA PLATE,RETAINER
014.0 95934733 2.0 EA WASHER,LOCK
015.0 95919569 2.0 EA CAPSCREW
016.0 57130270 1.0 EA PIN
017.0 95210852 2.0 EA PIN, COTTER
018.0 58056425 1.0 EA KEY,SQUARE
019.0 57676595 1.0 EA CLEVIS,T3W DH-50K
021.0 57507857 1.0 EA PIN
022.0 95147997 2.0 EA REDUCER,SAE 0-RING 10-6
024.0 57660227 1.0 EA FITTING,45EL
025.0 57860561 1.0 EA HOSE ASSY
026.0 57860512 1.0 EA HOSE ASSY
027.0 57860553 1.0 EA HOSE ASSY
029.0 52251816 6.0 EA CLAMP ASSY
030.0 57262487 3.0 EA CLAMP ASSY
031.0 95301818 2.0 EA CLAMP,HOSE
032.0 57524456 3.0 EA STUD,WELD
033.0 95239521 3.0 EA NUT,HEX
034.0 95457586 1.0 EA CLAMP,HOSE
035.0 95452066 3.0 EA WASHER,FLAT
036.0 95042289 1.0 EA 0-RING
038.0 95055018 4.0 EA CAPSCREW
T3W
BOM c7N
57861254 BOOM,JIB ASSY
11 8
lull! 9
18
!
MI
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18
18 18
SECTION K•K
16,
13
SECTION H-H
3
SECTION PAM
D2657861254 REV 000

in( 142 WARNING- This manual contains data SPECIFIC to the drilling rig with serial number: US021250
T3W
1304 1A,1254

001.E 57264731 1.0 EA BAR
002.0 95201547 2.0 EA FITTING,LUBE
003.0 95093399 2.0 EA PIN,COTTER
004.0 57440224 1.0 EA SLIDE,JIB BOOM
005.0 57440190 1.0 EA HOUSING,JIB BOOM
57441982 1.0 EA - PIVOT PIN
57511255 1.0 EA - SEAL KIT
007.0 57130379 1.0 EA CLEVIS ASSY
008.0 97507857 2.0 EA PIN
009.0 95018982 2.0 EA PIN,COTTER-3/16 X 1-1/2
010.0 57440307 1.0 EA PLATE
011.0 57440323 2.0 EA LUG CYL.
012.0 57129785 2.0 EA SHEAVE,5/8 WIRE ROPE
013.0 54386636 4.0 EA BEARING,CYL ROLLER
014.0 57130213 1.0 EA SHEAVE PIN
015.0 57441990 1.0 EA PIN SHEAVE
016.0 57507816 36.0 EA BALL,CHROMESTEEL13/32DIA
017.0 57406720 1.0 EA SHOE,SUPPORT
018.0 95208971 5.0 EA FITTING,LUBE-90 DEG
019.0 95280913 1.0 EA FITTING,LUBE
•
T3W
BOM 57425811
SEIZE END
37
TB2657425811 REV 002
T3W
/5811
57425811 LINE,1 PART/18K WINCH

Ri PART NO. QTY UNIT DESCRIPTION NOTES
03E 58166224 1.0 EA HOOK,SUCKER ROD-#9120TON
57511933 1.0 EA - BEARING ASSY
57511941 1.0 EA - KIT, REPAIR
57511958 1.0 EA - NUT AND RIVIT
57511966 1.0 EA - PIN, LOCK
037. 56804743 4.0 EA CLAMP, CABLE
038.1 56773096 1.0 EA THIMBLE, WIRE ROPE-5/8
039.0 57404964 150.0 FT WIRE ROPE-5/8 DYFORM-18
WAkNING This manual contains data SPECIFIC to the drilling rig with serial number: US021250 page 145
•
T3W
BOM 57860991

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•
T3W
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6
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D2657860991 REV 002 •
T3W
860991

001.0 57818692 1.0 EA CONTRL,4WAY,JIB
58004011 1.0 EA - RUBBER BELLOWS
002.0 57880692 1.0 EA HRC, STRT HANDEL
57937898 1.0 EA - BELLOWS,RUBBER
003.0 57844383 1.0 EA PLATE,COVER
004.0 95452066 8.0 EA WASHER,FLAT
005.0 95403044 4.0 EA CAPSCREW
008.0 57888273 1.0 EA NAMEPLATE, CONTR HELPER
009.0 57863318 1.0 EA GUARD,JIB CONTROLLER
011.0 57817199 1.0 EA NUT,PLASTIC GORTEX VENT
012.0 57817181 1.0 EA VENT,GORTEX
•
•
•
Section E - Powerpack/Engine
•
T3W
BOM 57869257
D2657869257 REV 000
T3W
Engine Block
45
Per Engine Manufacture 63 14

18 Fusible Link
53
Engine Ground
Alternator
DETAIL "D"
24
14
Fusible Linkl 14
18
From \ 22
Batteries
From
Batteries
Starter Motor
2
STARTER 1 STARTER 2
DETAIL "G"
D2657869257 REV 000
•
T3W
BOM 57869257
24
57 58
107
Relay
Mtg Bracket
RELAY RELAY
65 7 'TARTER 2 STARTER 1i
107
DETAIL "F"
D2657869257 REV 000
T3W
'57
• D2657869257 REV 000
•
BOM 57869257 T3W
77
43
•
49 36
50 37
25
34
23 35
page 156
D2657869257 REV 000
0
•
•
T3W
BOM 57869257
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D2657869257 REV 000
•
T3W
BOM 51869257
57869257 ENGINE ELEC INSTLN, T3W

002.0 57412710 2.0 EA CABLE, STARTER JUMPER
004.0 57400004 1.0 EA PLUG,SEALING-SIZE 12
008.0 95073920 4.0 EA SCREW
009.0 95923025 4.0 EA NUT,MACHINE SC.#6
010.0 95922548 4.0 EA LOCKWASHER
011.0 54529623 1.0 EA PLUG,ELEC CONNECTOR
012.0 57386955 7.0 EA CONTACT,14 AWG SOCKET
013.0 57615338 1.0 EA WEDGE,CONNECTOR 8 PIN
014.0 50695063 3.0 EA B2B
016.0 59956466 2.0 EA RELAY,SOLENOID-24VMARINE
018.0 56999360 3.0 EA WIRE LINK-9
021.0 95484408 6.0 EA TERMINAL
022.0 95359329 2.0 EA TERMINAL,12-10,1/2 RING
023.0 57869513 1.0 EA HARNESS CONSOLE/JUNC BOX
•
024.0 57752719 1.0 EA HARNESS,ENGINE,2STRT-T3W
025.0 57394348 1.0 EA CABLE,90 DEG.PLUG
026.0 57780439 1.0 EA HARNESS,WIRING,T3W
027.0 50625938 20.0 IN WIRE, 14AWG-GREEN
030.0 57196677 2.0 EA DIODE,3AMP,600 VOLT
034.0 95318440 1.0 EA CONNECTOR
035.0 52236569 1.0 EA GASKET, 3/4
036.0 95373999 1.0 EA CONNECTOR,STRAIGHT-1
037.0 52236551 1.0 EA GASKET, 1
038.0 98632888 3.0 EA SEAL,HOLE
040.0 57435034 3.0 EA BRIDGE, ELEC. INSULATED
043.0 57435075 7.0 EA BRIDGE,UK-4,INSULATED
045.0 57093080 18.0 EA MARKER, WIRE
046.0 57551947 1.0 EA HOLDER, FUSE, WATERPROOF
047.0 57551954 1.0 EA FUSE, TIME DELAY, 2A
049.0 95245072 1.0 EA CONNECTOR,1/2, STR LT
050.0 52236577 1.0 EA GASKET,SEALING
053.0 95359600 1.0 EA TERMINAL
056.0 95748802 24.0 EA TIE,CABLE
057.0 95922183 8.0 EA WASHER,FLAT
063.0 56949084 1.0 EA WIRE,GROUND
•
56937022 18.0 FT - WIRE ELEC
065.0 57139131 4.0 EA MOUNT,FLEX-BOLTSANDWICH
065.1 57139131 4.0 EA MOUNT,FLEX-BOLTSANDWICH
067.0 50812411 125.0 IN 14 THHN GRAY
T3W
257

076. 58150202 1.0 EA CONNECTOR,16-14 BUTT SPL
077.( 58150228 4.0 EA TERMINAL, FEMALE PUSHON
079.0 50249655 36.0 IN WIRE,14AWG-BLACK
096.0 57429722 1.0 EA PLUG, 6MM COMPONENT
097.0 57429714 1.0 EA BLOCK, 6MM COMPONENTELEC
098.0 57498339 1.0 EA RESISTOR CF .25W 5.1K
099.0 95301883 1.0 EA CLAMP,HOSE
100.0 57684433 1.0 EA BRACKET
104.0 57678088 1.0 EA CONNECTOR,3 PIN
105.0 57678096 1.0 EA WEDGE,3 PIN
106.0 54530985 3.0 EA PIN,SIZE 16
107.0 57147969 4.0 EA TERMINAL,RING 8GA,5/16
page 159
•
T3W
BOM 57847279
57847279 ENGINE ASSY,W/IN-OUT BOX
110
109
120
/ 132
138 127 129131 133 130
•
-
112
•
22 2 19 46 43 30 32 35
24
21 36 34
DETAIL B
DETAIL A
TB2657844227 REV 003
• BOM 57847279

T3W
SEE DETAIL E )::31

c*" -
,,,,--- ."...•""
. .„,,,,...,...- I MA I NI RAME
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F2c•
DETAIL C
119 9 23 112 2 23 109
120 110
118
1
11 74
10 86
77
87 66
78
123
124
125 81 89
DETAL E
DETAIL C
• TB2657844227 REV 003
T3W
BOM 57847279
118 20
36
SECTION G-G
- .
ti
TB2657844227 REV 003
T3W
BOM f-,7:47279
128
138
(FNGINF OH PAN)
134
135
136
137
• DETAIL F
TB2657844227 REV 003
page 163
•
T3W
BUM
70 68 73
TORQUE: 85-40 FT-LBS
57
•
20
36
37- TOROLE: 23-30 FT-LBS
36
58
TORQUE: 23-30 FT LBS
TORCH 35-50 FT-LBS
page 164
TB2657844227 REV 003
•
T3W
Ii0M 57847279

REF., PART NO. QTY UNIT DESCRIPTION NOTES
001.0 57772675 1.0 EA ENGINE,C15,580HP@1800 T3 See Page 168
002.0 51061661 6.0 EA MOUNTING,ANTI-VIBRATION
003.0 57405821 1.0 EA BUSHING,QD,2-3/8 SHAFT
004.0 57903494 1.0 EA COUPLING,LORD
005.0 57245870 2.0 EA ADAPTERFRT.ENG.CAT3406TA
006.0 57580284 2.0 EA COVER,CLUTCH HOUSING
007.0 57776288 1.0 EA SUPPORT,FRONT ENGINE,T3W
008.0 57660649 1.0 EA MOUNT,ENGINE LEFT
009.0 57660631 1.0 EA MOUNT,ENGINE RIGHT
010.0 57599672 1.0 EA BLOCK,SWITCH MOUNTING
011.0 57599714 1.0 EA CAM SHAFT,WELDMENT
57599664 1.0 EA - SHAFT,CAM
012.0 95922225 12.0 EA WASHER,FLAT
014.0 95934626 24.0 EA CAPSCREW,HEX
017.0 57604738 1.0 EA PLATE,DRIVE
018.0 95103867 2.0 EA CAPSCREW
019.0 57660680 1.0 EA SHIM SET
020.0 95922894 2.0 EA NUT,HEX
020.1 95922894 2.0 EA NUT,HEX
021.0 58050782 2.0 EA WASHER
022.0 58042060 2.0 EA LOCKNUT
023.0 57412124 4.0 EA BAR W/2-.81 HOLES
025.0 95934774 4.0 EA CAPSCREW
026.0 95209425 6.0 EA WASHER,LOCK
027.0 95013728 6.0 EA CAPSCREW
028.0 95670535 1.0 EA ADAPTER,FEMALE,STRT THRD
029.0 95279519 1.0 EA FITTING,HYD
030.0 57599557 1.0 EA PLATE,MOUNTING,WELDMENT
032.0 57600843 1.0 EA ELEC BOX ASSY,3406E See Page 176
034.0 95239521 4.0 EA NUT,HEX
035.0 95928982 4.0 EA CAPSCREW
038.0 95338356 2.0 EA WASHER,BEVEL
041.0 95920682 6.0 EA CAPSCREW,HEX
043.0 95934550 2.0 EA CAPSCREW,HEX
044.0 95934584 2.0 EA CAPSCREW
045.0 57846792 1.0 EA INSTL,DRIVE SHAFT GAURD See Page 178
page 165
•
T3W
BUM 57847,
046.0 57578205 1.0 EA BRACKET,RELAY MOUNTING

047.0 57491862 1.0 EA SWITCH, PROMIMITY
049.0 95279519 1.0 EA FITTING,HYD
051.0 95360608 1.0 EA BEARING,BALL
054.0 57604746 1.0 EA WELDMENT,CLUTCH HOUSING
055.0 57747727 1.0 EA COUPLING,TORSIONAL DRIVE
056.0 57604787 1.0 EA SHAFT,CLUTCH
057.0 57728974 1.0 EA SLEEVE,CLUTCH
058.0 57578924 2.0 EA PLATE,CLUTCH ENGAGEMENT
059.0 57599763 1.0 EA SHAFT,CLUTCH ENGAGEMENT
061.0 57579039 1.0 EA HOUSING,BEARING,ASSM
95033841 2.0 EA - PIN,DOWEL
062.0 57170284 1.0 EA BEARING, CLUTCH PILOT
•
063.0 57600199 2.0 EA BUSHING,SELF LUBE
066.0 57611097 1.0 EA PIN,FAST
067.0 54596960 1.0 EA BEARING
070.0 95212106 1.0 EA WASHER,LOCK-BEARING
072.0 57604597 1.0 EA LUBRICANT,DRY,SPRAY-ON
073.0 95209904 1.0 EA LOCKNUT,BRG
074.0 57599698 1.0 EA CAM,LOCKING
075.0 57229452 12.0 EA CAPSCREW,SELF LOCKING
076.0 95064697 12.0 EA WASHER,FLAT 1/2
077.0 57599730 1.0 EA CLUTCH LEVER,WELDMENT
078.0 57604555 1.0 EA ANGLE,PINNING
079.0 95718060 1.0 EA BOLT,SHOULDER
080.0 95417929 1.0 EA NUT,LOCK,HEX,PREV TORQUE
081.0 58148446 10.0 IN CHAIN
084.0 95935235 6.0 EA CAPSCREW
086.0 57604563 1.0 EA NAMEPLATE,UPPER CAM
•
087.0 57604571 1.0 EA NAMEPLATE,PIN HOLE
088.0 95081865 12.0 EA WASHER,LOCK
089.0 57604589 1.0 EA NAMEPLATE,COMP DRIVE
109.0 95930723 8.0 EA CAPSCREW,HEX
• BOM 57847279
REF.
112.0
PART NO.
95929139
QTY
6.0
UNIT DESCRIPTION
EA CAPSCREW,HEX
T3W
NOTES
113.0 95077319 6.0 EA NUT,HEX,STOP

118.0 95245775 6.0 EA WASHER,BEVEL
119.0 57156770 8.0 EA CAPSCREW
120.0 50759455 8.0 EA WASHER,LOCK M20
121.0 57740763 1.0 EA LUBRICATION,SYSTEM See Page 182
122.0 95387387 1.0 EA ADPT 90 DEG.
123.0 56964257 1.0 EA HOSE ASSY
124.0 95287629 1.0 EA CONNECTOR,MALE,37 DEG
125.0 95201547 1.0 EA FITTING,LUBE
126.0 95457974 2.0 EA CAPSCREW
127.0 57052565 1.0 EA HOSE ASSY
128.0 95279436 1.0 EA FITTING,HYD
130.0 52235363 1.0 EA BRACKET,OIL
•
131.0 95315222 1.0 EA FITTING,HYD
132.0 57917635 1.0 EA BALL VALVE,-12NPT,LOCK
133.0 95279105 1.0 EA FITTING,HYD
134.0 95919569 1.0 EA CAPSCREW
135.0 95935003 1.0 EA WASHER,FLAT
136.0 95209409 1.0 EA WASHER,LOCK
138.0 58000365 1.0 EA BRACKET ASM,HOSE MOUNT
139.0 57447245 1.0 EA CLAMP ASSY,STAUFF1-1/40D
page 167
•
T3W
BOM 57772675
57772675 ENGINE,C15,580HP@1800 T3
C2657772675 REV 003
page 168 WARNING: This manual contains data SPECIFIC to the drilling rig with serial number. US021250
T3W
BO 57172675
57772675 ENG NE,C15,580HP©1800 T3

000.0 58000530 1.0 EA BELT, ALTERNATOR 53.5"
001.0 57656266 1.0 EA ENGINE,BARE C15/560HP
001.0 57890444 1.0 EA FILTER,OIL
002.0 51061661 6.0 EA MOUNTING,ANTI-VIBRATION
002.0 57294829 1.0 EA FILTER,FUEL,SECONDARY
003.0 57405821 1.0 EA BUSHING,QD,2-3/8 SHAFT
003.0 57886301 1.0 EA FILTER,FUEL,PRIMARY
004.0 57903494 1.0 EA COUPLING,LORD
004.0 57928913 1.0 EA FILTER,COOLANT,SERVICE
005.0 57245870 1.0 EA ADAPTERFRT.ENG.CAT3406TA
006.0 57580284 2.0 EA COVER,CLUTCH HOUSING
008.0 57660649 1.0 EA MOUNT,ENGINE LEFT
009.0 57660631 1.0 EA MOUNT,ENGINE RIGHT
010.0 57599672 1.0 EA BLOCK,SWITCH MOUNTING
011.0 57599714 1.0 EA CAM SHAFT,WELDMENT
57599664 1.0 EA - SHAFT,CAM
012.0 95922225 6.0 EA WASHER,FLAT
014.0 95934626 24.0 EA CAPSCREW,HEX
015.0 95081865 24.0 EA WASHER,LOCK
017.0 57604738 1.0 EA PLATE,DRIVE
018.0 95103867 4.0 EA CAPSCREW
019.0 57660680 1.0 EA SHIM SET
020.0 95922894 4.0 EA NUT,HEX
021.0 58050782 2.0 EA WASHER
022.0 58042060 2.0 EA LOCKNUT
023.0 57412124 4.0 EA BAR W/2-.81 HOLES
025.0 95934774 4.0 EA CAPSCREW
026.0 95209425 6.0 EA WASHER,LOCK
027.0 95013728 6.0 EA CAPSCREW
028.0 95670535 1.0 EA ADAPTER,FEMALE,STRT THRD
029.0 95279519 1.0 EA FITTING,HYD
030.0 57599557 1.0 EA PLATE,MOUNTING,WELDMENT
031.0 57311730 1.0 EA WASHER,ENG MTG SPACER
032.0 57600843 1.0 EA ELEC BOX ASSY,3406E See Page 172
034.0 95239521 4.0 EA NUT,HEX
035.0 95928982 4.0 EA CAPSCREW
038.0 95338356 2.0 EA WASHER,BEVEL
page 169
•
T3W
BOM 577.(2. 75
57772675 ENGINE,C15,580HP@1800 T3
039.0 95922894 2.0 EA NUT,HEX

041.0 95920682 6.0 EA CAPSCREW,HEX
043.0 95934550 2.0 EA CAPSCREW,HEX
044.0 95934584 2.0 EA CAPSCREW
045.0 57313207 1.0 EA GUARD, DRIVESHAFT T3WCAT
046.0 57578205 1.0 EA BRACKET,RELAY MOUNTING
047.0 57491862 1.0 EA SWITCH, PROMIMITY
049.0 95279519 1.0 EA FITTING,HYD
051.0 95360608 1.0 EA BEARING,BALL
054.0 57604746 1.0 EA WELDMENT,CLUTCH HOUSING
055.0 57747727 1.0 EA COUPLING,TORSIONAL DRIVE
056.0 57604787 1.0 EA SHAFT,CLUTCH
057.0 57728974 1.0 EA SLEEVE,CLUTCH
058.0 57578924 2.0 EA PLATE,CLUTCH ENGAGEMENT
059.0 57599763 1.0 EA SHAFT,CLUTCH ENGAGEMENT
061.0 57579039 1.0 EA HOUSING,BEARING,ASSM
95033841 2.0 EA - PIN,DOWEL
062.0 57170284 1.0 EA BEARING, CLUTCH PILOT
063.0 57600199 2.0 EA BUSHING,SELF LUBE
066.0 57611097 1.0 EA PIN,FAST
067.0 54596960 1.0 EA BEARING
070.0 95212106 1.0 EA WASHER,LOCK-BEARING
072.0 57604597 1.0 EA LUBRICANT,DRY,SPRAY-ON
073.0 95209904 1.0 EA LOCKNUT,BRG
074.0 57599698 1.0 EA CAM,LOCKING
075.0 57229452 12.0 EA CAPSCREW,SELF LOCKING
076.0 95064697 12.0 EA WASHER,FLAT 1/2
077.0 57599730 1.0 EA CLUTCH LEVER,WELDMENT
078.0 57604555 1.0 EA ANGLE,PINNING
079.0 95718060 1.0 EA BOLT,SHOULDER
080.0 95417929 1.0 EA NUT,LOCK,HEX,PREV TORQUE
081.0 58148446 10.0 IN CHAIN
083.0 95943668 2.0 EA CAPSCREW,HEX
T3W
57772675 ENGINE C15,580HP@1800 T3

084.0 95935235 2.0 EA CAPSCREW
085.0 95929006 2.0 EA CAPSCREW
086.0 57604563 1.0 EA NAMEPLATE,UPPER CAM
087.0 57604571 1.0 EA NAMEPLATE,PIN HOLE
088.0 95081865 12.0 EA WASHER,LOCK
089.0 57604589 1.0 EA NAMEPLATE,COMP DRIVE
109.0 95930723 8.0 EA CAPSCREW,HEX
112.0 95929139 6.0 EA CAPSCREW,HEX
113.0 95077319 4.0 EA NUT,HEX,STOP
118.0 95245775 4.0 EA WASHER,BEVEL
119.0 57156770 8.0 EA CAPSCREW
120.0 50759455 8.0 EA WASHER,LOCK M20
121.0 57740763 1.0 EA LUBRICATION,SYSTEM See Page 174
122.0 95387387 1.0 EA ADPT 90 DEG.
123.0 56964257 1.0 EA HOSE ASSY
125.0 95201547 1.0 EA FITTING,LUBE
US021250 page 171
T3W
57600843 ELEC BOX ASSY,3406E
tl
14
C2657600843 REV 001
pie, 172 WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250
• EOM 57600843
REF.
001.0
PART NO.
57599755
QTY
1.0
UNIT DESCRIPTION
EA BOX,MACHINED,ELECTRICAL
T3W
NOTES
57472789 1.0 EA - BOX,1/4 TURNBUCKLE

002.0 57472938 1.0 EA PANEL,BOX DEVICEMOUNTING
005.0 57429730 2.0 EA COVER,TERMINAL BLOCK END
006.0 57443525 13.0 EA BLOCK,UK10 TERMINAL
007.0 56273642 30.0 EA BLOCK, UK4 TERMINAL
008.0 57429748 4.0 EA HOLDER, LOCKING END
009.0 57221855 8.5 IN MOUNTING RAIL (DIN)
010.0 58218280 8.0 EA RIVET, 1/8 DIA. X .5 POP
011.0 57196677 3.0 EA DIODE,3AMP,600 VOLT
013.0 57448425 1.0 EA RELAY, 24VDC COIL
014.0 95921623 1.0 EA SCREW,TAPPING-10-24 X1/2
•
015.0 95922563 1.0 EA WASHER,LOCK
BOM 57740763
57740763 L.UBRICATION,SYSTEM
T3W
•
5
C57740763 REV 000

o(63 T3W
REF . PART NO. QTY UNIT DESCRIPTION

NOTES
001 0 57740771 1.0 EA TUBE,LUBRICATION
002.0 95038634 1.0 EA COUPLING,PIPE
004.0 57291049 1.0 EA RESTRICTOR, JIC/JIC .062
US021250 page 175
T3W
BON;
C2657600843 REV 001
• REF.
001.0
PART NO.
57599755
QTY
1.0
UNIT DESCRIPTION
EA BOX,MACHINED,ELECTRICAL
T3W
NOTES
57472789 1.0 EA - BOX,1/4 TURNBUCKLE

002.0 57472938 1.0 EA PANEL,BOX DEVICEMOUNTING
005.0 57429730 2.0 EA COVER,TERMINAL BLOCK END
006.0 57443525 13.0 EA BLOCK,UK10 TERMINAL
007.0 56273642 30.0 EA BLOCK, UK4 TERMINAL
008.0 57429748 4.0 EA HOLDER, LOCKING END
010.0 58218280 8.0 EA RIVET, 1/8 DIA. X .5 POP
011.0 57196677 3.0 EA DIODE,3AMP,600 VOLT
013.0 57448425 1.0 EA RELAY, 24VDC COIL
014.0 95921623 1.0 EA SCREW,TAPPING-10-24 X1/2
•
015.0 95922563 1.0 EA WASHER,LOCK
• WARNING: This manual contains data SPECIFIC to the drilling

page 177
•
T3W
BOM 57846792
57846792 INSTL,DRIVE SHAFT GAURD
page 178
D2657846792 REV 001
•
S BOM 57846792 T3W
•
SEE DETAIL A
VEIN C-C
D2657846792 REV 001
WARNING: This manual contains data SPECIFIC to the drilling rig

with serial number: US021250
page 179
•
T3W
BOM 57846792
DETAIL A
DETAIL
D2657846792 REV 001
page 180 WARNING! This manual contains data SPECIFIC to the drilling rig with serial number: US021250
T3W

NOTES
001.0 57844235 1.0 EA GUARD,DRIVE SHAFT,T3W
95416871 4.0 EA - NUT,WELD-3/8-16 THRU
95922373 2.0 EA - WASHER,FLAT
57867905 1.0 EA - PLATE, COVER
95922639 2.0 EA - LOCKWASHER,HELICAL SPRNG
003.0 95922373 8.0 EA WASHER,FLAT
005.0 95919197 5.0 EA CAPSCREW

page 181
BOM 57740763
T3W
C57740763 REV 000

number: US021250
page 182 WARNING: This manual contains data SPECIFIC to the drilling rig with serial
' T3W
57740763 LUBRICATION,SYSTEM
PART NO. QTY UNIT DESCRIPTION
NOTES
001 0 57740771 1.0 EA TUBE,LUBRICATION
002.0 95038634 1.0 EA COUPLING,PIPE
004.0 57291049 1.0 EA RESTRICTOR, JIC/JIC .062
WARNING: This manual contains data SPECIFIC to the drilling rig with
serial number: US021250 page 183
BOM 57752644
57752644 BATTERY,INSTL-2STRT,T3W
T3W
13 19
CcO
17
16
14
10 3
10 16
page 184
TB57129538 REV 005
•
• BOM ''52644
REF.
001.0
PART NO.
95261467
QTY
3.0
57752644 BATTERY INSTL-2STRT,T3W
UNIT DESCRIPTION
EA NUT,WING
T3W
NOTES
003.2 95922894 6.0 EA NUT,HEX

005.1 57037517 3.0 EA STUD,LOCK
006.0 35562156 2.0 EA FRAME,HOLD
007.0 50258474 1.0 EA CLIP FRAME
008.0 57124315 1.0 EA GUARD,BATTERY
010.0 57113177 2.0 EA BATTERY,12V-8DW/ELECTROL
011.0 57371510 1.0 EA BATTERY CABLE POS
012.0 57371528 1.0 EA BATTERY CABLE NEG
013.0 30441570 1.0 EA CABLE,BATTERY
014.0 35108216 2.0 EA CLIP
016.2 95922373 9.0 EA WASHER,FLAT
017.0 58234949 3.0 EA SPACER
018.1 58234907 2.0 EA INSULATION
•
019.0 58234972 1.0 EA DECAL, CAUTION
020.0 52246519 1.0 EA CABLE,GROUND-1/0 X 36
021.2 95104147 2.0 EA CAPSCREW,HEX
022.1 95064697 2.0 EA WASHER,FLAT 1/2
• WARNING: This manual contains data SPECIFIC to the drilling

page 185
•
T3W
BOM 57714404
57714404 EXHAUST,W/SLNCR INSULTN
19
20
8 21
14
15
16
17
10
11
12
13
11
page 186
TB2657660557 REV 004
WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: U5021250
•
B(IM 4 T3W
57714404 EXHAUST,W/SLNCR INSUL'TN
19
20
18
21
22
24 23
18
TB2657660557 REV 004
WARNING: This manual contains data SPECIFIC to the drilling rig

with serial number: US021250
page 187
•
T3W
BOM 57714404
57714404 EXHAUST,W/SLNCR INSULTN
page 188
TB2657660557 REV 004
•
T3W
57714404 EXHAUST,VV/SLNCR INSULTN

k L F. PART NO. QTY UNIT DESCRIPTION
NOTES
001.0 57656647 1.0 EA SILENCER,6"W/INSULATION
002.0 57442527 1.0 EA ELBOW,FLEX W/FLANGE-CAT
003.0 57358665 1.0 EA ELBOW,EXHAUST-6 FLANGED
004.0 57580557 1.0 EA WELDMENT,FRONT EXHAUST
005.0 57580599 1.0 EA WELDMENT,REAR EXHAUST
006.0 57714396 2.0 EA CLAMP,13.5" DIA
008.0 50469238 1.0 EA CAP, WEATHER
009.0 52175023 1.0 EA CLAMP, EXHAUST-TURBO
010.0 95919569 5.0 EA CAPSCREW
011.0 95934733 7.0 EA WASHER,LOCK
014.0 95920682 4.0 EA CAPSCREW,HEX
017.0 95922894 4.0 EA NUT,HEX
018.0 50419670 2.0 EA GASKET
019.0 95934378 16.0 EA CAPSCREW,HEX
022.0 95934840 2.0 EA CAPSCREW
024.0 57701120 1.0 EA BLANKET,EXH ELBOW
025.0 57742371 2.0 EA SHIM,7 GAUGE,EXHAUST

page 189
BO M 57765224
57765224 PIPING,RADIATOR
T3W
•
11 15 18
17
29
14
6
27
25
26
13
24
16
34
21
22
2
23
22
24
20
19
7
35
D2657765224 REV 004
BOM 57765224 T3W
• 12
15
• D2657765224 REV 004
T3W
BOM
57765224 PIPING,RADIATOR
15 11
18
17
29
35 23 14 22
26
7 I r 24 22
35
19
VIEW LOOKING FORWARD
D2657765224 REV 004
na ci;) WARNING This manual contains data SPECIFIC to the drilling rig with serial number: US021250
EUt✓ ( '124 T3W

NOTES
001.0 57765232 1.0 EA PIPE,COOLER OUTLET
002.0 57765240 1.0 EA PIPE,ENGINE OUTLET
003.0 57765265 1.0 EA PIPE,COOLER INLET
004.0 57768525 1.0 EA PIPE ASM,ENGINE INLET
57765257 1.0 EA - PIPE,ENGINE INLET
57348476 1.0 EA - COUPLING,SAE HALF
005.0 57688095 1.0 EA ELBOW,ENGINE COOLANT
006.0 95209094 1.0 EA FITTING,HYD
007.0 57580581 1.0 EA ELBOW,RUBBER
54506738 1.0 EA - HOSE,COOLANT
008.0 57765281 1.0 EA ELBOW
009.0 57531162 1.0 EA HOSE HUMP,REDUCING
010.0 56943582 2.0 EA HOSE,RAD.
57101750 6.0 IN - HOSE, RADIATOR
011.0 57213399 1.0 EA HOSE, RADIATOR
57101750 8.0 IN - HOSE, RADIATOR
012.0 57101750 11.0 IN HOSE, RADIATOR
013.0 57767279 1.0 EA BRACKET,RADIATOR INLET
014.0 95481800 2.0 EA U-BOLT
015.0 58175514 10.0 EA CLAMP,HOSE
016.0 58146903 1.0 EA CLAMP,HOSE
017.0 95934733 4.0 EA WASHER,LOCK
020.0 57053183 8.0 IN HOSE,HYD-A06 BULK
021.0 57765273 1.0 EA TUBE,VENT
022.0 95301834 2.0 EA CLAMP,HOSE
023.0 52223070 2.0 EA CLAMP
024.0 95302642 4.0 EA CLAMP,HOSE
025.0 57053183 56.0 IN HOSE,HYD-A06 BULK
026.0 95301883 2.0 EA CLAMP,HOSE
027.0 59506436 1.0 EA FITTING,HOSE
028.0 57780488 1.0 EA BRACKET,PIPE MOUNTING
029.0 57587602 2.0 EA PAD,ANTI-VIBRATION
032.0 95934584 2.0 EA CAPSCREW
033.0 95489159 1.0 EA PLUG,1/4-ORING, HEX SOC
034.0 58086141 1.0 EA CLAMP,HOSE
035.0 58173097 2.0 EA CLAMP,HOSE
US021250 page 193
•
T3W
BOM 57847634
57847634 INSTALLATION,COOLER,T3W
D2657847634 REV 002
•
T3W
BOM 57847634
10 35
•
20
7 26
11 25
24
• D2657847634 REV 002
•
T3W
BONE 5./84 F!3 4
D2657847634 REV 002
pa WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250
• BOM 57847634
T3W
a0 0. 0 DO a OD
0' 0 0
a
ft .1
ILY
• C
38
L.
SECTION C-C
TI
i-
• VIEW B-B
D2657847634 REV 002
•
T3W
BOM 57847634
32
D2657847634 REV 002
T3W
'04
57847634 tNSTALLAT1ON,COOLER,T3W
001.0 57765075 1.0 EA COOLER,ASSEMBLY See Page 200
002.0 56950579 1.0 EA KIT,SPLIT FLANGE
003.0 57657660 1.0 EA MOTOR,HYDRAULIC FAN
57756561 1.0 EA - KIT,SEAL
57756553 1.0 EA - KIT,SHAFT(SHAFT,BRG,KEY)
004.0 57436024 1.0 EA FAN BLADE-54IN. 8 BLADE
006.0 57480980 1.0 EA BUSHING, TAPER-1.75 BORE
007.0 57685034 1.0 EA FLANGE,RUN TEE,CODE 62
010.0 57685026 1.0 EA ADAPTER
011.0 56940281 1.0 EA O'RING,SPLIT FLANGE (20)
012.0 95929121 6.0 EA CAPSCREW,HEX
015.0 54573704 2.0 EA WASHER,BEVEL,SQ,PLATED
016.0 95077301 6.0 EA NUT,HEX STOP
017.0 95935201 4.0 EA CAPSCREW,HEX
018.0 95200093 4.0 EA WASHER,FLAT
019.0 95077319 4.0 EA NUT,HEX,STOP
020.0 95335394 4.0 EA CAPSCREW
022.0 57775579 1.0 EA SHIM,COOLER
023.0 57775587 1.0 EA SUPPORT,COOLER
024.0 95064697 4.0 EA WASHER,FLAT 1/2
025.0 95934733 4.0 EA WASHER,LOCK
026.0 95934659 2.0 EA CAPSCREW,HEX
027.0 95104212 2.0 EA CAPSCREW
029.0 57786360 1.0 EA SHIMSET,COOLER SUPPORT
031.0 57880825 1.0 EA MANIFOLD, ANTI-CAV
57367278 1.0 EA - CARTRIDGE,CHECK VLV.
032.0 57464018 1.0 EA HOSE ASSY
033.0 57848244 1.0 EA HOSE ASSY
037.0 95013769 4.0 EA CAPSCREW
n. 57775561 1.0 EA PLATE,COOLER SUPPORT
•
T3W
BOM 57765075
57765075 COOLER,ASSEMBLY
19
28
30
38
40 23
7 33
36
38
40
•
18
38
40
24
29
31
42
44
45
46
47
48
42
43
44
45
•
39 —NOT SHOWN
D2657765075 REV 003
T3W
BIM S7ti5075
37
40
41
38-
40 32
35
15
37 -
40
14.4.1"1111 U.
1111.1.,L11.11111 . . . .;...
110.1.72.1.11101 ,,. _
11114 14411111111414-1111
timaitlikl., .11
11 0.b.21111 14.-
111111iyimmilll ittimialiti...... 111114111110
11111111111U .--.11
11111 illiiiiiirocL 441 11ro. f ' '
itillitliiia...illomftilioN.--
20 111444..-- IIIIII -"11Ê
It
itatisaiimo,.zmmoit
Irnitelorigirli.- -.imilkIIIINWC
tru ill
11 `fir kaiiiikke....., ita;
_ 111%111%/111ftut-
Nliritotil. -,.,12%rniormi:
itiritaiba-2.--.4lamiiiiii...-
1111114M11111111 illorlit- lii,
1441.___ 20
Novilswitit Nolliral
---41..1% —1:
11111111kiiMillit lir 4114
1 %ftr.
1111*11 1.1111111 . IIII1Mt%
ill %km
Ili 1140.411 il1141111.1
- 111.1 It IMII
1111411.111111
111414411111%1
....11,111111111
F41
111111441%:L1110
Ilk 11 II aId
ler.- - -"milk%
11411111111111%
INItir41111141111101 it I
41114
ININIgalli. 1.111%411111. .1 1111. 1
1"111"1"441111
10111111 L
all"
%
11411141.17111,11111111m11 11011111111.III I
iiitaci:61 1111111
1
38 11141 1.111
40 itmlft. "oh— r41.1•44•44:-
___141110114•41
kotiftkiiii %iiiift044411.4%fti
%%04":"%i
iiiiim ,,,
iiiiikiiii vi%ok
14
32
35
D2657765075 REV 003
T3W
BOM 5-
tifil ill
,
' N
\
•
‘
1 i efifiiiiill / \\\ N§
\0.\\ 1
12
16
D2657765075 REV 003
page: A') WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250
•
T3W
BOM 57765075
11
CAC R AD HOC COC
• 13 10 6 10
• D2657765075 REV 003
•
T3W
BOM 57765075
001.0 57783532 1.0 EA FRAME,BOTTOM,COOLER
002.0 57775330 1.0 EA FRAME,COOLER,RHT CHANNEL
57775371 32.0 EA - INSERT,3/8"THREADED
003.0 57775355 1.0 EA FRAME,COOLER,LFT CHANNEL
95416871 32.0 EA - NUT,WELD-3/8-16 THRU
004.0 57775447 1.0 EA COOLER,FRAME TOP
005.0 57775520 1.0 EA CAC,HEAT EXCHANGER
006.0 57775538 1.0 EA RADIATOR,HEAT EXCHANGER
007.0 57775546 1.0 EA HOC,HEAT EXCHANGER
008.0 57775553 1.0 EA COC,HEAT EXCHANGER
009.0 57775389 32.0 EA BRACKET,RETAINER
010.0 57775397 3.0 EA SEPARATOR,HEAT EXCHANGER
011.0 57782856 1.0 EA TANK,SURGE
012.0 57775405 1.0 EA SHROUD,ASSEMBLY
57725574 1.0 EA - SHROUD
•
95922894 24.0 EA - NUT,HEX
013.0 57736878 1.0 EA SHROUD,ROLLED RING
014.0 57782781 1.0 EA PANEL,BOTTOM,REAR,ASM
57775306 1.0 EA - PANEL,BOTTOM,REAR
57782807 8.0 EA - INSERT,THREADED,3/8"
015.0 57782799 1.0 EA PANEL,TOP,REAR,ASM
57775421 1.0 EA - PANEL,TOP,REAR
57782807 8.0 EA - INSERT,THREADED,3/8"
016.0 57736803 1.0 EA MOUNT,MOTOR,ASM
017.0 57775496 4.0 EA STRAP,SHROUD
018.0 57547580 2.0 EA GAUGE,SIGHT
019.0 57547614 2.0 EA BARB,HOSE
020.0 57736779 2.0 EA GUARD,WIRE TRASH (HALF)
021.0 57736837 1.0 EA GUARD,FINGER 56" SYM
022.0 57736845 1.0 EA BRACKET,MOTOR
023.0 57775439 2.0 EA FITTING,BARBED HOSE
024.0 95301883 3.0 EA CLAMP,HOSE
025.0 51792323 1.0 EA CAP,RADIATOR
026.0 57775413 2.0 EA SEAL,TRIM
027.0 57775488 18.0 IN HOSE,BULK
028.0 57775488 18.0 IN HOSE,BULK
•
029.0 57775504 132.0 IN HOSE,BULK
030.0 95220844 4.0 EA CLAMP,HOSE
031.0 95301370 2.0 EA CLAMP,HOSE
032.0 95935227 72.0 EA CAPSCREW
033.0 95916821 4.0 EA CAPSCREW,HEX
• BONY 57765075
REF.
034.0
PART NO.
95077665
QTY
64.0
UNIT DESCRIPTION
EA NUT,HEX FINISHED,BRASS
T3W
NOTES
035.0 95922225 140.0 EA WASHER,FLAT

037.0 95237079 18.0 EA SCREW,FLANGE,CAP HEX
038.0 95366761 66.0 EA SCREW,FLANGE,CAP HEX
042.0 95035408 24.0 EA CAPSCREW,HX
044.0 95064697 44.0 EA WASHER,FLAT 1/2
045.0 95934733 24.0 EA WASHER,LOCK
047.0 95200093 8.0 EA WASHER,FLAT
T3W
BON
57765034 PIPING,CHG AIR COOLER
10
11
0111111111
10
11
7
17
8
9
111111111111 12
16
10
11 7
8
9
"
4111111111111111
10
11
D57765034 REV 002
T3W
57765034 PIPING,CHG AIR COOLER
REI PART NO. QTY UNIT DESCRIPTION NOTES

001. 57765042 1.0 EA PIPE,INLET CAC
002.0 57765059 1.0 EA PIPE,OUTLET-CAC
003.0 57580474 1.0 EA STACK,ENG.INLET
005.0 57760746 1.0 EA SUPPORT,PIPING CAC
006.0 57765166 1.0 EA BRACKET,PIPE SUPPORT
007.0 95391173 2.0 EA U-BOLT
009.0 95934733 8.0 EA WASHER,LOCK
010.0 56280852 12.0 EA CLAMP,CONSTANT TORQUE
011.0 57580516 4.0 EA CONNECTOR,CHRG AIR
015.0 95934584 2.0 EA CAPSCREW
017.0 95935003 2.0 EA WASHER,FLAT
•
•
•
Section F - Air Cleaners
•
T3W
BOM 5777'1659
57772659 CLEAN ER,AIR,T3W,1070,ASM
TOWER REST
TURBO
COMPRESSOR
-- 9
COVER PLATE
ENGINE
13 5 16 20
TB2657772659 REV 001
T3W
BOM 57772659
57772659 CLEANER,AIR,T3W,1070,ASM

001.0 50616028 2.0 EA AIR CLEANER See Page 212
002.0 58044561 1.0 EA HOSE HUMP,REDUCING
003.0 57402828 1.0 EA TUBE ,AIR-INLET 7 X 70
004.0 56799844 1.0 EA HOSE HUMP
005.0 56940364 1.0 EA HOSE HUMP
006.0 57580342 1.0 EA TUBE,AIR DUCT
007.0 52277431 1.0 EA ELBOW,RUBBER
008.0 57580359 1.0 EA TUBE,AIR DUCT
009.0 57579179 1.0 EA COVER,BAFFLRE PLATE
010.0 58044744 2.0 EA BAND,MOUNTING
011.0 52265311 2.0 EA INDICATOR,RESTRICTION
012.0 57176141 1.0 EA ELBOW,RUBBER-45 DEG
014.0 57580367 1.0 EA INTAKE,COMPRESSOR
015.0 59896308 6.0 EA SCREW,HEX WASHER HEAD
018.0 95934592 4.0 EA CAPSCREW,HEX
020.0 95922894 4.0 EA NUT,HEX
021.0 56899669 2.0 EA SHROUD,INLET
•
T3W
BOM.50616028
16 NOT SHOWN
14
page 212
D347759 REV 006
•
T3W
RE I- PART NO. QTY UNIT DESCRIPTION NOTES

000,0 50621796 1.0 EA KIT, GASKET-AIR CLEANER
001.0 50816479 1.0 EA CUP ASSY
002.0 50816487 1.0 EA CLAMP
004.0 50816503 1.0 EA INLET,AIR
005,0 50816511 1.0 EA CLAMP
006,0 50816529 1.0 EA BODY ASSY-AIR CLEANER
007.0 50616408 1.0 EA ELEMENT,SAFETY
009.0 50816420 1.0 EA NUT
010.0 95002697 1.0 EA PIN, COTTER
0 0 50616390 1.0 EA ELEMENT, PRIMARY
2.0 50816446 1.0 EA NUT, WING
014.0 50816537 1.0 EA ACCESS COVER
016.0 56899669 1.0 EA SHROUD,INLET
•
•
•
Section G - Fuel System
•
T3W
BOM 57581605
To inlet of Check Valve

of Fuel Pump Assembly
(by I—R) mounted on engine
Attach to Fuel Return port

on engine at rear of block.
13
•
5
6 29 30
30 11 6
11
14 14
9
page 216
TB2657372294 REV 007
•
T3W

001.0 57581563 1.0 EA TANK,FUEL,ALUMINUM
002.0 57581589 2.0 EA TUBE,FUEL SIPHON
003.0 57848251 1.0 EA GUAGE,FUEL TANK
004.0 95267092 1.0 EA PETCOCK
005.0 50219518 1.0 EA FILLER, TANK-2.5 NPT
57497190 1.0 EA - HEAD ASSY,FILLER-2.5NPT
54418090 1.0 EA - GASKET
006.0 95054128 8.0 EA CAPSCREW
008.0 95077590 8.0 EA NUT,HEX,STOP
009.0 95037446 1.0 EA BUSHING,PIPE
011.0 56954365 1.0 EA HOSE ASSY
012.0 95279402 1.0 EA ELBOW,90DEG MALE 37DGFL
013.0 95356721 1.0 EA ELBOW,90 DEG MALE
014.0 95002143 2.0 EA PLUG,PIPE-SQ HEAD
015.0 57594426 1.0 EA BREATHER,FUEL TANK
029.0 52246774 100.0 GL FUEL, DIESEL
T3W
BOM !-‘7 rFar
57784084 PIPING & FUEL COOLER
'.."-TCL TANK
2
1
12
3
FROM ENGINE
10
7
7
9
8
10 9
10 .-14c41Puirift"Itivfti
11 14
15
16
17
SEE DETAIL A
DETAIL A
DETAIL
TB2657784084 REV 006
T3W
57784084 PIPING 8, FUEL COOLER

00 95357570 2.0 EA CONNECTOR,STRT THRD
002 ( 57370439 1.0 EA HOSE ASSY
00 56956725 1.0 EA HOSE ASSY
004 ( 57780868 2.0 EA BRACKET,FUEL COOLER
005 57780850 1.0 EA SUPPORT,FUEL COOLER
006 57775595 2.0 EA RAIL,FUEL COOLER FRAME
007.t 95916821 8.0 EA CAPSCREW,HEX
008 95943668 2.0 EA CAPSCREW,HEX
009 ( 95929782 8.0 EA NUT,HEX,FINISHED
010.(. 95922225 10.0 EA WASHER,FLAT
011.( 95934303 8.0 EA WASHER,LOCK,PLATED
012.0 57472698 1.0 EA COOLER,FUEL,QSK19ENGINES
013.0 95169660 1.0 EA SWIVEL,90DEG-INTNPT/JIC
014.( 95935128 2.0 EA CAPSCREW
015.0 95922894 2.0 EA NUT,HEX
016.0 95064689 4.0 EA WASHER,PLAIN,FLAT,TYPE A
•
T3W
BOM 57902868
57902868 ETHER,C15,INSTALLATIONI
CAC P.
SEE DETAIL B
ENG.
MAIN COOLER
page 220
TB2657902876 REV 000
•
• BUM 57902868
57902868 ETHER,C15,INSTALLATION
T3W
4
3 n
2
1
• ti) i443t4%==•
0
Ir4
a 0 0
0
V-
•
DETAIL. VIEW A
TB2657902876 REV 000
•
T3W
BOM 57902868
UPPER CAC ELBOW ATOMIZER
SP
11111 I se
Alibltalir -
El
la '.131111=tiiams
ll
41 021I %
--'4.04".11w..1,
irli Ali .A.
giaatimmoimenia 1:1 °.
11W4 1111 .!....:
n 4 ' iriartp N111
- 144-
111111......... ' -.L411,114N
tirWlil lr la !tlieraar".MWBOFill - '..).
1411,
',IS
fttS
I
4111111111M.11011
(.... ,
Ver11111111111111,61/4 44
4
‘.1041.......
.4 . .61
N .eanko ioo
ttelt
.. ••••••••••...."...n. '
DETAIL VIEW B
TB2657902876 REV 000
rape 222 WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250
T3W
868
57902868 ETHER,C15,INSTALLATION

001.( 95934998 4.0 EA WASHER,FLAT
002.0 95959144 4.0 EA WASHER,LOCK-5/16
004.0 95105243 4.0 EA CAPSCREW
005.E 57903015 1.0 EA ETHER,KIT,CAT C15 See Page 224
006.0 57902850 1.0 EA BRACKET,ETHER,MOUNTING
007.0 57903098 1.0 EA CYLINDER,ETHER
008.0 54651237 1.0 EA PLUG,2 CIRCUIT
009.0 50249671 240.0 IN WIRE,14AWG-WHITE
•
T3W
BOM 57903015
C2657903015 REV 000
• BUM
T3W
• C2657903015 REV 000
T3W
B(,
C2657903015 REV 000
Page WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250
•
T3W
BUM 57903015
57903015 ETHER,KIT,CAT C15

001.0 57903023 1.0 EA VALVE ASSY,ETHER
002.0 57903049 1.0 EA CONTROL FITTING,ETHER
003.0 57903031 1.0 EA BRACKET,ETHER MOUNTING
004.0 57903064 1.0 EA TUBING,ETHER,48"
005.0 57902827 1.0 EA ATOMIZER,ETHER,C15
T3W
57728289 PROHEAT,INST,T3W
VIEW A—A
19
FNGINF
-
TO HHOH-
EAT
18
— ••%-t......ar
FUEL
LINE t
it
tl
17 12 1
D2657728289 REV 001
T3W
• 2
3
RETURN FROM
20 PROHEAT
N,
16
13
VIEW D—D 11
12
•
18 17
D2657728289 REV 001
BOM 2V18$1
57728289 PROHEAT,INST,T3W
T3W
•
rr
1
1 Il
It COOLANT OUT
la
ELECTRICAL
4 II WIRING
5 tl
6
7 I COOLANT FUEL
I I IN —1 IN
II
-7
I
1
;1
11
U
• •
•••
-8
VIEW B—B
HEATING SYSTEMS
MANUAL
WED / 2
14 15 o
Ti in
,s_
ri AM
U O
CLOCK it TIME Ir. DAY 11)
ca ) TIMER
VIEW D—D
D2657728289 REV 001
T3W

001 1. 57643827 1.0 EA HEATER,DIESEL FIRED See Page 232
002.G 57655722 1.0 EA TIMER,7 DAY DIGITAL
003.0 95958765 2.0 EA SCREW,ROUND HD- T-UDRIVE
004.G 95929006 4.0 EA CAPSCREW
005.0 95922225 4.0 EA WASHER,FLAT
008.0 57729790 2.0 EA ANGLE,W/HOLES
009.0 56970379 1.0 EA PIPE, THD
010.0 95264909 1.0 EA ELBOW,90DEG-EXT/INT NPT
011.0 50212224 2.0 EA VALVE,BALL-3/4
012.0 50112895 2.0 EA HOSE STEM-3/4
013.0 95323358 1.0 EA FITTING,STR-EXT NPT RUN
014.0 95264958 1.0 EA TEE,MALE RUN,NPTF
015.0 95219739 1.0 EA ADAPTER
016.0 95341053 1.0 EA FITTING,HYD
017.0 95220844 4.0 EA CLAMP,HOSE
018.0 57044828 200.0 IN HOSE,HYD-Al2 BULK
019.0 57044828 200.0 IN HOSE,HYD-Al2 BULK
020.0 95037438 1.0 EA BUSHING,PIPE
BOM 57643827
T3W
•
71
79 73
79
74
75
7
70
77
WELDED IN
76 72 BASE PLATE
3 46 47
E2657643827 REV 001
gage 232 WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: U5021250
•
T3W
BOM 57643827
57643827 HEATER,DIESEL FIRED
• 80
37
• E2657643827 REV 001
•
T3W
BOM 57643827
32
25
81
E2657643827 REV 001
T3W
BOM 57643827
i 57643827 HEATER,DIESEL FIRED
• E2657643827 REV 001
T3W
BOM 5:71,4

001.0 .5/654949 5.0 EA ELBOW,3/16HOSE X 1/8 NPT
002.0 57654956 1.0 EA SENSOR,FLAME
003.0 57654964 6.0 EA SCREW,HEX HD
004.0 57654972 12.0 EA SCREW,HEX FLNG
005.0 57654980 1.0 EA GASKET,SEAT,IGNITER
006.0 57654998 1.0 EA IGNITER
007.0 57655003 1.0 EA LEAD,IGNITION W/BOOT
008.0 57655011 1.0 EA GLASS KIT,SIGHT
009.0 57655029 1.0 EA BLOWER,24V
010.0 57655037 1.0 EA GASKET,BLOWER
011.0 57655045 1.0 EA NOZZLE,FUEL
012.0 57655052 1.0 EA O-RING,NOZZLE
013.0 57655060 1.0 EA CASTING,FAN END
014.0 57655078 5.0 EA CLAMP,FUEL HOSE
015.0 57655086 1.0 EA REGULATOR,FUEL
016.0 57655094 5.0 FT HOSE,AIR & FUEL
017.0 57655102 1.0 EA SCREEN,BLOWER INLET KIT
018.0 57655110 1.0 EA CLAMP,SPRING,AIR
019.0 57655128 1.0 EA BLADE,FAN
020.0 57655136 1.0 EA HEAT EXCHANGER
021.0 57655144 1.0 EA TUBE,COMBUSTION
022.0 57655151 4.0 EA SCREW,SOCKET
023.0 57655169 6.0 EA LOCKWASHER,#10
024.0 57655177 1.0 EA CLAMP,EXHAUST PIPE
025.0 57655185 1.0 EA PIPE,EXHAUST
026.0 57655193 3.0 EA BRACKET, "J"
027.0 57655201 1.0 EA COIL,IGNITION
029.0 57655219 2.0 EA ELBOW,3/4 HOSE
030.0 57655227 1.0 EA NUT,NYLON
031.0 57655235 1.0 EA CLAMP,CUSHIONED
032.0 57655243 1.0 EA MOUNT KIT,RUBBER
037.0 57655250 2.0 EA CLAMP,GEAR #32
038.0 57655268 1.0 EA INPUT,AUXILIARY PCM
039.0 57655276 1.0 EA HARNESS,MAIN INTERNAL
040.0 57655284 1.0 EA KIT,HOLDER,FUSE
041.0 57655292 1.0 EA FUSE,15A
042.0 57655300 3.0 EA SPACER,CONTROLLER
043.0 57655318 3.0 EA GROMMET,CONTROLLER MOUNT
044.0 57655326 1.0 EA SENSOR,TEMPERATURE
045.0 57655334 1.0 EA O-RING,TEMP.SENSOR
046.0 57655342 2.0 EA CLIP,WIRE HARNESS
047.0 57655359 1.0 EA SENSOR,OVERHEAT
T3W
57643827 HEATER,DIESE
048.0 57655367 1.0 EA O-RING,OVERHEAT
049.0 57655375 1.0 EA HARNESS,SWITCH
050.0 57655383 1.0 EA HARNESS,POWER
051.0 57655391 1.0 EA COVER,CONNECTOR
052.0 57655409 1.0 EA COMPRESSOR,24V
053.0 57655417 2.0 EA COUPLING
054.0 57655425 1.0 EA PUMP,FUEL-GEAR
055.0 57655433 2.0 EA SCREW
056.0 57655441 1.0 EA FITTING,FILTER CAP
057.0 57655458 1.0 EA O-RING,FUEL FILTER
058.0 57655466 1.0 EA FILTER, FUEL
059.0 57655474 1.0 EA VALVE KIT,RELIEF
060.0 57655482 1.0 EA SCREW
061.0 57655748 1.0 EA WASHER,SEALING
062.0 57655490 1.0 EA FILTER,AIR
063.0 57655508 1.0 EA BRACKET
064.0 57655516 2.0 EA CLAMP GEAR #36
065.0 57655524 4.0 EA SCREW,SOCKET
066.0 57655532 4.0 EA LOCKWASHER,1/4
067.0 57655540 1.0 EA HOSE,COOLANT
068.0 57655557 2.0 EA CLAMP,#10 SILICONE
069.0 57655565 1.0 EA PUMP,COOLANT 24V
070.0 57655573 1.0 EA PLATE,BASE MOUNTING
071.0 57655581 1.0 EA LID, ENCLOSURE
072.0 57655599 1.0 EA BASE,ENCLOSURE
073.0 57655607 4.0 EA GROMMET
074.0 57655615 2.0 EA NUTS, PANEL
075.0 57655623 2.0 EA SCREW,HEX FLNG
076.0 57655631 4.0 EA SCREW
077.0 57655649 8.0 EA WASHER,5/16
078.0 57655656 4.0 EA NUT,SELF-LOCKING
079.0 57655664 2.5 FT SEAL,WEATHER,ENCLOSURE
080.0 57655672 15.0 FT HOSE,AIR & FUEL
081.0 57655680 1.0 EA PICKUP ASM,FUEL
087.0 57655698 1.0 EA SWITCH,ON/OFF,24V
088.0 57655706 4.0 EA CONNECTOR
089.0 57655714 1.0 EA DECAL,TOGGLE SWITCH
091.0 57655730 1.0 EA TIMER KIT INSTALLATION
page 237
to the drilling rig with serial number'. US021250
SPECIFIC
WARNING'. This manual contains data
•
•
•
Section H - Compressor/Air System
•
T3W
BOM 57846768
//-(COMPRESSOR INLET)
45
28 42 43 6
44 20
34
33
29
26
40
28
27
31 9 32
13 10
TB2657846768 REV 003
T3W
BO 17846168
• 57846768 COMP ASSY,1070 HR 2.5
36
37
38
POSITION DISCHARGE 11
PIPE AS SHOWN
TB2657846768 REV 003
•
T3W
BOM 57846768
57846768 COMP ASSY,1070 HR 2.5
3 PIVOT FOR CHECK VALVE MUS -

FIE ON TOP AS SUOWN
TB2657846768 REV 003
• BOM /846768
REF.
002.0
PART NO.
36017549
QTY
1.0
UNIT DESCRIPTION
EA AIREND - HR 2.5
T3W
NOTES
See Page 244
003.0 36843720 1.0 EA VALVE,CHECK
004.0 57815433 1.0 EA VALVE,BUTRFLY 8" FOR EAR
005.0 95568960 2.0 EA GASKET
006.0 56946247 8.0 EA CAPSCREW
007.0 50855923 2.0 EA WASHER,LOCK
008.0 95364154 2.0 EA GASKET
009.0 35292135 8.0 EA CAPSCREW
011.0 57922254 1.0 EA FLANGE,PIPE,COMP VICT
013.0 95266425 2.0 EA 0-RING
014.0 95754875 1.0 EA FITTING,HYD
019.0 57593840 1.0 EA BRACKET,PILOT VALVE
020.0 50759455 8.0 EA WASHER,LOCK M20
•
025.0 57134157 2.0 EA SCREW, HEX-M16 X 20
026.0 52247657 2.0 EA PLATE,COVER
027.0 95928982 4.0 EA CAPSCREW
029.0 52263787 2.0 EA GASKET
031.0 57409104 1.0 EA SENSOR, 2WIRE-TEMPERTURE
033.0 35596436 1.0 EA SWITCH,TEMP
034.0 57866220 1.0 EA SENSOR, TEMPERATURE
57807869 1.0 EA - SENSOR,TEMP,0-150DEG C
57895120 1.0 EA - CABLE,EXTENSION 4PIN
035.0 57793077 1.0 EA SENSOR,PRESSURE 14.5 PSI
036.0 57861841 1.0 EA ACTUATOR,HEATER See Page 246
037.0 96701958 4.0 EA CAPSCREW, HEXHEAD,METRIC
038.0 96727573 4.0 EA LOCKWASHER (METRIC)
039.0 57861494 1.0 EA CABLE,EXTENSION 4PIN
040.0 57863359 1.0 EA CABLE,EXTENSION,4-PIN
042.0 57863391 1.0 EA BOX,ELECTRICAL See Page 248
043.0 57865974 1.0 EA BRACKET,BO BOX
044.0 95928982 4.0 EA CAPSCREW
045.0 95239521 4.0 EA NUT,HEX
•
T3W
BOM 3601 7549
36017549 AIREND - HR 2.5
AIR END 36020519 HR2.5

1420-6F1829 95303376
FOR LIFTING CONNECTOR
3/4-15x.10J
2 35305648
SwiVEL 90'
36861144 7/13-148-103
OIL PUMP m20 644729
l
fi s
•k‘e -
FOR LIFTING
56561053v
PLUG 0., ,,,.......,
1/$6 rii
dirr,s4,4
stk.,..
t
ittik
-...>...,,
W
Ilik, *.
4111 35279927
ELBOW 90.
9/16 18X 6J
-111414ii,.6.040.„
41°
--111 ..67-
4.90. 1110,..:.„._
_
36860476 44rOW ; 1 .... 36858108 TUBE
OIL FILTER
2x 36860336
ill lir %%IN,
w-... SEAL
ELEmENT
36858173 TUBE
FILTER OUTLET
4*-el
trrt 0,
I Ì
35364991
COMM. ORIF .093
9/16.18X -6J
3500221 28 36798205
8
al
BX 112-13111.50 1 COVER
IPTAI"°1
35279801
ELBOW 90.
3/4-15x83 A 4.olio*
40,4i,
36858199 TIME
250 636 MALE
SRO SLAV.
35279827
ELBOW 90.
9/16-188 6J
irea 1
AIWA".
35286954
CONNECTOR
7/8-148-10J
1086
'0‘0
•
368513140
2ND STO HALE
DISCH SRO
35207895
CONNECTOR
9/16.1118-83 35581309
ELEL ORIF .113
9/16-1158-64
36858157 TUBE
250 516 Mai 151 ORG 565A1054V
PLUG
5654105 V 3/4-16,
PI.U0 20011C201225
9/16-IS 565010538
36861540 PLUG 0-R INO 20011C24/225
ELBOW 90. 9/16- /8 20A11C214222
1 5/16-12x-127 36861557 -R INGS
PLUG
7/8-14
35 FT. LBS. TORQUE
4 BOLTS
36658181 TUBE
PUMP OUTLET
35,120223
35279827 eX 1/2•13X2.0 HEX
ELBOW 90.
9/16.188-63
35296433
36858116 TIJ CONNECTOR
,SFT R SRO 7/4- Mx • 12,
35279827 36058165 TUBE

ELBOW 90. PRESS RELIEF
9/16.18x -6J
36858124 TUBE 20011C2M225
END STO FEIN 200110201222
OISCH BRO 0-RINGS
355131909
ELS. OR IF .113
144023513
ELBOW 90•
35279827 I 1 Ail IZX -343
ELBOW 90•
9/10-1811 -6.1
35288165 2001tC2m255
CONNECTOR 0-RING
35581909
3/4 Mx 8J ELS. OW .II3
35287911 9/16-183 -63
SWIVEL 90• 279
3/4-168-0.1 STRAINER £551
36858132 TUBE 1405C10121
19473724 15T STO mai 4X WASHER
35279835 OIL SRO
NIPPLE /" NPT ELBOW 45. 35020221
9/16-19X MJ 48 1/2-1381.50 14Ex
10507525 35287895 35277797
TEE SIR r. NPT 565 AMS3v CONNECTOR O - RING
PLU O 9/16-198 •8J 35370063
9/16-18 SCREEN
36845030
28 PRESS RLF PLv
36845055
SHIELD PRESS Ali
1 —GEAR SET-1050HR2.5
va186713
36861649 TUBE
CLAMP 6 —AIREND,REBUILT
36797652
•
2ND 516 FEN
aim scAv. SCREW 7 —KIT,REBUILT HR2.5
E2636861581 REV 012
•
T3W
B0114 36017549

001.0 36798973 1.0 EA GEAR SET-1250HR2.5
002.0 36861144 1.0 EA PUMP,OIL
003.0 36860476 1.0 EA FILTER, BASE
004.0 36860336 2.0 EA ELEMENT,OIL FILTER
005.0 35092279 1.0 EA STRAINER ASSY-HR2
36751295 1.0 EA - STRAINER BODY
35609098 1.0 EA - PLUG,STRAINER
35370063 1.0 EA - ELEMENT,STRAINER-HR2
35277797 1.0 EA - O'RING
006.0 36020055 1.0 EA AIREND,REBUILT
007.0 36039519 1.0 EA KIT,REBUILD HR2.5
008.0 42428847 1.0 EA KIT,HR2.5 TUBE
T3W
BOM 57861841
57861841 ACTUATOR,HEATER
C2657861841 REV 000
T3W
.41
RE; PART NO. QTY UNIT DESCRIPTION NOTES

001.6 57723645 1.0 EA ACTUATOR,WITH HEATER
003.0 57861551 1.0 EA CORDSET,MALE,8PIN
•
T3W
BOM 57863391
ISO VIEW
D2657863391 REV 000
page 248 WARNING' This manual contains data SPECIFIC to the drilling rig with serial number: US021250
• BOM 51863391
REF. PART NO.

001.0 57895005
1.0 EA BOX,ELEC,4X6,NEM4
T3W
NOTES
002.0 57847436 1.0 EA RECEPTACLE,MALE 10PIN

•
T3W
BOM 57846842
57846842 PIPING,COC,T3W
(RECEIVER TANK)
(RADIATOR, HOC /COC ) SEE DETAIL E

12 48
-----"---
°
1-ti
7.1.1=1,
120' \ 'Si"..4..r,
..
,'
1\ ‘1%..•
um.
N. \111
1
WI
-- .4
49
49 mil
—
i .-1-- ...0
c (.) •
(A' REND)
rA
LA
VIEW C-C
D2657846842 REV 002
• BOM 5? 46 42
T3W
31
13
12
4
14
4
13
32
•
48 (Receiver Tank)
• VIEW F-F
D2657846842 REV 002
DETAL E
page 251
T3W
57846842 PIPING,C0C,T3W
14
38
39
40
40
46
44
45
VIEW A-A
14
DETAIL D
49
(CONSOLE)
VIEW 0-0
D2657846842 REV 002
• BOM 57846842
REF.
001.0
PART NO.
36037190
QTY
1.0
UNIT DESCRIPTION
EA KIT,RELIEF VALVE
T3W
NOTES
002.0 95219853 2.0 EA ELBOW,90 DEG MALE

004.0 95365177 2.0 EA FITTING,HYD
005.0 95279477 1.0 EA FITTING,HYD
006.0 95387346 2.0 EA ADAPTER
008.0 57139982 1.0 EA BRACKET, MOUNTING-AMOT
011.0 52226164 2.0 EA FITTING, HYD
012.0 95316949 1.0 EA CROSS
013.0 95208682 2.0 EA FITTING,HYD
014.0 57170821 1.0 EA VALVE, TEMPERATUREBYPASS See Page 254
029.0 56956857 1.0 EA HOSE ASSY
030.0 58206954 1.0 EA HOSE ASSY
031.0 56948565 1.0 EA HOSE ASSY
032.0 58158668 1.0 EA HOSE ASSY
•
033.0 57095143 1.0 EA HOSE ASSY
037.0 57080251 1.0 EA FITTING, HYD
038.0 95055067 4.0 EA CAPSCREW,AH
039.0 95201331 4.0 EA NUT,HEX JAM
044.0 95934733 4.0 EA WASHER,LOCK
046.0 95249702 1.0 EA PLUG,PIPE,SQ HEAD
048.0 51867901 1.0 EA HOSE ASSY
049.0 57877201 1.0 EA HOSE ASSY
•
T3W
BOW, '0/11.06Z1
5717082 VALVE, TEMPERATUREBYPASS
C2657170821 REV 003
T3W

001.0 57170839 1.0 EA ELEMENT
002.0 95000477 1.0 EA ORING
003.1 95022281 1.0 EA 0-RING
T3W
BOM 57847725
57847725 PIPING,COMP TO REC TANK
(RECEIVER TASK)
SEE DETAIL A
(MAINFRAME) (COMPRESSOR)
J-1
SEE DETAIL B
TB2657847725 REV 001
page 256 WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US02.1250
• BOM !?647725
REF.
001.0
PART NO.
57936411
57847725 PIPING COMP TO REC TANK
1.0 EA HOSE,UA48,117 OAL,VICT
T3W
NOTES
57922437 112.5 IN - HOSE,BULK 3" GATES HNBR

57922213 2.0 EA - FITTING,GMCO,VICTAULIC
002.0 57920829 2.0 EA COUPLING,RIGID VICTAULIC
57920837 1.0 EA - GASKET,VITON VICTAULIC
003.0 57358145 2.0 EA CABLE, HOSE RESTRAINT
•
T3W
BOM 57847188
57847188 INSTALLATION,REC TANK,LP
D2657847188 REV 005
• BOM 57847188

T3W
ASSEMBLE CONTROL ROD

THROUGH THE HOLE AS SHOWN
(BIT AIR PRESSURE)
(RECEIVER PRESSURE)
• D2657847188 REV 005
•
T3W
BOM 57847188
33
20
30
14
35
23
D2657847188 REV 005
T3W
•
10
9
8 12 7 19
31
3
25
3 29
• VIEW A-A
D2657847188 REV 005
page 261
BOM 57847188

T3W
11 28 23
22
SECTION B-B
D2657847188 REV 005
T3W
88

001.1 57845877 1.0 EA RECEIVER TANK ASSY,LP See Page 264
002 95919569 8.0 EA CAPSCREW
003.0 52187861 2.0 EA SILENCER
004.0 57580664 1.0 EA ROD,CONTROL,BALL VALVE
005.0 95279451 1.0 EA ELBOW,90 DEG MALE
007.0 50829605 1.0 EA VALVE,BALL-1/2
008.0 95372850 2.0 EA U-BOLT
010.0 95239521 4.0 EA NUT,HEX
011.0 95415667 1.0 EA FITTING, HYD
012.0 95279097 2.0 EA FITTING,HYD
013.0 95064697 2.0 EA WASHER,FLAT 1/2
014.0 95257333 1.0 EA CAP,JIC-4
015.0 58231242 1.0 EA HANDLE,BLACK
•
016.0 95064697 2.0 EA WASHER,FLAT 1/2
017.0 95002689 1.0 EA PIN,COTTER
018.0 95934733 8.0 EA WASHER,LOCK
019.0 57058166 1.0 EA HOSE ASSY
022.0 57325433 1.0 EA HOSE ASSY
023.0 57861874 1.0 EA HOSE ASSY
024.0 22252043 28.5 GL OIL,BULK XHP605
025.0 95651683 1.0 EA ELBOW,90DEG,FORGED STL
026.0 50258128 1.0 EA VALVE,3-WAY
027.0 95032074 1.0 EA ELBOW-MALE
028.0 56955867 1.0 EA FITTING, HYD
029.0 95038212 1.0 EA BUSHING,PIPE,REDUCING
030.0 56950447 1.0 EA HOSE ASSY
031.0 95446415 1.0 EA ELBOW PIPE
032.0 57446411 1.0 EA HOSE ASSY
034.0 95257325 1.0 EA CAP,37 DEG FLARED
035.0 95473443 1.0 EA FITTING, HYD
•
T3W
BONE 57845877
57845877 RECEIVER TANK ASSY,LP
DETAIL A
142
146
145
148 144
-- 143
17
61
121 68
VIEW B-B
D2657845877 REV 007
T3W
147
10° I
112 110 111 136 77 13

TOP VIEW
14
•
148 95
13
69
tp I0
70
• D2657845877 REV 007
page 265
T3W
BOM
125
36 54 63 47 34 33
SERVICE UNE DETAIL
56 150
VIEW C-C
130
149
64
132
E DETAIL E
DETAIL D
D2657845877 REV 007
p /6r, WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250
T3W
SF 77

RE F PART NO. QTY UNIT DESCRIPTION NOTES
001.0 57687444 1.0 EA TANK,SEPARATOR
002.0 57587644 4.0 EA WELDMENT,TANK MOUNT
003.0 57569758 1.0 EA ELEMENT,SEPARATOR
006.0 57889453 1.0 EA GLASS,SIGHT-RECEIVER TNK
007.0 95357729 1.0 EA FITTING,HYD
008.0 95748562 1.0 EA FITTING, HYD
009.0 95934659 6.0 EA CAPSCREW,HEX
010.0 95934733 12.0 EA WASHER,LOCK
011.0 57637894 1.0 EA STEM W/ ORIFICE
50023910 1.0 EA - STEM
57637902 1.0 EA - ORIFICE,MINIMUM PRESSURE
012.0 50743731 2.0 EA CLAMP,HOSE
013.0 57847170 1.0 EA MANIFOLD,AIR,LP See Page 270
014.0 95313961 33.0 IN HOSE,AIR-R32 BULK
015.0 57922262 1.0 EA FLANGE,PIPE,RCVR VICT
017.0 95952354 4.0 EA CAPSCREW,HEX
018.0 95279162 1.0 EA ELBOW,45 DEG.MALE
021.0 95243200 1.0 EA NIPPLE,PIPE
022.0 95038212 1.0 EA BUSHING,PIPE,REDUCING
024.0 50621986 1.0 EA VALVE, SAFETY
026.0 56793243 2.0 EA CABLE, SAFETY WHIP
027.0 95033593 1.0 EA PLUG,PIPE,SQ HEAD,SOLID
029.0 95372850 2.0 EA U-BOLT
030.0 95481800 1.0 EA U-BOLT
032.0 95922894 2.0 EA NUT,HEX
033.0 95264941 3.0 EA TEE,MALE RUN,NPTF
034.0 95330023 1.0 EA FITTING, HYD
036.0 95395737 1.0 EA NIPPLE,NPTF DRYSEAL
038.0 95371209 1.0 EA ADAPTER,90DEG-0-RING/JIC
040.0 95239521 4.0 EA NUT,HEX
041.0 95366001 1.0 EA ADAPTER,90DEG-0-RING/JIC
043.0 57391047 1.0 EA VALVE,MIN.PRESSURE
57514846 1.0 EA - KIT-REPAIR
047.0 52172723 1.0 EA VALVE,MANUAL SHUTOFF
50212224 1.0 EA - VALVE,BALL-3/4
048.0 57552275 1.0 EA VALVE,CHECK,.25NPT
050.0 95279998 1.0 EA ELBOW,90 DEG STREET
0.51 C 95364469 1.0 EA FITTING,HYD
•
T3W
BUM 57845877

052.0 57039521 1.0 EA SIGHT,FLOW
053.0 95323457 1.0 EA FITTING,HYD
054.0 50829605 1.0 EA VALVE,BALL-1/2
056.0 95219721 1.0 EA CONNECTOR,MALE,37 DEG.
063.0 95323358 2.0 EA FITTING,STR-EXT NPT RUN
064.0 95489050 2.0 EA TEE BRANCH
066.0 95041091 1.0 EA ELBOW
068.0 54640040 1.0 EA DECAL,XHP605 OVAL
069.0 57580649 1.0 EA PLATE,SPACER
070.0 57580656 1.0 EA BRACKET,AIR LINE MNT
072.0 95231031 1.0 EA FITTING,HYD
077.0 95413449 1.0 EA U-BOLT
095.0 95235370 2.0 EA BOLT,EYE
100.0 57442477 1.0 EA REGULATOR,PRESSURE
57789034 1.0 EA - GAUGE,PRESSURE 0-160PSI
50603869 1.0 EA - SERVICE KIT
110.0 39871702 1.0 EA TUBE,SCAVENGE
111.0 39417118 1.0 EA ADAPTER,1/4"
112.0 39322748 1.0 EA ORIFICE,.110 SCAVENGE
113.0 57569923 1.0 EA BLOCK, FLANGE 2"NPT
115.0 57546160 1.0 EA GASKET,COMP DISCHARGE
116.0 54565569 8.0 EA SCREW,CAP,HEX
117.0 95043162 8.0 EA LOCKWASHER
120.0 95022372 1.0 EA 0-RING
121.0 57140352 1.0 EA DECAL,WARNING-HIGH PRESS
124.0 95415667 2.0 EA FITTING, HYD
125.0 95257341 3.0 EA CAP,JIC-6
126.0 57846461 1.0 EA BRACKET,ACTUATOR
127.0 57777351 1.0 EA VALVE,BLOW DOWN
128.0 57846453 1.0 EA FITTING
129.0 57794935 1.0 EA SENSOR,PRESSURE 725 PSI
130.0 57861841 1.0 EA ACTUATOR,HEATER See Page 272
132.0 95279857 1.0 EA FITTING,STR-EXT NPT
133.0 95279410 1.0 EA FITTING,HYD
134.0 95934733 2.0 EA WASHER,LOCK
135.0 95297602 2.0 EA CAPSCREW (6R8)
1360 58183070 1.0 EA HOSE ASSY
137.0 57002867 1.0 EA HOSE ASSY
• BOM 57845877
REF.
139.0
PART NO.
96727573
QTY
3.0
UNIT DESCRIPTION
EA LOCKWASHER (METRIC)
T3W
NOTES
140.0 96704564 3.0 EA BOLT

141.0 57862458 1.0 EA BRACKET,BREAK OUT BOX
143.0 95922365 4.0 EA WASHER,FLAT
144.0 95938544 4.0 EA CAPSCREW
149.0 57815458 1.0 EA INSERT,ACTUATOR
150.0 95257325 1.0 EA CAP,37 DEG FLARED
US021250 page 269
•
T3W
BOM 57847170
SEE DETAIL A
27
19 11 20
6 25 13 15 18 14 16
18 5 18
DETAIL A
D2657847170 REV 004
BOW ;711/17170
T3W

001.0 50023910 1.0 EA STEM
002.0 95458055 1.0 EA PLUG, PIPE-3/4NPT
003.0 95485074 2.0 EA TEE,FORGED STEEL THRD
004.0 95033593 1.0 EA PLUG,PIPE,SQ HEAD,SOLID
005.0 95338026 1.0 EA ELBOW PIPE
006.0 855017P0344 1.0 EA VALVE,BALL
007.0 57432338 1.0 EA TEE MALE 2 NPT
008.0 95037339 1.0 EA BUSHING,PIPE
009.0 95922415 3.0 EA WASHER,FLAT,PLAIN
010.0 95298428 1.0 EA PLUG,PIPE
011.0 95033379 1.0 EA PLUG,PIPE
013.0 95286910 1.0 EA ELBOW,90 DEG MALE
014.0 52206604 1.0 EA VALVE AIR-QUICK EXHAUST
015.0 95041091 1.0 EA ELBOW
0161 95293403 1.0 EA ELBOW,90 DEG MALE
018.0 95097291 3.0 EA NIPPLE,PIPE,EXTRA STRONG
019.0 95242624 1.0 EA NIPPLE,PIPE
020 (1 57594962 1.0 EA NIPPLE,PIPE 2" AIR
022.0 95038766 1.0 EA COUPLING
023.0 95037453 1.0 EA BUSHING,PIPE
024.0 95209094 1.0 EA FITTING,HYD
025.0 95279386 1.0 EA FITTING,HYD
026.0 57142358 1.0 EA LEVER VALVE
027.0 95446696 1.0 EA COUPLING,FORGED STEEL
page 271
•
T3W
BOM 57861841
C2657861841 REV 000
• BO!
REF
001.0
PART NO.
57723645
1.0 EA ACTUATOR,WITH HEATER
T3W
NOTES

003.0 57861551 1.0 EA CORDSET,MALE,8PIN
page 273
•
T3W
BOM 57ity'r2M
ISO VIEW
D2657863391 REV 000
T3W
BOW tzi391
001.0 57895005 1.0 EA BOX,ELEC,4X6,NEM4
•
T3W
BOM 57721no3
57721003 PIPING,DRILL AIR,70K,350
•
1
5
7
18
D2657721003 REV 003
• REF .
001.0
`721003
PART NO.
58048919
QTY
3.0
57721003 PIPtNG,DRILL AIR,70K,350
UNIT DESCRIPTION
EA COUPLING, HOSE STEM-3
T3W
NOTES
001.1 58048919 1.0 EA COUPLING, HOSE STEM-3

002.0 95048906 1.0 EA NIPPLE PIPE
003.0 95038006 1.0 EA BUSHING,PIPE
004.0 58042656 1.0 EA SPUD,FEMALE
005.0 58048968 3.0 EA NUT, SWIVEL-3
005.1 58048968 1.0 EA NUT, SWIVEL-3
006.0 57546061 4.0 EA CLAMP,HOSE
006.1 57546061 1.0 EA CLAMP,HOSE
007.0 58197260 3.0 EA SPUD,MALE
018.0 57784910 85.0 IN HOSE,BULK 3"ID BULDOG GD
019.0 57689846 1.0 EA PIPE,HARD
027.0 57251894 4.0 EA CLAMP ASSY
page 277
BOM 57843799
57843799 PIPING,AIR,STD
T3W
POWER HEAD ASSY

REF
/
1
n-----r
r----- 3
L.._—`_.._.L
- -6
4
2
3
4
8
piP>LE
REF
-R(r COUPLING ON
RISER PLATE
D2657843799 REV 000
page 278 WARNING: This manual contains data SPECIFIC to the drilling rig with serial number. US021250
T3W
57843799 PIPING,A
001.0 95746335 2.0 EA ELBOW,PIPE
004.0 57546061 2.0 EA CLAMP,HOSE
005.0 58048919 1.0 EA COUPLING, HOSE STEM-3
006.0 58048968 1.0 EA NUT, SWIVEL-3
007.0 58197260 1.0 EA SPUD,MALE
008.0 50428572 1.0 EA STEM,HOSE-3
009.0 95050035 1.0 EA NIPPLE,PIPE FITTIING
page 279
•
T3W
BOM 57872327
57872327 PIPING,PNEUP/CLUTCH
OVAL
IIIERNATIDPUL All DRYER DETM_
'EMELT OP DRYER MM.
Xt. °17 VALVE PETAL
kVf
\ I. \I•
II
.•-•"
LONER OffAKOUT DETIIL • .
D2657872327 REV 002
• BOM 57872327
57872327 PIPING,PNEU,W/CLUTCH
T3W
(CONSOLE) (AIR MANIFOLD)
0 - 27
14
TO FOOT
VALVE (B)
17
SUPPLY HOSE FROM
HYDRAULIC TANK
PORT 2
8
19
TO PRESSURE
15 PROTECTION VALVE
16 8 PORT I \\--(BREAKOUT WRENCH

CONTROL VALVE)
CONSOLE DETAIL
TO VIR PORT ..") TO RR PORT

ON BULKHEAD 9 .4- ON BULKHEAD
TO WP PORT A r,
11 TO Ft' PORT
ON BULKHEAD ILJ
ON BULKHEAD
D2657872327 REV 002
T3W
BOW
15 =ROM PORT 2 ON BREAKOUT

'WRENCH CONTROL VALVE
16
FROM PORT I ON BREAKOUT
WRENCH CONTROL VALVE
LOWER BREAKOUT DETAIL
TO GOVERNER
PORT 2 ON DECK 23
FROM DECK 20 22 COMPRESSOR
COMPRESSOR
20
10 GOVERNER PORT
ON TRUCK ENGINE
COMPRESSOR
57
-48
35
20 47
TO TRUCK-1 36 33
COMPRESSOR 46
22 36 33 35 32 UNLOADER PORT
FROM TRUCK
TO GOVERNER PORT 2 COMPRESSOR
ON DECK ENGINE INTERNATIONAL PETERBILT
COMPRESSOR AIR DRYER DETAIL AIR DRYER DETAIL
D2657872327 REV 002
T3W
BOW ,P /327
n 17
11
.
/ i 1 ii
•
i
I: i i 1!!
i
1-i .:.=..._.._
i.._..,
-,. 7-T-- E_:/ eJ ..— " —.. )\L:i L .
.%,- • —.7-
Li
1 .I
• ./ \. .i
•
8
rr WR RP R
SS VS is il
l
In IN Al 111
TM IIii1171 ,us
10
12
FROM PORT I
ON FOOT VALVE (b) FROM PORT I
ON FOOT VALVE (Al
9 11
FROM PORT 2 FROM PORT 2

ON FOOT VALVE (8) ON FOOT VALVE (Al
SECTION A-A
• D2657872327 REV 002
•
T3W
BOM 57872327
18 21 22 19 17 15 16
n
•
,17
VIEW B-13
page 284
D2657872327 REV 002
•
T3W
FROM MANIFOLD
37 19 1 N CONSOLE
• 29
( SECONDARY
AIR TANK}
28
VIEW C-C
18 TO 5 LEON DAR T
AR TANK
(PRIMARY
AIR TANK .1
TO COMPRESSOR
(CARRIER ENGINE)
21
TO •
D-2 GOVERNER L
•
34
45 40 44 39
VIEW D-D
D2657872327 REV 002
•
T3W
BOM 57872327
38
43
OVERNOR
20
TO AIR 41
DRYER
. "-DECK LNG I NE_

COMPRESSOR
21
FROM PRIMARY 22 TO AIR DRYER
AIR TANK
VIEW E-E
D2657872327 REV 002
• BOIO
T3W
38 22
TO COMPRESSOR
(CARRIER ENGINE)
TO COMPRESSOR
r-TCARRIER ENGINE)
VIEW F-F (AIR DRYER)

20
SHUTTLE VALVE
—TO COMPRESSOR DETAIL
33 (DECK ENGINE)
35
TO COMPRESSOR
(CARRIER LNG1NE I
36
32
INTERNATIONAL
SHUTTLE VALVE DETAIL
FROM DECK ENGINE

FROM DECK GOVERNOR--, COMPRESSOR
PORT 2
22
20
TO CARRIER--' 35
COMPRESSOR
UNLOADER PORT
FROM CARRIER
COMPRESSOR
PETERBILT
SHUTTLE VALVE DETAIL
D2657872327 REV 002
T3W
BOM 57872327
1F,
71
1).
International
D2657872327 REV 002
• BONN 57872327
I-
-J
T3W
R
W
SR
• D2657872327 REV 002
WARNING This manual contains data SPECIFIC to the drilling rig with serial number: US021250 page 289
•
T3W
BOM 57872327
REF.. PART NO. QTY UNIT DESCRIPTION NOTES
001.0 58036260 2.0 EA VALVE-AIR

002.0 95335980 5.0 EA ELBOW,90 DEG,MALE
003.0 58054305 4.0 EA PLUG,PIPE
95033601 1.0 EA - PLUG,PIPE,SQ HEAD
004.0 951)98760 1.0 EA FITTING,HYD
005.0 95293403 2.0 EA ELBOW,90 DEG MALE
006.0 95302113 1.0 EA FITTING,HYD
007.0 95419073 2.0 EA TEE, NPT/JIC
008.0 95263380 6.0 EA FITTING,HYD-NPT/JIC
014.0 57873069 1.0 EA HOSE ASSY
018.0 56974892 1.0 EA HOSE ASSY
026.0 95934782 8.0 EA CAPSCREW
027.0 95257341 1.0 EA CAP,JIC-6
028.0 95302733 1.0 EA FITTING
029.0 58054370 1.0 EA VALVE
030.0 58054362 1.0 EA VALVE,AIR
031.0 95219721 1.0 EA CONNECTOR,MALE,37 DEG.
032.0 95395737 1.0 EA NIPPLE,NPTF DRYSEAL
033,0 95298428 1.0 EA PLUG,PIPE
034.0 52243649 3.0 EA FITTING, HYD
035.0 95338406 2.0 EA FITTING,HYD
036.0 50707280 1.0 EA VALVE, BRAKE
•
037.0 95279493 1.0 EA ELBOW,90 DEG MALE
038.0 95303350 1.0 EA ELBOW
039.0 95330023 2.0 EA FITTING, HYD
040.0 95219739 1.0 EA ADAPTER
04 1 0 95209086 1.0 EA FITTING,HYD
• BOM 57872327
REF.
043.0
PART NO.
95293387
QTY
1.0
UNIT DESCRIPTION
EA ELBOW,90 DEG EXTRA LONG
T3W
NOTES
044.0 95367025 1.0 EA FITTING, HYD

045.0 95279956 2.0 EA TEE
046.0 57136897 1.0 EA FITTING, HYD
047.0 95323457 1.0 EA FITTING,HYD
048.0 52226362 1.0 EA FITTING, HYD
057.0 95302121 1.0 EA FITTING,HYD
•
•
•
Section I - Hydraulic System
T3W
BOM 57844672
57844672 PUMP DRIVE INSTALLATION
17
18
16
15 12
14
DETAIL B
DETAIL A
TB2657844672 REV 002
• BONI 57844672
REF.
001.0
PART NO.
57816742
QTY
1.0
UNIT DESCRIPTION
EA PUMP DRIVE ASSEMBLY
T3W
NOTES
See Page 296
002.0 57844045 2.0 EA BRACKET,PUMP DRIVE MOUNT
004.0 95209409 4.0 EA WASHER,LOCK
005.0 95935003 4.0 EA WASHER,FLAT
006.0 95245767 8.0 EA WASHER,BEVEL
008.0 95860730 4.0 EA CAPSCREW/35A2D323G
010.0 95935052 4.0 EA WASHER
011.0 95934501 4.0 EA CAPSCREW,HEX
012.0 57128720 1.0 EA SHAFT,DRIVE
013.0 95935037 8.0 EA WASHER
014.0 95920674 8.0 EA CAPSCREW,HEX
015.0 95931432 8.0 EA LOCKWASHER/14A5C76Z3
•
016.0 95077673 8.0 EA NUT,HEX,BRASS
017.0 95934733 4.0 EA WASHER,LOCK
018.0 95297602 4.0 EA CAPSCREW (6R8)
T3W
BOM 57816742
25 5
1 34
3
32 3
TB2657844607 REV 003
T3W
BOM 5/816742
• TB2657844607 REV 003

•
T3W
BOM 57816742
57816742 PUMP DRIVE ASSEMBLY

001.0 57880833 1.0 EA PUMP, DRIVE 59000 SERIES
57917304 1.0 EA - TUBE,LEVEL GAUGE
57917312 1.0 EA - LEVEL, GAUGE
57901993 1.0 EA - HOUSING,TRIPLE
59383422 1.0 EA - PLUG, EXPANSION
57925430 1.0 EA - TUBE, DIPSTICK
57917312 1.0 EA - LEVEL, GAUGE
59514976 1.0 EA - PLUG, MAGNETIC
57367328 4.0 EA - PLUG, PIPE
59686451 1.0 EA - ELBOW, STREET
57367377 1.0 EA - BUSHING, REDUCER
57902009 1.0 EA - BREATHER
57902017 1.0 EA - PLATE,IDENTIFICATION
50874833 2.0 EA - SCREW, DRIVE
•
57902090 8.0 EA - CAPSCREW
57114332 3.0 EA - GEAR, PUMP DRIVE
57902025 6.0 EA - BEARING,S.H. BALL
57586091 1.0 EA - GEAR,PINION
57171910 1.0 EA - BEARING
57367385 1.0 EA - BEARING
57925455 1.0 EA - PUMP ADAPTER C
59595629 1.0 EA - 0-RING
57902058 4.0 EA - CAPSCREW
50597632 1.0 EA - ADAPTER,PUMP D
50717743 1.0 EA - O'RING
59383463 4.0 EA - STUD, ADAPTER
50943240 4.0 EA - NUT
58087784 2.0 EA - ADAPTER
57198111 1.0 EA - ADAPTER, INPUT SHAFT
57153793 1.0 EA - INPUT SHAFT
57902074 1.0 EA - BEARING, BALL
57902082 1.0 EA - SEAL, OIL
50597442 1.0 EA - RING,SNAP
95223475 1.0 EA - RING,RETAINING
•
002.0 57818585 1.0 EA PUMP,145CC P3 See Page 300
003.0 57895138 1.0 EA PUMP,60CC P2 FAN See Page 304
004.0 57799322 1.0 EA PUMP,P7,9A CONT See Page 308
005.0 57821241 1.0 EA HOT OIL SHUT, DR REC See Page 338
006.0 58149790 1.0 EA PLATE COVER
• BOM 578'4,7.42
REF.
007.0
PART NO.
95934519
QTY
2.0
57816742 PUMP DRIVE ASSEMBLY
UNIT DESCRIPTION
EA CAPSCREW,HEX
T3W
NOTES

015.0 95934501 8.0 EA CAPSCREW,HEX
016.0 56940042 2.0 EA O'RING
017.0 57843724 1.0 EA 0-RING 3"
019.0 95043162 4.0 EA LOCKWASHER
020.0 58235128 1.0 EA KIT,SPLIT FLANGE See Page 340
022.0 95055406 8.0 EA CAPSCREW
031.0 59924019 1.0 EA FITTING,REDU 12X060FS
032.0 57167983 2.0 EA FITTING,L45,12OFS X12SAE
033.0 95650156 2.0 EA ADAPTER
•
034.0 57328676 2.0 EA FITTING,TEST
035.0 95708293 1.0 EA FITTING, 0-RING ADAPTER
T3W
BOM 57818585
578 8585 PUMP,145CC P3
121
D2657818585 REV 002
T3W
BGIt 57818585
57818585 PUMP,145CC P3
• 31
SEE DETAIL
BELOW
35 7 41 30 36
SINGLE SHAFT SEAL ASSEMBLY

P2 -1OS 021D-01EI
• D2657818585 REV 002
•
T3W
BOM 57818585
SHAFT ASSEMBLY KITS

ITEM 57
D2657818585 REV 002
T3W
E ',(818585

006 0 57925737 1.0 EA BEARING, SPHERICAL
007.0 57925745 1.0 EA BEARING RING
028.0 57925752 1.0 EA SNAP RING-EXT. 55mm
035.0 57925794 1.0 EA 0-RING
036.0 57925802 1.0 EA 0-RING
041.0 57925810 1.0 EA SHAFT SEAL
057.0 57925828 1.0 EA SHAFT ASSEMBLY
065.0 57925836 1.0 EA COMPENSATOR ASSEMBLY
067.0 57925844 1.0 EA SEAL ASSEMBLY,SINGLE
T3W
BOM 57895138
7895138 PUNIP,6OCC P2 FAN
57
30
67
65
D2657895138 REV 002
T3W
6
30
57
SEE DETAIL
s
BELOW
33 67 31 41
1
/
IN NER --/t OUTER

LOC 01061 LOCATION
SINGLE SHAFT AEA' ASSEMBLY

P2 460421 0-01 L73
• D2657895138 REV 002
T3W
BOM 57895138
SHAFT ASSEMBLY KITS

ITEM 57
28
SH.AFT ASSEMBLY /CLIME SHAFT, BEARING, AND MAP. FANG
D2657895138 REV 002
par '10E WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250
•
T3W
BOM 57895138

006.0 57925638 1.0 EA BEARING, SPHERICAL
026.0 57925646 4.0 EA BOLT m5x50
030.0 57925661 1.0 EA SNAP RING EXT. 80mm
031.0 57925679 1.0 EA SNAP RING EXT. 52mm
033.0 57925687 2.0 EA 0-RING
041.0 57925695 1.0 EA SEAL, SHAFT CARRIER
057.0 57925703 1.0 EA SHAFT ASSEMBLY
065.0 57925711 1.0 EA COMPENSATOR ASSEMBLY
067.0 57925729 1.0 EA SINGLE SEAL ASSEMBLY
•
T3W
BOM 57799322
57799322 PUMP,P7,9A CONT
MAX VOL
page 308
D2657799322 REV 000
•
T3W
57799322

001.0 54407309 1.0 EA DRIVE SHAFT & BEARING See Page 310
002.0 57153090 1.0 EA KIT-SHIM
003.0 54416946 1.0 EA KIT,RETAINING RING See Page 312
004.0 52154515 1.0 EA SEAL, SHAFT
005.0 57307902 1.0 EA 0-RING
006.0 54407358 1.0 EA RETAINER,SEAL W/0 RING
007.0 52154499 4.0 EA GASKET
008.0 54407366 4.0 EA SCREW
009.0 52201738 1.0 EA SERVO PLATE
010.0 52154580 1.0 EA PLATE
011.0 54407366 2.0 EA SCREW
012.0 52154606 2.0 EA SCREW
013.0 52154622 8.0 EA WASHER, NYLITE
014.0 54407390 4.0 EA SCREW
015.0 57052631 1.0 EA SERVO OUTPUT See Page 314
016.0 57731846 1.0 EA STROKER,9A ELECTROHYD
57770232 2.0 EA - VALVE,PROP PRESS CONT.
57770240 2.0 EA - COIL,24VDC
017.0 54407648 8.0 EA SCREW
018.0 57417339 2.0 EA SERVO-CONT.COVER GASKET
020.0 54408612 1.0 EA HOLDDOWN,GEROTOR& BARREL See Page 316
021.0 54408620 1.0 EA PORT BLOCK/HOUSING ASSY See Page 318
022.0 54408638 1.0 EA HOUSING,END CAP See Page 322
023.0 54408646 1.0 EA BARREL/SHAFT/CRADLE ASM See Page 326
024.0 57306268 1.0 EA VALVE BLOCK ASSY See Page 336
•
T3W
BOM 5440. / 309
54407309 DRIVE SHAFT & BEARING
B2654407309 REV 002
T3W
BONE 54407309

001.0 52201662 1.0 EA SUB 54407309 SHAFT ASM
002.0 54407317 1.0 EA BEARING
003.0 52155751 2.0 EA RING, RETAINING
T3W
54416946 KIT,RETAIN NG RING
19 VALVE BLocx
ASV, itapi. to 3o UNA
.4 Wit
12
13
BARREL / stun' & 14
CRADLE ASS'Y PARTS 15 21
aNTERNAL)
Port of dam
21
22
VO
24
GEROTOR &
BARREL
ROLDDOWN TIOUSITSO,
PORT A
PARTS CAP, CAM &
16 PORT MAXI( & RAR2PL ASSIt
17 Houswo Assn' PARTS
3
4
5
6
TB2652226834 REV 012
T3W
54416946 KIT,RETAINING RING

001. 54407325 1.0 EA RING,RETAINING
T3W
BOM 57052631
57052631 SERVO OUTPUT
12
17 B
15
11
10
SECTION B—B SECTION A—A
C2657052631 REV 001
page !:111 WARNING: This manual contains data SPECIFIC to the drilling rig with serial number US021250
T3W
BO NI /1„0

001.0 54409123 1.0 EA SERVO SHAFT ASSY
002.0 54407390 4.0 EA SCREW
004.0 52201803 2.0 EA RING,RETAING
005.0 54407416 1.0 EA 0-RING
006.0 52154622 4.0 EA WASHER, NYLITE
007.0 95097689 2.0 EA 0-RING
008.0 57153108 1.0 EA SHEAR SEAL
010.0 52201811 1.0 EA PIPE PLUG
011.0 57151144 1.0 EA COVER
012.0 54407473 1.0 EA INDICATOR
013.0 52201779 2.0 EA WASHER
014.0 52201761 1.0 EA SEAL,SHEAR
015.0 57417339 1.0 EA SERVO-CONT.COVER GASKET
017.0 57240756 1.0 EA SCREW, SET
•
T3W
BOM 54408612
54408612 HOLDDOVVN GEROTOR& BARREL
18 12 11
1716 15 14
C2654408612 REV 001
• BOM 54408612
REF.
001.0
PART NO.
57512188
54408612 HOLDDOWN,GEROTOR& BARREL
QTY
1.0
UNIT DESCRIPTION
EA SIDE PLATE
T3W
NOTES
002.0 54407739 1.0 EA KEY,SQUARE

003.0 54407671 1.0 EA GEROTOR
004.0 52201894 1.0 EA PIN, DOWEL
005.0 52204831 1.0 EA GEROTOR
007.0 54407762 1.0 EA 0-RING
008.0 54407796 1.0 EA 0-RING
009.0 52154770 1.0 EA PLATE
010.0 52154788 2.0 EA WASHER
011.0 52154796 1.0 EA BEARING
012.0 52201928 1.0 EA RING
013.0 54407812 1.0 EA NUT
014.0 54407838 1.0 EA PIN
015.0 56988728 1.0 EA COVER,FTG/90514L
016.0 95086310 1.0 EA 0-RING, 20A11CM147
•
017.0 52201936 1.0 EA RING
019.0 54407879 1.0 EA 0-RING
020.0 54407903 1.0 EA PLUG
•
T3W
BOM 54408620
B2654408620 REV 001
T3W
B( f120

001 54407945 4.0 EA SCREW
002.0 52204815 1.0 EA BLOCK-PORT See Page 320
003.0 50817089 5.0 EA PINS
004.0 52204799 1.0 EA PLATE, PORT-RH 15/32
005.0 57487274 1.0 EA GASKET, PORT BLOCK
BOM 52204815
T3W
B2652204815 REV 001
page 320 WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US0212S0
T3W
/o F7
52204815 BLOCK-PORT
RI PART NO. QTY UNIT DESCRIPTION NOTES
00 52201852 1.0 EA BLOCK
00: (; 52154739 1.0 EA BEARING
003.0 54407960 2.0 EA RING
004';52154887 2.0 EA CLAMP
004. 52154895 2.0 EA SCREW
006 52154903 2.0 EA LOCKWASHER
007.t 52154911 2.0 EA VALVE ASSY
008.0 54407994 2.0 EA PLUG
009.0 52154929 1.0 EA PLUG
010.0 52154937 1.0 EA 0-RING
BOM 54408638
54408638 HOUSING,END CAP

T3W
B2654408638 REV 001
T3W
BOM ,,013638

001.('50817089 5.0 EA PINS
002,0 57027377 1.0 EA FACEPLATE, BARREL-15/32
003.0 52155033 1.0 EA GASKET,HOUSING
004.0 52204765 1.0 EA HOUSE,ASM See Page 324
•
T3W
BOM 522(k,'• ?6
52204765 HOUSE,ASM
C2652204765 REV 001
T3W
BOM t7,2i04765

001.0 57416935 1.0 EA HOUSING ASSY
002.0 52155041 1.0 EA BEARING
003.0 52155017 2.0 EA PIN,ROLL
004.0 52155025 4.0 EA PIN
005.0 52154994 1.0 EA 0-RING
006.0 54408059 1.0 EA PLUG
007.0 54408133 1.0 EA RETAINER,BEARING
008.0 57416950 1.0 EA 0 RING
•
T3W
BOM 54408646
C2654408646 REV 001
T3W

001 54408190 1.0 EA BARREL/AUX SHAFT ASSY See Page 328
002.0 52248119 2.0 EA TUBE,PRESS
003.0 52201670 1.0 EA TUBE
004 C 52155066 1.0 EA TUBE ASM
005.0 54410741 1.0 EA RETAINER PALTE See Page 330
•
T3W
BOM 54408140
54408190 BARRELJAUX SHAFT ASSY
page 328
B2654408190 REV 001
•
T3W
bOF 5/14n t 190
54408190 BARREL/AUX SHAFT ASSY

001.0 54408232 1.0 EA BARREL & SLEEVES
002.0 57045882 1.0 EA SHAFT,DRIVE
003.0 57514895 1.0 EA STOP
004.0 54408273 1.0 EA SPRING
005.0 57514903 1.0 EA SPRING, RETAINER
006.0 54408414 2.0 EA PIN,DOWEL
007.0 52155116 1.0 EA MTG FLG
008.0 54409776 2.0 EA PLUG
009.0 52155314 2.0 EA 0-RING
page 329
BOM 54410741
54410741 RETAINER PATE

T3W
page 330
C2654410741 REV 001
•
T3W
BOM 54410741

001.0 54414743 1.0 EA RETAINING RING GROUP See Page 332
003.0 57123283 1.0 EA CAM STROKER ASSY See Page 334
004.0 52204880 1.0 EA KIT,RETAINER PISTON/SHOE
007.0 52203668 1.0 EA PLATE,CREEP
T3W
BOM 54414743
C54410741 REV 000
T3W
BUM 544 ?43

•
T3W
BOM 57123283
page 334
C54410741 REV 000
•
•
T3W
BOM 57123283

006.0 57240749 2.0 EA SCREW, MOTOR
007.0 52201738 1.0 EA SERVO PLATE
008.0 52155256 2.0 EA SCREW
009.0 57240764 1.0 EA PLATE, MOTOR
010.0 54408331 4.0 EA SCREW
011.0 54408349 4.0 EA SCREW
012.0 54408356 4.0 EA SCREW
013.0 52155306 5.0 EA PLUG
014.0 52155314 5.0 EA 0-RING
015.0 52155330 1.0 EA COVER,CONTROL
016.0 52155348 4.0 EA PIN
017.0 54408364 2.0 EA CONTROL CHAMBER
018.0 52155363 2.0 EA SEAL
019.0 52155371 4.0 EA BALL
020.0 52203718 1.0 EA CRADLE
•
021.0 57064065 8.0 EA VANE HOLD DOWN SPRING
022.0 57181307 4.0 EA HOLD DOWN-VANE
023.0 52155322 1.0 EA COVER
024.0 54408406 1.0 EA ROCKER AND PLUG
025.0 57240756 2.0 EA SCREW, SET
026.0 54408372 4.0 EA PLATE,SEAL VANE
027.0 54408380 2.0 EA SEAL VANE
028.0 52203767 2.0 EA 0-RING
029.0 54408398 2.0 EA SPACER,VANE
030.0 57150617 2.0 EA CHECK VALVE
•
T3W
BOM 57306268
STRAINER
20
25
19 23
4
22
CHECK
VALVE 21
23
22 2
14
REPLENISHING
PILOT VALVE
36
25 CHECK
VALVE
COMPENSATOR
3 5 35
2 31 i 3 26
1
\ 10 DUAL
RELIEF 34
9 POPPED
15
\7 33 4 ,SERVO
I go POPPET
SEQ. 32
45 35
POPPET
33
30
REPL.
POPPET 31 DUAL
27 31 RELIEF
POPPET
46 28
28 SEQ.
30 POPPET
42
27 29
48
37 46
28
43
47
48
C2657306268 REV 001
T3W
B. (.268

001.0 54408422 1.0 EA VALVE BLOCK
002.0 52154911 2.0 EA VALVE ASSY
003.0 54408430 4.0 EA PLUG
004.0 54408448 3.0 EA 0-RING
005.0 52155603 1.0 EA SEAT
006.0 52248093 1.0 EA SET SCREW
007.0 54408455 1.0 EA NUT,HEX JAM
008.0 52155637 1.0 EA HOUSING
009.0 52155645 1.0 EA 0 RING
010.0 52155660 1.0 EA SPRING GUIDE,PISTON SEAL
011.0 95017984 1.0 EA 0-RING
012.0 54408463 1.0 EA SPRING
013.0 52155686 1.0 EA CONE
014.0 52203627 1.0 EA STRAINER ASY
015.0 52155546 3.0 EA SPRING
016.0 54408471 4.0 EA POPPET,DUAL & REPL
019.0 52154937 1.0 EA 0-RING
020.0 54408489 1.0 EA PLUG
021.0 54408497 1.0 EA PIN,MODULATING
022.0 52155314 5.0 EA 0-RING
023.0 52155306 2.0 EA PLUG
025.0 57302143 2.0 EA PLUG-HEX
026.0 52155454 2.0 EA PIN
027.0 52155439 2.0 EA SEQUENCE SEAT
028.0 52155447 4.0 EA VALVE SEAT
029.0 54408505 1.0 EA GASKET,VLV BLK
030.0 54408513 2.0 EA POPPET,SEQ
031.0 54408471 4.0 EA POPPET,DUAL & REPL
032.0 57063737 1.0 EA SPRING
033.0 52155520 2.0 EA SPRING
034.0 52155512 1.0 EA RETAINER
035.0 52155546 3.0 EA SPRING
036.0 54408547 1.0 EA VALVE,PILOT (400 PSI)
037.0 52155488 1.0 EA 0-RING DEN-671-000
042.0 54408570 1.0 EA PLATE,RETAINER
043.0 54408588 4.0 EA SCREW
044.0 52155447 4.0 EA VALVE SEAT
045.0 57269698 1.0 EA NUT
046.0 50830199 2.0 EA PIN-ROLL
047.0 54407416 2.0 EA 0-RING
048.0 54408596 2.0 EA 0-RING
•
T3W
BOM 57821241
57821241 HOT OIL SHUT, DR REC
140 120 130
D2657821241 REV 001
• BC'
REF.
100.0
PART NO.
57844870
1.0 EA MANIFOLD BLOCK
T3W
NOTES
110.0 57325599 1.0 EA VALVE,SHUTTLE CART

57303794 1.0 EA
- SEAL KIT
120.0 57844888 1.0 EA VALVE,RELIEF
130.0 57844896 2.0 EA VALVE,CHECK
140.0 57844904 1.0 EA VALVE,CHECK
•
T3W
BOAR 58236128
58236128 KIT,SPLIT FLANGE
TB2658235128 REV 003
T3W
a
BOM 58235128

001.0 57405185 2.0 EA FLANGE HALF,SIZE 20-CD62
004.0 95934733 4.0 EA WASHER,LOCK
T3W
BOM 57861015
57861015 HYDRAULIC TANK INSTALL
3
2
!I r‘..!
DETAIL A
SCALE :4F iii 11.4L
.
NTDRALIL IC TANK
MAINFRAME T3IN-A \L". REF
REF
\\.!
(.. . • •
SEE DETAIL A—
BO YEW
D2657861015 REV 000
T3W
BOM 51861015

001 0 57818668 1.0 EA TANK,HYD,ASM See Page 344
002.0 95462750 4.0 EA CAPSCREW
003.0 95064697 4.0 EA WASHER,FLAT 1/2
•
T3W
BOM 57818668
57818668 TANK,HYD,ASM
42 44 49
52
53
HANDLE ON
BOTTOM
page 344
DETAIL-B
D2657818668 REV 006
WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: U8021250
•
T3W
47 34 40 41 15
53
SEE DETAIL A
SEE DETAIL D C
48
ti
• D2657818668 REV 006
39
page 345
•
T3W
21 22 26 35
36
20
35
5
--- 24
46
23 SEE DETAIL C
DETAIL A
•
14
12 13 33 45
page 346
DETAIL - C
D2657818668 REV 006
•
T3W
r
BONI 57818668
29
38
29
•
SECTION C-C
DETAIL - D
N
30
DETAIL - E
D2657818668 REV 006
page 347
•
T3W
BOM 57818668
QTY UNIT DESCRIPTION NOTES

REF. PART NO.
001.0 57884512 1.0 EA TANK, HYDRAULIC
002.0 57828659 2.0 EA COCK,DRAIN
003.0 57828543 1.0 EA BREATHER,PRESSURIZED
004.0 57828550 1.0 EA GUAGE,PREESSURE
005.0 57828568 1.0 EA BALL,VALVE
006.0 57828451 1.0 EA FLANGE,WELDMENT
007.0 57828576 3.0 EA BALL,VALVE
009.0 57828584 1.0 EA BALL,VALVE
011.0 57895146 1.0 EA SIGHT,GAUGE
012.0 57828618 3.0 EA GASKET,FILTER
013.0 57828634 3.0 EA COVER,FILTER
014.0 57828626 3.0 EA ELEMENT,FILTER
015.0 57828600 1.0 EA SENSOR,PRESSURE
•
016.0 57828436 1.0 EA BRACKET,HAND PUMP
017.0 57426926 1.0 EA PUMP,HAND FILL
018.0 57828667 1.0 EA UNION,STRAIGHT THREAD
019.0 57348997 1.0 EA COUPLING,QUICKDISCONNCT
57357907 1.0 EA - COUPLING, QD HALF, M
57357915 1.0 EA - COUPLING, Q.D. HALF, F
020.0 57828535 1.0 EA BRACKET,AIR FILTER
021.0 95922183 4.0 EA WASHER,FLAT
022.0 95934774 4.0 EA CAPSCREW
023.0 57828527 1.0 EA FILTER,AIR
024.0 95048179 2.0 EA NIPPLE
026.0 57828675 1.0 EA REGULATOR,AIR
028.0 95934550 4.0 EA CAPSCREW,HEX
029.0 57828642 5.0 EA MAGNET
030.0 57828519 1.0 EA GASKET,CLEAN OUT
031.0 57828501 1.0 EA COVER,CLEAN OUT
032.0 95922894 16.0 EA NUT,HEX
033.0 95923314 18.0 EA NUT,ELASTIC LOCK
034.0 95396776 1.0 EA CLAMP,HOSE SUPPORT
035.0 95293403 1.0 EA ELBOW,90 DEG MALE
•
036.0 58000670 1.0 EA HOSE ASSY
037.0 95207767 1.0 EA PLUG,PIPE
038.0 95227682 1.0 EA PLUG PIPE
039.0 57408353 1.0 EA PLUG,MAGNETIC,1NPT
T3W
1866/1

041.0 95934642 1.0 EA CAPSCREW,HEX
044.0 50805118 1.0 EA VALVE,CHECK See Page 350
045.0 95922365 18.0 EA WASHER,FLAT
047.0 57888182 1.0 EA FILTER, CASE DRAIN
57895278 1.0 EA - FILTER, CANISTER
048.0 50810993 1.0 EA DECAL,HYD.OIL LEVEL
049.0 56944507 1.0 EA FITTING HYD
050.0 95038139 1.0 EA BUSHING,PIPE
051.0 95040952 1.0 EA ELBOW,STREET,90DEG
052.0 57869554 1.0 EA FITTING,20 SAEX20 SAE
053.0 95209094 1.0 EA FITTING,HYD
•
T3W
BOM 50805118
Y383594 REV 001
T3W
EsOr,'
001.G 50879246 1.0 EA CAP,END KP-1004C-10
002.0 50879253 1.0 EA SEAL,FLEXBLE KP-3004-105
003.0 50879261 1.0 EA RETAINER KP-3004C-10
004.0 50879279 1.0 EA POPPET KP-3004C-10
005.0 50879287 1.0 EA SPRING KP-1004-104
006.0 50879295 1.0 EA BODY KP-1004C-10
•
T3W
BOM 57880619
57880619 PIPING,HYD,40K,T3W
219
221
220 •
..
N, ".....,,, ,.., .
-•-...• ''••••.. .." .

,
s".... ,,, `:•:,...., '''••
---,, -.... '•-

•-4,.. :..-,., '''•
.) N. -k.N. -.,..
-.... `,.....
- -.... .
N. •••,..
Iy
N.
--- !I 'N..
--1;)
/ H
0
TB2657880627 REV 005
Paq• WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250
• BOM 5/8/10619
T3W
1 9 43 103
28 104 43
29
11
100,
16 N
82,
48
101
11
232
DETAIL E
TB2657880627 REV 005
•
T3W
BOM 57880619
DETAIL F
TB2657880627 REV 005
BOM 57880619
T3W
229
215
VIEW M-M
45
33
32
•
31
201
92
90
93 --
91
95
94
221
•
127 219
VIEW A-A
TB2657880627 REV 005
page 355
•
T3W
BOM 57880619
178 177 181 182
•
201
page 356
TB2657880627 REV 005
•
• BO MI 57880619
T3W
118
119
B !
122 I((7jt
11
121
II 201
142 142
143 N 203
121
154
122
234
1
170
169
118 --
119
202
120
123
122
121 119 118 147

VIEW B-B
TB2657880627 REV 005
page 357
BOM 57880619
T3W
•
143
85
84 169
170
202
168 234
166
167
169
165 / 170
/
1
U 167
C
168
147
143
154
166 234
208
165
208
165
166
234
VIEW C-C
TB2657880627 REV 005
T3W
BOM 57880619
31
TB2657880627 REV 005
T3W
BOM 57880619
207
134
88 211 134 140144126 126

213/
126 129124 127

204
129 125 27
202 45
34
35
TB2657880627 REV 005
•
Serial Number: 05021250
BOM 57880619
T3W
210
131 135 233
149
205
SEE DETAIL H
•
218
233
\ 160
141
117
175
149
DETAIL H
TB2657880627 REV 005
page 361
BOM 57880619
T3W
79
26
25 49
116 46
206
130 131
164
2 34 — 160
110
111 150
112
133 — 145
25
117
217
235 208
148
145
44
218 57
3
'15 58
209
146 47
DETAIL I
150 59
208 141
VEW
TB2657880627 REV 005
•
T3W
BOM 57880619
<
K
162
164
174 172
176
173
152
174
164 162
VIEW K-K
TB2657880627 REV 005
page 363
•
T3W
BOM 57880619
187
56
187
56
25
151
152 158
VIEW N-N
VIEW P-P
174
•
216 151
SEE DETAIL J— 164 233
159
162
page 364
TB2657880627 REV 005
DETAIL J
~174
•
T3W
DETAL L
231
TB2657880627 REV 005
•
T3W
BOM 57880619
224
228
225
•
223
, 222
227
226
page 366
TB2657880627 REV 005
•
• BONI 0619
T3W
195
196
-76
155
.
10
26N
78
156
43
12 ---
155-
155
VIEW R4
TB2657880627 REV 005
•
T3W
BOM 57880619
184
183
6 82
132
140
-134
231
RETURN MANIFOLD DETAIL
TB2657880627 REV 005
• BUM 57880619
REF.
000.0
PART NO.
57888182
QTY
1.0
UNIT DESCRIPTION
EA FILTER, CASE DRAIN
T3W
NOTES
57895278 1.0 EA - FILTER, CANISTER

001.0 57818825 1.0 EA VALVE ASSY,10-SPOOL See Page 374
006.0 50462944 2.0 EA VALVE,CHECK-DBL PILOTOP
008.0 57464208 2.0 EA CLAMP,ASSY 3/4 -STACK
009.0 57447260 2.0 EA CLAMP ASSY, STAUFF3/4 OD
010.0 57821225 1.0 EA VALVE, REL ELEC PROPOR
013.0 95650156 2.0 EA ADAPTER
016.0 57273716 1.0 EA VALVE, COUNTER BALANCE
026.0 95096350 4.0 EA LOCKWASHER
027.0 95860730 4.0 EA CAPSCREW/35A2D323G
029.0 95934550 4.0 EA CAPSCREW,HEX
031.0, 95919841 3.0 EA CAPSCREW
033.0 95922910 3.0 EA NUT,HEX,PLATED
034.0 95934733 6.0 EA WASHER,LOCK
035.0 95104147 6.0 EA CAPSCREW,HEX
044.0 57779589 1.0 EA VALVE,RELIEF
57780041 1.0 EA - VALVE,RELIEF CARTRIDGE 2
59476705 1.0 EA - SEAL KIT
57780033 1.0 EA - VALVE,CHECK CARTRIDGE
57780058 1.0 EA - KIT,SEAL
045.0 95931242 7.0 EA LOCKWASHER/14A5C120Z3
046.0 95971552 2.0 EA CAPSCREW,HEX
048.0 95943668 4.0 EA CAPSCREW,HEX
049.0 95452066 2.0 EA WASHER,FLAT
•
050.0 95920682 4.0 EA CAPSCREW,HEX
056.0 50429356 2.0 EA VALVE,2-WAY
058.0 95055315 2.0 EA CAPSCREW
059.0 95922894 2.0 EA NUT,HEX
•
T3W
BOM 57880619
065.0 57470866 1.0 EA CLAMP ASSY,STAUFF 1.560D

067.0 57309064 1.0 EA FITTING,BST,160FS X16OFS
076.0 95650149 1.0 EA REDUCER,EXPANDER
078.0 95920724 2.0 EA CAPSCREW
079.0 95416335 2.0 EA NUT, HEX-1/4-20 ZINC
085.0 95928982 4.0 EA CAPSCREW
•
098.0 57380214 1.0 EA HOSE ASSY
101.0 57849770 1.0 EA HOSE ASSY
104.0 57380099 1.0 EA HOSE ASSY
110.0 57895112 1.0 EA VALVE,REL,3750
112.0 95934857 2.0 EA CAPSCREW,HEX
117.0 57363251 1.0 EA HOSE ASSY
121.0 57861411 1.0 EA HOSE ASSY
122.0 57861411 1.0 EA HOSE ASSY
124.0 57849853 1.0 EA HOSE ASSY
126.0 57849861 1.0 EA HOSE ASSY
127.0 57860785 1.0 EA HOSE ASSY
• BOM 57880619
REF.
128.0
PART NO.
57918617
QTY
1.0
UNIT DESCRIPTION
EA HOSE,ASSEMBLY
T3W
NOTES
129.0 57863409 1.0 EA HOSE ASSY

130.0 57380743 1.0 EA HOSE ASSY
131.0 57380743 1.0 EA HOSE ASSY
134.0 57849838 1.0 EA HOSE ASSY
135.0 57381097 1.0 EA HOSE ASSY
140.0 57860157 1.0 EA HOSE ASSY
145.0 57381329 1.0 EA HOSE ASSY
147.0 57381212 1.0 EA HOSE ASSY
150.0 57860009 1.0 EA HOSE ASSY
151.0 57860025 1.0 EA HOSE ASSY
152.0 57860033 1.0 EA HOSE ASSY
153.0 57380099 1.0 EA HOSE ASSY
154.0 57849713 1.0 EA HOSE ASSY
155.0 57860041 1.0 EA HOSE ASSY
157.0 57860884 1.0 EA HOSE ASSY
159.0 57860066 1.0 EA HOSE ASSY
160.0 57464430 1.0 EA HOSE ASSY
162.0 57860074 1.0 EA HOSE ASSY
164.0 57860074 1.0 EA HOSE ASSY
165.0 57860108 1.0 EA HOSE ASSY
166.0 57860116 1.0 EA HOSE ASSY
167.0
•
57860124 1.0 EA HOSE ASSY
168.0 57864100 1.0 EA HOSE ASSY
169.0 57860140 1.0 EA HOSE ASSY
172.0 57860173 1.0 EA HOSE ASSY
•
T3W
BOM 57880619
173.0 57860637 1.0 EA HOSE ASSY

174.0 57860645 1.0 EA HOSE ASSY
175.0 57860678 1.0 EA HOSE ASSY
176.0 57849820 1.0 EA HOSE ASSY
182.0 57860652 1.0 EA HOSE ASSY
183.0 95958930 2.0 EA CAPSCREW
187.0 50429455 2.0 EA BRACKET, VALVE
195.0 57284028 1.0 EA CAP,FACE SEAL 0-RING -12
201.0 57860165 1.0 EA VALVE ASSY,2-SPOOL See Page 378
2020 57862971 1.0 EA MANIFOLD ASM,HRC See Page 380
203.0 57863557 1.0 EA MAIN MANIFOLD ASSY See Page 382
204.0 57849994 1.0 EA MANIFOLD ASSY,RETURN See Page 386
205 0 57849929 1.0 EA MANIFOLD ASSY,RETURN See Page 388
206.0 57863540 1.0 EA MANIFOLD ASSY See Page 390
207-0 57319683 1.0 EA FITTING,STR,160FS X16SAE
?08.0 57319592 5.0 EA FITTING,STR,040FS X06SAE
210.0 57283186 1.0 EA PLUG,FACE SEAL 0-RING -8
211.0 57502882 1.0 EA CLAMP,STAUFF,G12,STACK
212.0 57642555 4.0 EA FITTING
215.0 57869505 1.0 EA HOSE HOOP ASSY
218.0 57380131 1.0 EA HOSE ASSY
220.0 57860934 1.0 EA HOSE ASSY
221.0 57860793 1.0 EA HOSE ASSY
222.0 57849960 1.0 EA HOSE ASSY
223.0 57849960 1.0 EA HOSE ASSY
224.0 57849960 1.0 EA HOSE ASSY
225.0 57849960 1.0 EA HOSE ASSY
227.0 57849812 1.0 EA HOSE ASSY
228 0 57690695 1.0 EA HOSE ASSEMBLY
229.0 57849887 1.0 EA PLATE,BULKHEAD
230.0 57865008 4.0 EA BULKHEAD UNION-16,L45
232.0. 57871725 2.0 EA FITTING,ELBOW
T3W
BO 57880619

233.0 57861957 1.0 EA HOSE ASSY
234.0 57862633 1.0 EA HOSE ASSY
235.0 57283996 1.0 EA CAP,FACE SEAL 0-RING - 4
235.0 57308892 1.0 EA FITTING,BRT,040FS X04SAE
•
T3W
BOM 57818825
14
13
page 374
D2657818825 REV 003
•
T3W
lat (.;

001.0 57818601 1.0 EA VALVE, 10-SPOOL M4-12 See Page 376
003.0 57644155 7.0 EA FITTING
004.0 57862963 7.0 EA FITTING L90,060FSX1OSAE
005.E 57167934 1.0 EA FITTING,L90-120FSX12SAE
009.0 95938221 6.0 EA PL.HEXSAE 0.88-14V
011.0 95426235 1.0 EA REDUCER, 0-RING
012.0 57644163 1.0 EA FITTING
013.0 57868135 5.0 EA HANDLE,VALVE,10 SPOOL
57868143 1.0 EA - SPRING, PIN 1/8" DIA
014.0 50627918 5.0 EA BALL,KNOB
•
T3W
BOM 57818601
57818601 VALVE, 10-SPOOL M4-12
List Only
PENDING REV 000
• BOM 57818601
REF.
001.0
PART NO.
58004094
QTY
11.0
57818601 VALVE, 10-SPOOL M4-12
UNIT DESCRIPTION
EA KIT,SEAL,SECTION
T3W
NOTES
002.0 58004102 1.0 EA KIT,SEAL,A SIDE,MANUAL

58006016 9.0 EA - 0-RING
57937880 9.0 EA - SEAL
58006024 18.0 EA - SEAL RING
003.0 58004136 1.0 EA KIT,SEAL,B SIDE,MANUAL
57937880 9.0 EA - SEAL
58006099 9.0 EA - BOOT,DUST,W/PLATE
004.0 58004110 1.0 EA KIT,SEAL,A SIDE,HYD PLT
58006032 1.0 EA - SEALING NUT (M8X1)
58006040 1.0 EA - 0-RING (5.28X1.78)
58006057 1.0 EA - SEAL RING
58006024 2.0 EA - SEAL RING
58006065 1.0 EA - SEAL RING
•
005.0 58004128 1.0 EA KIT,SEAL,B SIDE,HYD PLT
58006032 1.0 EA - SEALING NUT (M8X1)
58006073 1.0 EA - BONDED SEAL RING
58006081 1.0 EA - SEAL RING
006.0 58006131 1.0 EA KIT,HANDLE
400.0 58006115 1.0 EA HOUSING,A SIDE
408.0 58006123 1.0 EA SHIM
410.0 58006107 2.0 EA CAPSCREW,SH.
•
T3W
BONI 57860165
D2657860165 REV 002
• BOM 57860165

T3W
NOTES
001.0 57818833 1.0 EA VALVE 2-SPOOL M4-22
004.0 57863169 5.0 EA FITTING,L90,040FSX04BSPP
005.0 57863151 4.0 EA FITTING,STR,040FSX04BSPP
007.0 57642647 1.0 EA FITTING
008.0 57863680 1.0 EA FITTING,24-20,CODE 61
009.0 57864985 1.0 EA FLANGE ADAPTER,STR,20-24
010.0 57660227 1.0 EA FITTING,45EL
011.0 57865016 2.0 EA FLANGE,STR,16 CODE62
013.0 96706189 8.0 EA SCREW,HEX HEAD,COARSE TH
014.0 96726625 8.0 EA LOCKWASHER/14M5EG14Z3
015.0 56883614 4.0 EA O'RING
016.0 96701198 16.0 EA SCREW,HEX HEAD/34M2AA464
017.0 96720834 16.0 EA WASHER, SPRING LOCK
018.0 92329309 8.0 EA SCREW-HEX M10X1.5X35MM
019.0 96712096 8.0 EA LOCKWASHER/14M5EA12M4HRT
•
T3W
BOM 57862971
MANIFOLD ASM,HRC
D2657862971 REV 000
page 380 WARNING: This manual contains data SPECIFIC to the drilling rig with serial number U5021250
T3W
BOM 57862971

001.0 57880882 1.0 EA MANIFOLD, HRC SHUTTLE
003.0 95754867 4.0 EA FITTING,HYD
T3W
BOM 57 'Y3
57863557 MAIN MANIFOLD ASSY
10
D2657863557 REV 002

page 3bz WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250
T3W
FCT
57863557 MAIN MANIFOLD ASSY

001.( 57818734 1.0 EA MANIFOLD, MAIN DEEP HOLE See Page 384
4.( 57167454 2.0 EA FITTING,STR,200FS X2OSAE
5.( 57319626 4.0 EA FITTING,STR,060FS X08SAE
6.( 57209744 1.0 EA FITTING,L90,160FS X16SAE
011.0 95147674 1.0 EA ADAPTER
012.t 57477325 1.0 EA ADAPTER, 1/4 ORS TEE
013.0 57328676 6.0 EA FITTING,TEST
014.( 95939856 1.0 EA PLUG,HEX HEAD
015 ( 5716-421 2.0 EA FITTING,L45,200FS X2OSAE
•
WARNING. This manual contains data SPECIFIC to the drilling rig with serial number: US021250 page 383
•
T3W
BOM 57818734
57818734 MANIFOLD, MAIN DEEP HOLE
170 190 180
100 230 220 160 140 200 110 110 110
AL 14 1 80 180 180
-0- -e-
c
4rro
7.4 , -ec-€1-4EK
•
170 210 240 180 180 180
20 120 120
-0-
80 110 110 110
page 384
D2657818734 REV 002
•
• BOM 57818734
REF.
100.0
PART NO.
57844748
QTY
1.0
UNIT DESCRIPTION
EA MANIFOLD BLOCK
T3W
NOTES
110.0 57844920 6.0 EA VALVE,PO CHECK

120.0 57844755 3.0 EA VALVE,4 WAY
130.0 57844763 6.0 EA COIL,24V
140.0 57844771 1.0 EA VALVE,3 WAY
150.0 57844789 1.0 EA COIL,24V
160.0 57844797 1.0 EA VALVE,4 WAY DO3
170.0 57844805 2.0 EA RELIEF
180.0 57844813 8.0 EA VALVE,SHUTTLE
190.0 57844821 1.0 EA VALVE,PRESSURE REDUCING
200.0 57844839 1.0 EA VALVE,PRESSURE REDUCING
210.0 57844938 1.0 EA VALVE,PRESS REDUC/RELIE
220.0 57844847 1.0 EA VALVE,4 WAY DO3
230.0 57844854 1.0 EA VALVE,CHECK
240.0 57872863 1.0 EA VALVE,MODULATING
•
T3W
BOM
57849994 MANIFOLD ASSY,RETURN
/ 13
x
7
14
0
D2657849994 REV 002
T3W
BOrrt 57849994

001.0 57818817 1.0 EA MANIFOLD,RETURN,50PSI
57844698 1.0 EA - MANIFOLD BLOCK
57844706 3.0 EA - RELIEF, 50 PSI
004.0 57848566 4.0 EA FITTING,RED ORB24-16
007.0 57863052 1.0 EA FLANGE,32-24,CODE 61
008.0 57283178 1.0 EA PLUG,FACE SEAL O-RING-6
009.0 57866220 1.0 EA SENSOR, TEMPERATURE
57807869 1.0 EA - SENSOR,TEMP,0-150DEG C
57895120 1.0 EA - CABLE,EXTENSION 4PIN
010.0 57328676 2.0 EA FITTING,TEST
012.0 95055034 4.0 EA CAPSCREW
013.0 95018461 1.0 EA 0-RING
014.0 95209870 1.0 EA O'RING
015.0 95663803 2.0 EA FITTING, TUBE
•
T3W
BOM 57849929
57849929 MANIFOLD ASSY,RETURN
D2657849929 REV 002
T3W
SOM 57849929

001.0 57888216 1.0 EA MANIFOLD,RETURN
008.0 95663803 1.0 EA FITTING, TUBE
009.0 95735346 3.0 EA FITTING,HYD
010.0 95479739 1.0 EA REDUCER, SAE/ORING 16-8
•
T3W
BOM 57863540
page 390
D2657863540 REV 000
•
T3W
REI PART NO. QTY UNIT DESCRIPTION NOTES

001.0 57379505 1.0 EA MANIFOLD,ALUM-ORING
004.0 95147674 2.0 EA ADAPTER
•
T3W
BOM 57849325
TOWER REF
TOWER REF
DETAL A
DETAL B
SEE DETAL B
DETAL A
DERRICK SPFORi
Rif
AIRFRAME REF
DETAL C
•
LJ
page 392
D2657849325 REV 001
DETAL C
WARNING: This manual contains data SPECIFIC to the drilling rig with serial number. US021250
•
•
T3W
BOM 57849325

001.0 57727117 2.0 EA CYLINDER,HYDRAULIC
57753485 1.0 EA - SEAL KIT,HYD CYL
002.0 57235863 2.0 EA PIN, CYLINDER-RAISING
003.0 57916553 4.0 EA BAR LOCKING
004.0 95920674 8.0 EA CAPSCREW,HEX
006.0 57217648 2.0 EA PIN,DERRICK PIVOT
007.0 95201547 4.0 EA FITTING,LUBE
008.0 95208989 2.0 EA FITTING,LUBE
•
T3W
BOM 57847295
57847295 PIPING,TOWER 40K
12 . • --Th
.
N
18 ~•
30
12„
18-
28 DETAIL J
DETAL K
34
33
45 32
DETAIL A
page 394
D2657847295 REV 002
•
T3W
BOM 57847295
36 35 37
39
DETAL F
DETAIL D
•
28
30
• D2657847295 REV 002

DETAIL C
WARNING: This manual contains data ,SPECIFIC to the drilling rig with serial number: US021250 page 395
•
T3W
BOM 57847295
2
16 25 18 261418
17 21 18
\ 14
IP ,'
2 -- 18
16-- 2 22
17 16
7 2
16 16
17 17
2- ,z/
111 2
16
26 / 17
16 21
17 18
13
\t,
40
25 k
DETAIL E 22 \ratiatt..,,,
41
• -13
18
•
29
23
page 396
27 24 TOP VIEW
D2657847295 REV 002
WARNING' This manual contains data SPECIFIC to the drilling rig with serial number: US021250
•
•
T3W
BON6 57847295
39
DETAIL H
•
11
DETAIL S
• D2657847295 REV 002
•
T3W
BOM 57847295
57847295 PIPING,TOVVER 40K
ri
2
17
16
16
17
J
34
35
SEE DETAIL M 33
17
16
2
DETAIL M
D2657847295 REV 002
T3W
45
30 25
DETAIL B
D2657847295 REV 002
•
T3W
BOM 57847295
23
DETAL P
D2657847295 REV 002
•
T3W
BOO S7847295
57847295 P PING,TOWER 40K

001.0 95280541 1.0 EA FITTING,HYD
002.0 50034826 46.0 EA CLAMP,HOSE,HALF
003.0 57233280 1.0 EA FITTING,STR,16OFSX12SAE
004.0 52251816 6.0 EA CLAMP ASSY
005.0 57233983 1.0 EA FITTING,L90,16OFS X2OSAE
006.0 57262479 6.0 EA CLAMP ASSY
007.0 57262487 13.0 EA CLAMP ASSY
008.0 52251766 4.0 EA CLAMP ASSY
009.0 57217416 2.0 EA CLAMP, BOTTOM-SINGLETIER
010.0 57847709 2.0 EA OIL LINE
011.0 57866006 1.0 EA OIL LINE -12 ORS
012.0 95032074 2.0 EA ELBOW-MALE
013.0 95083051 6.0 EA CONNECTOR
014.0 95129599 2.0 EA FITTING,HYD
016.0 95096137 13.0 EA LOCK WASHER,HEL SPR.
•
017.0 95239521 13.0 EA NUT,HEX
018.0 95268215 12.0 EA FITTING,HYD
021.0 50263813 74.0 IN HOSE,HYD-A04 BULK
022.0 50263813 66.0 IN HOSE,HYD-A04 BULK
023.0 57862443 1.0 EA HOSE ASSY
024.0 57862443 1.0 EA HOSE ASSY
025.0 50263813 290.0 IN HOSE,HYD-A04 BULK
026.0 50263813 290.0 IN HOSE,HYD-A04 BULK
027.0 57380834 1.0 EA HOSE ASSY
028.0 50263813 197.0 IN HOSE,HYD-A04 BULK
029.0 57865230 1.0 EA HOSE ASSY
030.0 50263813 195.0 IN HOSE,HYD-A04 BULK
032.0 57847352 1.0 EA HOSE ASSY
033.0 57847360 1.0 EA HOSE ASSY
035.0 57847386 1.0 EA HOSE ASSY
037.0 95735346 1.0 EA FITTING,HYD
038.0 57847410 1.0 EA HOSE ASSY
039.0 57847428 1.0 EA HOSE ASSY
040.0 57860520 1.0 EA HOSE ASSY
1.0 EA HOSE ASSY
•
041.0 57860538
042.0 57860546 1.0 EA HOSE ASSY
T3W
Bong
(HYDRAULIC TANK)
PUMP D (GEAR BOX)
/\(MUD PUMP)
PUMP A
PUMP C
PUMP 8--
(HYDRAULIC TANK)
(MUD PUMP INSTL)
TB2657844680 REV 001
page i2 WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250
•
T3W
BOM 4,1612;,,
z-HYDRAUL IC TANK)
___y
• DETAIL PUMP A
TB2657844680 REV 001
•
T3W
BOAR",
(HYDRAULIC TANK)
22
(MAINFRAME) 15
DETAIL PUMP B
TB2657844680 REV 001
T3W
PING,SUCTION
/
(HYDRAULIC TANK)
(GEAR BOX)
• rI l
3
14
11
DETAIL PUMP C
• TB2657844680 REV 001
•
T3W
60Ni 57846127
(GEAR BOX)-
12
13
12
II
•
II
(HYDRAULIC TANK)
DETAL PUMP D
(OPTIONAL FOR 701(1
page 406
TB2657844680 REV 001
•
•
T3W
BOM 57846123

001.0 57878225 1.0 EA TUBE,2.5"SUCTION
002.0 52232949 2.0 EA KIT,SPL FLG
91310136 1.0 EA - 0-RING 20A11DM232
003.0 57842676 1.0 EA FITTING,HOSE 2.00",STR
004.0 58173097 4.0 EA CLAMP,HOSE
005.0 58086141 4.0 EA CLAMP,HOSE
006.0 56928534 3.0 EA KIT, -32 SPLIT FLANGE
007.0 57878217 1.0 EA TUBE,2.5"SUCTION
008.0 56883572 1.0 EA KIT,SPLIT FLANGE
009.0 57843161 1.0 EA SPLIT FLANGE,-16
011.0 57878183 1.0 EA TUBE, 2" SUCTION
014.0 56946734 8.0 IN HOSE,HYD-C32 BULK
015.0 57917726 1.0 EA CLAMP,2.5"STAUFF,RAIL
016.1 56947112 12.0 IN HOSE,HYD-C40 BULK
•
018.( 57452666 1.0 EA HOSE ASSY
022.0 57608283 2.0 EA PLUG,C61-32
•
•
•
Section J - Electrical System
•
T3W
BOM 57863300
REF:TOP OF COOLER
DRILL END
21
22
00 14
MOUNT a(„/ 15
MC 11 BOX
1. 24
23
•
TO JUNCTION BOX
3
, TO BO BOX,BUUO-EAD ON AR NECEMB
TO BO BOXALKNEAD CN COMPRESSOR
32 TO CONSOLENUO-EAD
TO HYD TEMP SENSOR
TO FAN SPEED CONTROL
TO ENMNE,JR39 CONNECTCR
6
\7
page 410
D2657863300 REV 005
•
•
T3W
BOM 57863300
•
HELPER
CONTROLLERS
TO MCII
DETAIL A BOX nH
9
• D2657863300 REV 005
Orr£98i.c 010£1
afa
c ©hot, TO SLOW FEED TO ISOLATOR
VALVE VAL
.. _.
. ••
t4
MAMFOLD--- L •N
MOUNT MN)
0) al CO
"-MAIN FRAM
LOCATION OF THE MAIN MANIFOLD REF
GROUND ITEM 29 TO BOLT

ON FlEL LEVEL GUAGE. 00
TO HELPER
TO HELPER
CONTROL 3'
TO JB
CONTROLLER
TO JO / sy NG OUT
IrMAOT Ca
00C£99L99ZCI
/10caLyE
REMND
' TO CONSOLE
BULKHEAD
REF: ROTATION PUMP REF: MAIN MANIFOLD TOP
el=a
—WHITE
SOOA321
PRESSURE SNITCH
3
trrIVISNI1V011313313iM e:1
k•
REF : HYDRAULIC TANK TOP

Cn
CD
3
CD
U)
_u
W Cr'
C
WARNING: Thismanual contains dataSPECIFICtothedrillingrigwith serial number:US021250

O
•
T3W
BO WI 57863300

001.0 57918799 1.0 EA CABLE EXTENSION 10-PIN
006.0 57862146 1.0 EA CONNECTOR MALE,PLUG 5PIN
007.0 57861510 1.0 EA J1939 EUROFAST CONNECTOR
008.0 57866915 1.0 EA CABLE EXTENSION 4PIN
010.0 57862328 1.0 EA EUROFAST SPLITTER
011.0 57862393 4.0 EA EUROFAST CONNECTOR
012.0 57862336 1.0 EA CONNECTOR MALE,PLUG 5PIN
013.0 57862385 4.0 EA SPLITTER
014.0 95929071 4.0 EA WASHER,FLAT 1/4
015.0 95035408 4.0 EA CAPSCREW,HX
•
017.0 57862344 1.0 EA JUNCTION BOX, 6PORTS
019.0 95958682 3.0 EA SCREW,TRUSS HD
020.0 57862369 1.0 EA HARNESS
021.0 95934550 6.0 EA CAPSCREW,HEX
022.0 95929071 6.0 EA WASHER,FLAT 1/4
023.0 57865677 1.0 EA BRACKET, ELEC. BOX
57524449 4.0 EA - STUD,WELD
025.0 95064663 3.0 EA WASHER,FLAT
026.0 95076725 3.0 EA NUT,MACHINE,HEX
027.0 57868325 1.0 EA RECEPTACLE, 3 WAY
028.0 57868333 1.0 EA PLUG, 3 WAY
029.0 58150178 1.0 EA TERMINAL,16-14 5/16 RING
030.0 56930290 1.0 EA TERMINAL
031.0 95371266 1.0 EA TERMINAL
032.0 57875080 1.0 EA CLOSURE CAP,MALE
•
T3W
BOM 57863565
12
13
2
lihstiltacf
14
4-
Lmaireettamt
•
ISM$88881114118$8814181118t188881111811$888888$11
13
12 0
n n
page 414
9 67
D2657863565 REV 003

•
T3W
BOK
TO IF BOARD WIN 00:34
6RE0 TO IF BOARD WIN 40;30 33

Er 3/
31
08E1
PE/
NO (011E.0
GREY TO iT BOARD WIN 10:61
20
GUT 10 it' 00480 PIN I60,41
71 21
TN 26
10 IT 4000 PIN 101$9
69 25
BRET TO If BOARD PIN *0,70
BRET TO IF BOARO PIN 140,73
6801 66
•
600Y TO if 0000 RIR W0711
21
TO If BOARD PIN 00:12
20
GRIT TO IT 60446 13 BOOB 60
IS
TO if BOARD RIR 80I57
ORANGE TO If BC PlO 00 3 Il NO COMM

61a TO TT Be 16 NO [OULU
1,41"C,
8&00.( TO If BOARD
RCUBliClt TO IT WARD PI
INMAN TO If 0000 FIR 4
OEM AO ID If liCAPO PITT N0:42 33 15
e., TOIADK TO If BOARD PIN AWIt44
52 14
8E0E07014IT0 TO IT B000 PIN 00,43
GREEK TO IT BOAR0 Ptg gOtt 4S 13 00 0001(tT
1170 TO IT 0000 PIN 00:77
WOITE TO IT 80400 PIN 040:76
BLACK TO If BOARD f111 ROJO
44 12
4a
41 TO
ORANGE TO If BOARD FIR 00:50
0110 ID If 00480 PIN 80:56
48171.18tAEN TO If 00400 PIA 00,51
RCDTBT4(8 TO IT 0000 PIA 60:60
EEKIDLA:R TO If HARD PIR 04,53 44 8
08686216i4C4 TO IF BOARD PIN 00:51
RIO TO IT BOARD PIR 0O:46
GREER TO If Ickn PIN N0:44
61.601 TO If ISCARt PIM 00t67
It
R4I7E TO If 0000 PIA R0,14
3
36
31
10 If KM) P 61 36
8110 TO IT BOARD RIM 40.8,
1417(7M AC' 10 If 60400 P1 *0:00
800110#40 70 If 10080 810 00:66 2
OREERIIKAOW TO IT twat, PIN 60:64
04110016008 TO If BOARD PIN 10763 1
RED ID II BOARD PIN WO AI
GREEN TO If BOARD PIO 00.51
SERER TO IT 0(00 PIN N0,56
WiltE
0
• D2657863565 REV 003
TD
CU
CD
CD
c99£99LC WO8
TO IF BOARD PIN 110:14

10 IF BOARD PIN 40:19
TO IF BOARD PIN N0:20
1' TO IF BOARD PIN NO:23
TO IF BOARD PIN NO:II
10 IF BOARD PIN NO:24
TO IF BOARD PIN NO:2
TO IF BOARD PIN NO:I

TO IF BOARD PIN NO:2T
TO IF BOARD PIN 0O:25
£00/OH 999£981.99ZCI
W

10 IF BOARD PIN 00:1
To IF BOARD PIN N0:5
CW
WARNING! Thismanual contains dataSPECIFIC to the drillingrigwith serial number:US021250

OSZIZOSn :JaqwnN lePoS
• •
T3W
BOM 57863565

001.0 67604298 1.0 EA BOX,ELECTRICAL
002.0 57817504 1.0 EA CONTROLLER, NON-PROGRAMD
003.0 57891335 1.0 EA INTERFACE BOARD
005.0 50791557 1.0 EA PANEL,ELECTRICAL BOX
006.0 57817181 1.0 EA VENT,GORTEX
007.0 57817199 1.0 EA NUT,PLASTIC GORTEX VENT
011.0 98632888 3.0 EA SEAL,HOLE
012.0 95924080 4.0 EA SCREW,TAPPING-1/4-20X1/2
013.0 95959136 4.0 EA WASHER,LOCK
014.0 57815540 1.0 EA CONNECTOR,48 CIRCUIT
57930927 1.0 EA - IQAN EXTRACTION TOOL,MT
•
57930935 1.0 EA - IQAN,EXTRACTION TOOL,JPT
T3W
BOM 57864332
57864332 WIRING,CONSOLE T3W
1 18
T. /1
r, t 011.00 I
BRDSLI
,140,1115411
10 hIN 12 01 71541173Ii I E
J I TV ZtE
8 Oil 1lThIR / 11:)
i TIERSTKE (1
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TAGTI It
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10 \ 10
Itill
10 ICI 011100 -ice
- 10
0T
9 2 OE 1L.
1 ii.„
mita., 11-x1111014( ---4,
DRILL
STTIM6 1F11
0011111151511
AIR sy ICH
k I P1F35001
„.
, iS (SS" =
LICIT SE TON
Ell-
00110S IC
11
10
1,5)—
T
311900 110111
11
2.5730544
Dm 113 of 2131054311 013151
3 hL
Will 1.4-1
if 3/001C1
311: ,003L1.33
53 /5140!
IMO- ILA((
Ot)cwrat. TI
'PT
WIRES FROM IIONTITART

GORTAGT ON TT G011015.3TR TO CO3 50 TO CO
DO MOT ISE EILACT WIRE
— • —••
2 SPOT
ED HOOD DI 50
CC
TeR0110
LIMIT
SLOW 0010 IS
DO 301 wilE ROTATION
13111.5
3A1E1 I IIJO S.111
.10
,
0
'OAR
IA LET 50
TO CO3
•-,
3
k I
•
00 HO LUDT 70 3/3131 TtFlo 1 11 101
SEE SiTT1-
_.1
7 -- RI
ST
[TILL LEVEL
JIB 51110 RIGIIT
SI 110111
00
GROUND
ST/P1T SLOW FEED UP
DN IDD
.110 OUT
001 ,7E
ROT POOP (CO
18876K377
1111TI
TO FILTER WASS LINT 010051
000 TF/Bli
Di SHE CT - ILILR 71•0050
III PROVING LIFT
3 II SLOW 1E01 00WD
TF IS JIB IN
I 101 PIMP TIOTIOTISS
la
TO CO3 . 3 MOT OR MOT 210
D2657864332 REV 003
page 418 WARNING' This manual contains data SPECIFIC to the drilling rig with serial number US021250
•
T3W
BOM 57864332

001.0 57036881 1.0 EA BAR,COPPER
002.0 50465293 64.0 IN WIRE,8AWG-RED
003.0 57744674 4.0 EA HARNESS,GAUGE
004.0 57744682 1.0 EA RESISTOR,TERMINATION
005.0 50249655 119.0 IN WIRE,14AWG-BLACK
006.0 50465293 80.5 IN WIRE,8AWG-RED
007.0 50625938 61.75 IN WIRE, 14AWG-GREEN
008.0 57760555 2.0 EA HARNESS,CAN & POWER
009.0 54651187 1.0 EA RECEPTACLE,6 CIRCUIT
010.0 57625964 6.0 EA PIN,MALE
011.0 57668071 2.0 EA PLUG,3 CIRCUIT
018.0 50812429 24.5 IN WIRE, 14AWG-BLUE
050.0 50249648 246.5 IN WIRE,14AWG-RED
•
T3W
BOM 57728263
20
16
17
18
19
4 5
11
12
13 15
D2657728263 REV 003
• page 420 WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250
•
T3W
BOM 57728263

001.0 57147282 4.0 EA LAMP, FLOOD-70W HALOGEN
002.0 57157885 4.0 EA HOUSING, 4X6 LIGHT
003.0 52175809 1.0 EA BOX,4" STONCO W/COVER
004.0 56991193 7.0 EA CONNECTOR
005.0 95351540 4.0 EA ELBOW
008.0 95934659 4.0 EA CAPSCREW,HEX
009.0 95934733 4.0 EA WASHER,LOCK
010.0 58150103 480.0 IN CORD,14/2
012.0 95104071 4.0 EA CAPSCREW
013.0 52240959 4.0 EA PLATE,TAPPED
014.0 95344719 1.0 EA OUTLET BODY
015.0 56790330 2.0 EA ANGLE
016.0 95368338 12.0 EA CLAMP,HOSE
•
017.0 57524522 12.0 EA STUD,WELD
019.0 95922894 12.0 EA NUT,HEX
020.0 58150186 2.0 EA TERMINAL, RING
T3W
Refer o Detail B
Refer to Detail B
10 10
11 11
14
13
14 13
E2657234072 REV 004
T3W
1 ,72
Chassis Harness
Detail B
• E2657234072 REV 004
T3W
BOM 57234072
19 19
20 20
E2657234072 REV 004
T3W

001.1 58054610 2.0 EA LIGHT,RED
002.1 58150111 300.0 IN WIRE, ELECTRICAL-14/3
003.0 58150202 4.0 EA CONNECTOR,16-14 BUTT SPL
004.0 58150210 2.0 EA 2RC1OX
005.0 95301842 8.0 EA CLAMP,HOSE
006.0 95104071 8.0 EA CAPSCREW
009.0 58159088 1.0 EA INSULATOR, HEAT SHRINK.
010.0 95111043 8.0 EA SCREW,MACHINE
011.0 95923041 8.0 EA NUT,HEX,MACHINE,PLATED
012.0 58150160 12.0 EA RB14-14
013.0 57216848 2.0 EA LAMP, BACK-UP TURN RH
014.0 57216855 2.0 EA LAMP, BACK-UP TURN LH
019.0 56971914 2.0 EA 3302TB
020.0 50625839 2.0 EA BUSHING,CONDUIT
•
•
Section K - Options
T3W
BOM 57860223
(FR
(MAIN MANIFOLD:
19
17
TO 11[CLIKR TA1111.16
18
(CONSOLE)
15
VIEW A-A
TB2657860223 REV 002
T3W
BOIVI 57860223
19 15
18 17
ii a• 0 47— I
ole V,
1:54..p.
i
' 0 4
w o
CI * : 0
TOP VIEW 3
4
5
10 13
10
17 13
VIEW 8-8
TB2657860223 REV 002
T3W
BOM 57860223
ISO VIEW
TB2657860223 REV 002
•
T3W
BOM 57860223

001.0 57847642 1.0 EA INJ ASSY,WTR,18 BEAN See Page 432
002.0 95939955 4.0 EA WASHER,LOCK
003.0 95104014 4.0 EA CAPSCREW
004.0 95935003 4.0 EA WASHER,FLAT
005.0 95077772 4.0 EA NUT,HEX
006.0 58000357 1.0 EA WATER INJECTION MANIFOLD See Page 436
008.0 95105243 6.0 EA CAPSCREW
013.0 57328676 2.0 EA FITTING,TEST
014.0 95528808 1.0 EA ADAPTER
015.0 57861981 1.0 EA HOSE ASSY
016.0 57861999 1.0 EA HOSE ASSY
•
017.0 57862005 1.0 EA HOSE ASSY
018.0 57862039 1.0 EA HOSE ASSY
019.0 57358327 1.0 EA HOSE ASSY
020.0 57318628 1.0 EA HOSE ASSY
T3W
BOr,
15
14
11
12
13
14
15
33
23
D2657847642 REV 002
4 "i2 WARNING. This manual contains data SPECIFIC to the drilling rig with serial number: US021250
•
T3W
ES( 42
57847642 !NJ ASSY,WT11,18 BEAN
24 31 11 14 12 13 14 15
1S\
17
26
•
27
34 28 10
• 21
D2657847642 REV 002

23
1
page 433
•
T3W
BOM 57847642

001.0 57848491 1.0 EA BASE,WATER INJECTION
002.0 56257629 1.0 EA PUMP,WATER INJ,PISTON
57561367 1.0 EA - END,POWER
95379376 1.0 EA - PIN,ROLL
57561383 1.0 EA - COUPLING
57932535 4.0 EA - CUP:1 5/8" CARBOXILATED
57932543 1.0 EA - FLUID CYLINDER
50717917 8.0 EA - VALVE SEAT
50718121 8.0 EA - VALVE CAGE
57932576 8.0 EA - DISC & SPRING ASSEMBLY
57932584 12.0 EA - 0-RING
57932550 4.0 EA - UMBRELLA: BLACK
57778276 4.0 EA - WASHER,UMBRELLA
57932568 4.0 EA - 0-RING
50644269 4.0 EA
•
- GASKET,CYLINDER
57561037 4.0 EA - CYLINDER,CERAMIC 1.63DIA
57561045 4.0 EA - PACKING HOLDER
57303885 4.0 EA - PACKING WASHER
57561060 4.0 EA - SEAL RING
57561078 4.0 EA - O'RING,BUNA N
57932592 4.0 EA - ROD, CONNECTING E04
57932600 8.0 EA - BEARING,ROD,HALF SHELL
57932618 4.0 EA - PIN, WRIST
57932626 4.0 EA - SEAL HOLDER
50718089 4.0 EA - SEAL
57932634 1.0 EA - GASKET, BASE
57932642 4.0 EA - SEAL,OIL
57932659 4.0 EA - RING, RETAINING
57932667 1.0 EA - PIN,SPRING,SLOTTED
57727596 1.0 EA - FLANGE
54473335 1.0 EA - CHAMBER,VALVE
57678328 1.0 EA - SHAFT
57756520 1.0 EA - KIT,PACKING
57756538 1.0 EA - KIT,VALVE
003.0 50057215 1.0 EA STEM, HOSE-1 HOSETO1 NPT
004.0
005.0
006.0
page 434
95069464
95037792
57341604
57343402
1.0
1.0
1.0
1.0
EA
EA
EA
EA
ELBOW
BUSHING
STRAINER,B STYLE-1-1/4ST
- SCREEN, STRAINER - 1-1/4
•
•
T3W
1
- 642
57847642 !NJ ASSY, R,18 BEAN

57590580 1.0 EA - SCREEN,STRAINER,1.50
008.0 95006573 1.0 EA TEE,PIPE
009.0 95040986 1.0 EA ELBOW,STREET
010.0 95647798 1.0 EA FITTING, HYD
011.0 95702619 1.0 EA ADAPTER
012.0 95264909 1.0 EA ELBOW,90DEG-EXT/INT NPT
013.0 56996911 1.0 EA FITTING,HYD
014.0 95315222 2.0 EA FITTING,HYD
015.0 50212224 2.0 EA VALVE,BALL-3/4
016.0 95002143 1.0 EA PLUG,PIPE-SQ HEAD
017.0 52146883 1.0 EA VALVE,RELIEF
018.0 95279105 1.0 EA FITTING,HYD
019.0 57848186 1.0 EA MOTOR,HYD.,6 CU. IN.
020.0 95934469 4.0 EA CAPSCREW,HEX
021.0 95209391 4.0 EA WASHER,LOCK
022.0 58167743 1.0 EA HOSE, SUCTION
56947104 144.0 IN - HOSE,HYD-C16 BULK
023.0 95235131 2.0 EA CLAMP,HOSE
024.0 58047853 1.0 EA VALVE, CHECK
026.0 95934733 4.0 EA WASHER,LOCK
028.0 95279337 1.0 EA FITTING,HYD
030.0 57596108 1.0 QT OIL,SAE-30WT,NON-DETERG
031.0 95242988 2.0 EA NIPPLE,PIPE
032.0 52193653 1.0 EA FITTING,HYD
033.0 50112895 1.0 EA HOSE STEM-3/4
034.0 95387890 1.0 EA CAP,JIC-12
•
T3W
BOM 58000357
58000357 ATER INJECTION MANIFO
page 436
C2658000357 REV 000
•
•
T3W
BOM 58000357
58000357 WATER INJECTION MANIFOLD

001 58000456 1.0 EA VALVE, ROTARY, ON/OFF
002 58000464 1.0 EA HANDLE, BALL
003 58000472 1.0 EA VALVE, FLOW REGULATOR
004 58000480 1.0 EA VALVE, CARTRIDGE, 2 WAY
•
T3W
BOM 57752388
57752388 LUBE,DHD,7GAL INSTL
B
O
C C
VIEW A—A
D2657752388 REV 002
•
T3W
BOW 5%752388
10
•
VIEW B—B
VIEW C—C
• D2657752388 REV 002
T3W
BOM 57752388
57752388 LUBE,DHD,7GAL INSTL •
D
E
E
13
13
•
14
15
16
VIEW D—D VIEW E—E
page 440
D2657752388 REV 002
•
•
T3W
BOM 57752388

001.0 57752370 1.0 EA LUBRICATOR,DHD,7GAL ASSM See Page 442
002.0 95920674 4.0 EA CAPSCREW,HEX
004.0 95922894 4.0 EA NUT,HEX
006.0 95364469 1.0 EA FITTING,HYD
007.0 95279998 1.0 EA ELBOW,90 DEG STREET
008.0 57039521 1.0 EA SIGHT,FLOW
009.0 95323457 1.0 EA FITTING,HYD
010.0 57442857 1.0 EA HOSE ASSY
012.0 95338372 1.0 EA FITTING,HYD
013.0 57666000 1.0 EA SUPPORT,DHD LUBE
014.0 95934816 4.0 EA CAPSCREW,HEX
•
017.0 57199085 2.0 EA BAR-W/HOLES
•
T3W
BOM 57752370
30 —Insulating Varnish
32
L —I
Ia
9 -ems
19
D2657752370 REV 002

p',-11),- 442 WARNING! This manual contains data SPECIFIC to the drilling rig with serial number: US021250
•
T3W
BOM 57752370
14
11#
DHD LUBRICATOR FLOW SETTINGS_
• TICE, USE OkLY APPROVED ROCK DRILL OIL.
\,..1
, 16,
'"* 7_7'4 4. I LA
_A
'
• D2657752370 REV 002
•
T3W
BOM 57752370
page 444
D2657752370 REV 002
•
T3W
3010 57152370
57752370 LUBRtCATOR,DHD,7GAL ASSM
23
BLACK
FIXED 1.0 SECOND "ON" DELAY

r FLOW SWITCH
HARNESS
•
0
SECONDS GND
II +12V 1 N (
22.5
O,; PUMP
15 +I2V OUT
"OFF" +24V IN DHD2
DELAY
0
FLOW SWITCH
DHD LUBRICATOR TIMER tr)
WHITE
23 VIEW A-A
• D2657752370 REV 002
•
T3W
BOW 57757311)
(—) NEGATIVE
BATTERY
TO KEY ACTIVATED
WIRE IN CONSOLE 57354342
LOCATED AT TANK
DHD TIMER
DHD +24V +I2V +12V
LUBRICATOR
ON—OFF IN OUT IN GND (OPT)
LOCATED ON • • 0 •
CONSOLE
5A
0
DH DI
PUMP SOLENOID
•
VALVE AT TANK
57352973
DHD3 FLOW INDICATOR

0 ON CONSOLE
(+)
57533021
FLOW SWITCH 57297137
LOCATED AT TANK
page 446
D2657752370 REV 002
•
•
T3W
BOM i 7 52370

014.0 57361982 1.0 EA DECAL,DHD LUBE SETTINGS
015.0 57361990 1.0 EA NAMEPLATE, DHD CONTROL
016.0 57297137 1.0 EA LIGHT,LED INDICATOR
017.0 57179608 1.0 EA SWITCH,SPST/ON-OFF
019.0 95293403 1.0 EA ELBOW,90 DEG MALE
020.0 56780703 1.0 EA TIE,CABLE
021.0 58150251 1.0 EA TERMINAL,16-14 BULLET FE
023.0 95329249 4.0 EA TERMINAL,6 FORK
024.0 855017P0841-1 1.0 EA CONNECTOR,TAP TYPE
025.0 56933690 480.0 IN WIRE ELEC
026.0 57130577 1.0 EA HOLDER,FUSE
027.0 52279338 1.0 EA FUSE
030.0 57168916 1.0 EA VARNISH, INSULATING
032.0 57752362 1.0 EA LUBRICATOR,SUB ASM,7GAL See Page 448
033.0 58150244 1.0 EA TERMINAL,16-14,BULLET
•
T3W
BOM 57752362
1
'i7
If
ii
111#
if
ii
Ia
itt
I#
it 18
IE
73144 Z. 4
if I
it
if
I
32
if
rr -
—2
page 448
D2657752362 REV 001
•
•
T3W
BOM 57752362
21
20
POSITION PUMP WITH VENT

FACING DOWN
• D2657752362 REV 001
•
T3W
BOM 57752362
TO KEY ACTIVATED
WIRE IN CONSOLE
(-) NEGATIVE
BATTERY
57354342
01-10
LOCATED AT TANK
LUBRICATOR
ON-OFF
MID TIMER
LOCATED ON
CONSOLE 24V +12V +12V I (OPT)
IN OUT GND
Di-ID1 PUMP SOLENOID

VALVE AT TANK
FLOW INDICATOR
ON CONSOLE
(-)
57353021 (+)
FLOW SWITCH I 57297137
LOCATED AT TANK
FIXED 1.0 SECOND ON DELAY
SECONDS
II
22.5
GND
*I 211 IN
0 15 +12V OUT
"OFF' +21V IN
DELAY
DHD LUBRICA OR TIMER 22
VIEW A—A
page 450
D2657752362 REV 001
•
T3W
BOM 57752362

001.0 57352973 1.0 EA PUMP,DHD LUBRICATOR See Page 452
002.0 57353021 1.0 EA SWITCH, FLUID FLOW
57428914 1.0 EA - SWITCH, SPST REED
003.0 57752354 1.0 EA TANK,7-GAL DHD LUBE
004.0 57354342 1.0 EA TIMER,DHD LUBRICATOR
005.0 95315404 1.0 EA NUT,HEX JAM
007.0 57358830 16.0 IN CONDUIT, 3/8 NYLON
009.0 95219739 1.0 EA ADAPTER
010.0 95072971 1.0 EA VALVE
011.0 57481178 1.0 EA HOSE ASSY
018,.0 57408775 1.0 EA VALVE, CHECK
019.0 95293403 1.0 EA ELBOW,90 DEG MALE
020.0 95748802 6.0 EA TIE,CABLE
021.0 95239216 1.0 EA JOINT,WIRE,10,CLEAR
031.0 57408767 1.0 EA ADAPTER, SAE 8 STRAIGHT
032.0 95209870 1.0 EA O'RING
•
T3W
BOM 57352973
3
1
page 452
C2657352973 REV 005
•
•
T3W
BON,: 1 52973

001.0 57307886 1.0 EA SEAL KIT,PUMP
001.0 57725400 1.0 EA VENT,FILTER
002.0 57431223 1.0 EA PLUNGER, TEFLON
003.0 57560682 1.0 EA SPRING
005.0 57769390 1.0 EA BREATHER,VENT,DHD PUMP
•
•
•
Section L - Tools/Accessories
BOM 57917239

T3W
List Only
page 456
LIST REV 000
•
•
T3W
BUM 51917239

001.0 50245281 1.0 EA GUN,BLOW-WITH 25' HOSE See Page 458
002.0 57269649 1.0 EA GUN, GREASE
003.0 58148339 1.0 EA EXTENSION
004.0 57359523 1.0 EA KIT, 0-RING, HYDRAULIC See Page 460
006.0 57889594 1.0 EA SOCKET,EXTENSION-T3DH
95101044 1.0 EA - PLUG,PIPE
57130403 1.0 EA - EXTENSION SOCKET
007.0 57828626 3.0 EA ELEMENT,FILTER
008.0 57895278 1.0 EA FILTER, CANISTER
T3W
BUM 50245281
4
5 6
2
1
TB294839 REV 005

T3W
BOM 50245281
50245281 GUN,BLOW-WITH 25' HOSE

001.0 50067131 1.0 EA GUN,BLOW,D
003.0 57053183 300.0 IN HOSE,HYD-A06 BULK
004.0 50245299 1.0 EA CONNECTOR, HOSE
005.1 95220844 1.0 EA CLAMP,HOSE
006.0 50245307 1.0 EA COUPLING,QD
007.0 59506436 1.0 EA FITTING,HOSE
•
T3W
BOM 57359523
57359523 KIT, 0-RING, HYDRAULIC
FACE SEAL FITTING 0— RINGS SPUT FLANGE FITTING 0—RINGS

SAE J1453 SAE J518
4
1 2 9 10 18 19
5
4
6
11
13
12
14
20
22
21
23
•
7 8 15 16 17
•
STRAIGHT THREAD FITTING 0—RINGS
SAE J1926
page 460
C2657359523 REV 001
•
• EON? 57359523
REF.
001.0
PART NO.
57279630
QTY
100.0
57359523 KIT, 0-RING HYDRAULIC
UNIT DESCRIPTION
EA 0-RING, SEAL-LOK, -4
T3W
NOTES
002.0 57279648 100.0 EA 0-RING,SEAL-LOK,-6
003.0 57279655 100.0 EA 0-RING, SEAL-LOK, - 8
004.0 57365918 50.0 EA 0-RING, SEAL-LOK, - 10
005.0 57279663 50.0 EA 0-RING, SEAL-LOK, -12
006.0 57279671 50.0 EA 0-RING, SEAL-LOK, - 16
007.0 57279689 20.0 EA 0-RING, SEAL-LOK, -20
008.0 57279697 20.0 EA 0-RING,SEAL-LOK, -24
009.0 95479044 20.0 EA 0-RING, HYD
010.0 95266417 100.0 EA 0-RING
011.0 95266425 100.0 EA 0-RING
012.0 95209870 100.0 EA O'RING
013.0 95209888 20.0 EA 0-RING,HYD
014.0 95303756 30.0 EA 0-RING
015.0 95266433 30.0 EA 0-RING
•
016.0 95343737 20.0 EA 0-RING
017.0 95266441 10.0 EA 0-RING
018.0 95915229 20.0 EA 0-RING, HYD
019.0 95926861 20.0 EA 0-RING, HYD
020.0 95926879 20.0 EA 0-RING, HYD
021.0 91310128 20.0 EA 0-RING, HYD
022.0 95915245 20.0 EA 0-RING, HYD
023.0 95915252 10.0 EA 0-RING, HYD
• WARNING: This manual contains data SPECIFIC to the

drilling rig with serial number: US021250
page 461
•
T3W
BOM
15
HYDRAULIC TANK
COOLER ASSEMBLY
RECEIVER TANK
D2657155541 REV 008
page a WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250
T3W
100
8
BATTERY BOX ON TRUCK

100
8
T3W ••••••••••
BATTERY BOX ON RIG
•
POWER HEAD
111111111111111111111111111.
MANUAL LOCATION
TOWER RAISING CYLINDER
D2657155541 REV 008

page 463
BON.' 57155541
T3W
TOWER
FEED CYLINDER
HOIST
TOWER REST
D2657155541 REV 008
US021250
page 464 WARNING: This manual contains data SPECIFIC to the drilling rig with serial number:
T3W

NOTES
000.1 57404261 1.0 EA DECAL & MANUAL SET-T3W
57140477 1.0 EA - DECAL,CAUTION-EXCESSOIL
57156333 3.0 EA - DECAL,WARNING-FALL. PIPE
57140469 2.0 EA - DECAL,WARNING-ROT.BLADE
57140444 1.0 EA - DECAL, ENG.FAILURECOOLSY
57140402 1.0 EA - DECAL,WARNING-HOT FLUID
57140352 1.0 EA - DECAL,WARNING-HIGH PRESS
57140428 1.0 EA - DECAL,WARNING-HIGHPRESS
57140394 2.0 EA - DECALWARNING-COMBUST.GAS
57140360 2.0 EA - DECAL,WARNING-FALLDERRIC
57155517 1.0 EA - DECAL,WARNING-POWERHEAD
57140345 1.0 EA - DECALWARNING-ROTAT.PARTS
57140329 1.0 EA - DECAL,WARNING-FALL PWRHD
57156465 1.0 EA - DECAL,NOTICE-HYD.FAILURE
57318040 2.0 EA - DECAL,WARNING-NOCLIMBNG
57163677 1.0 EA - NAMEPLATE,INSTRUCTIONS
57313975 1.0 EA - MANUAL, SAFETY-T3W See Page 466
57345878 2.0 EA - DECAL, NOTICE
001.1 57140477 0.0 EA DECAL,CAUTION-EXCESSOIL
002.2 57156333 0.0 EA DECAL,WARNING-FALL. PIPE
003.1 57140469 0.0 EA DECAL,WARNING-ROT.BLADE
004.1 57140444 0.0 EA DECAL, ENG.FAILURECOOLSY
005.1 57140402 0.0 EA DECAL,WARNING-HOT FLUID
006.1 57140352 0.0 EA DECAL,WARNING-HIGH PRESS
007.1 57140428 0.0 EA DECAL,WARNING-HIGHPRESS
008.2 57140394 0.0 EA DECALWARNING-COMBUST.GAS
009.1 57140360 0.0 EA DECAL,WARNING-FALLDERRIC
010.1 57155517 0.0 EA DECAL,WARNING-POWERHEAD
011.2 57140337 0.0 EA DECAL,WARNING-ROTATINGPT
012.1 57140345 0.0 EA DECALWARNING-ROTAT.PARTS
013.2 57311086 0.0 EA DECAL,DANGER-HAZ. VOLT.
014.1 57140329 0.0 EA DECAL,WARNING-FALL PWRHD
015.1 57156465 0.0 EA DECAL,NOTICE-HYD.FAILURE
016.2 57310831 0.0 EA DECAL,WARNING-DON'TALTER
017.1 57318040 0.0 EA DECAL,WARNING-NOCLIMBNG
018.1 57163677 0.0 EA NAMEPLATE,INSTRUCTIONS
019.0 57799793 1.0 EA DECAL, DRAIN WATER SEP
020.1 57313975 0.0 EA MANUAL, SAFETY-T3W See Page 468
021.1 57318693 3.0 EA RIVET, DRIVE
100.2 57345878 0.0 EA DECAL, NOTICE

page 465
•
T3W
BOM 57313975
B2657313975 REV 002
• BOM 57313975
REF.
001.0
PART NO.
57311169
QTY
1.0
UNIT DESCRIPTION
EA PAGE,COVER
T3W
NOTES
002.0 57311649 1.0 EA PAGE,ORDER INFORMATION

003.0 57311656 1.0 EA PAGE,LABEL REFERENCE
004.1 57324162 1.0 EA PAGE, TABLE-T3W
005.0 57299612 1.0 EA PAGE,WARNING ROTATING PT
006.0 57299620 1.0 EA PAGE,WARNINGROTAT.PARTS
007.0 57299646 1.0 EA PAGE,WARNING FALLDERRICK
008.0 57299638 1.0 EA PAGE,WARNING HIGH PRESS
009.0 57299653 1.0 EA PAGE,WARNING COMBUSTGAS
010.0 57299661 1.0 EA PAGE,WARNING HOT FLUID
012.0 57299687 1.0 EA PAGE, DANGER HAZARD VOLT
013.0 57299695 1.0 EA PAGE,DANGER ROT.BLADE
014.0 57299703 1.0 EA PAGE,CAUTION EXCESS OIL
015.0 57299711 1.0 EA PAGE,WARNING POWER HD
•
016.0 57299729 1.0 EA PAGE,WARNING FALL DRLPIP
019.0 57318107 1.0 EA PAGE,WARNING DON'T CLIMB
020.0 57299604 1.0 EA PAGE,WARNING FALL PWRHD
US021250 page 467
•
T3W
BOM 5731 147.r
B2657313975 REV 002
57313975 T3W

NOTES
001.0 57311169 1.0 EA PAGE,COVER
002.0 57311649 1.0 EA PAGE,ORDER INFORMATION
003.0 57311656 1.0 EA PAGE,LABEL REFERENCE
004.1 57324162 1.0 EA PAGE, TABLE-T3W
005.0 57299612 1.0 EA PAGE,WARNING ROTATING PT
006.0 57299620 1.0 EA PAGE,WARNINGROTAT.PARTS
007.0 57299646 1.0 EA PAGE,WARNING FALLDERRICK
009.0 57299653 1.0 EA PAGE,WARNING COMBUSTGAS
010.0 57299661 1.0 EA PAGE,WARNING HOT FLUID
012.0 57299687 1.0 EA PAGE, DANGER HAZARD VOLT
013.0 57299695 1.0 EA PAGE,DANGER ROT.BLADE
014.0 57299703 1.0 EA PAGE,CAUTION EXCESS OIL
015.0 57299711 1.0 EA PAGE,WARNING POWER HD
019.0 57318107 1.0 EA PAGE,WARNING DON'T CLIMB
020.0 57299604 1.0 EA PAGE,WARNING FALL PWRHD
US021250 page 469
BOM 57557001
57557001 DECALS,T3W
T3W
•
6
T314 z
irtlasthpeo
JethIS COpCO
VIEW B—B
D2657557001 REV 003
• BOM 57'557001
REF.
001.0
PART NO.
57783458
QTY
2.0
UNIT DESCRIPTION
EA LOGO,AC-21X10,WHITE
T3W
NOTES
002.0 57767014 1.0 EA NAMEPLATE

003.0 95064192 4.0 EA SCREW,DRIVE
004.0 57148389 1.0 EA DECAL,MACHINE-T3W MODEL
005.0 36507820 1.0 EA DECAL,COMP REQ'D MAINT.
006.0 57209934 2.0 EA REFLECTOR, RED
007.0 57209942 2.0 EA REFLECTOR, AMBER
008.0 57783466 2.0 EA DECAL,AC,WHITE,25X12
009.0 57411175 1.0 EA NAMEPLATE, MAINT/SERVICE
012.0 57767790 2.0 EA DECAL,WEB PAGE
• WARNING: This manual contains data SPECIFIC to the drilling rig with
serial number: US021250 page 471
T3W
BOM 57c,
General Decal Kit
LM hood decal Right hood decal
Atlas Cbpco
atlascopao.com 4
Decal an by cd the taw
Rocktec Industr ial Design 20071212
dod o decal below cab doors
Deed an toolbox
TB2657923773 REV 000
page WARNING: This manual contains data SPECIFIC to the drilling rig with serial number US021250
• BOM 57923773
REF.
001.0
PART NO.
58000092
1.0 EA DECAL,T3W,7600,LT,LH
T3W
NOTES
002.0 58000100 1.0 EA DECAL,T3W,7600,LT,RH

003.0 57873721 2.0 EA DECAL WIDTH 23.60"
004.0 57873739 2.0 EA DECAL WIDTH 23"
005.0 57874224 1.0 EA DECAL,AC LOGO,20.87"
page 473
•
•
• Numerics
32 SPLIT FLANGE KIT (56928534) 407 SEAL PUMP KIT (57307886)
SEAL MOTOR KIT (58003989)

T3W
123
453
C SEAL SECTION KIT (58004094) 377
CAB SHEILD INSTL KIT (57391773) 3 SERVICE KIT (50603869) 268
E SHAFT(SHAFT BRG KEY) KIT (57756553). . . . 199
ETHER CAT C15 KIT (57903015) SHIM KIT (57153090) 309
223
F SPL FLG KIT (52232949) 407
FLARE REFLECTOR KIT (58051863) SPLIT FLANGE KIT (56883572) 407
23 SPLIT FLANGE KIT (56950579)
G 199
SPLIT FLANGE KIT (58235128) 299
GASKET-AIR CLEANER KIT (50621796) 213
GLASS SIGHT KIT (57655011) T
236
TIMER INSTALLATION KIT (57655730) 237
H
HANDLE KIT (58006131)
V
377 VALVE KIT (57756538)
HOLDER FUSE KIT (57655284) 236 434
HR2.5 TUBE KIT (42428847) VALVE RELIEF KIT (57655474) 237
245
M
MOUNT RUBBER KIT (57655243) 236
0
0-RING HYDRAULIC KIT (57359523) 457
•
P
PACKING KIT (57756520) 434
R
REBUILD HR2.5 KIT (36039519) 245
RELIEF VALVE KIT (36037190) 253
REPAIR 2B CUSHION KIT (57351959) 105
REPAIR 2B.NON CUSH KIT (57351942) 58
REPAIR KIT (57511941) 145
REPAIR KIT (57514846) 267
RETAINER PISTON/SHOE KIT (52204880) . . 331
RETAINING RING KIT (54416946) 309
S
SCREEN BLOWER INLET KIT (57655102). . . . 236
SEAL - CYLINDER KIT (57350035) 103
SEAL A SIDE HYD PLT KIT (58004110) 377
SEAL A SIDE MANUAL KIT (58004102) 377
SEAL B SIDE HYD PLT KIT (58004128) 377
SEAL B SIDE MANUAL KIT (58004136) 377
SEAL HYD CYL KIT (57753485) 393
SEAL KIT (57039695) 107
SEAL KIT (57250276) 123
SEAL KIT (57303794) 339
SEAL KIT (57511255) 141, 143
SEAL KIT (57729980) 29
SEAL KIT (57729998) 29
SEAL KIT (57756561) 199
•
SEAL KIT (57780058) 369
SEAL KIT (58212697) 87
SEAL KIT (58212705) 87
SEAL KIT (59476705) 369
SEAL KIT (59643718) 123
SEAL MOTOR KIT (54634886) 135
index 1
•
T3W
index 2 WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250
T3W
CPN BALL VALVE

14 THHN GRAY 158 -12NPT
2RC1OX 425 LOCK 167
3302TB 425 BAND
MOUNTING 211
A BAR 9, 143
ACCESS COVER 213 COPPER 419
ACTUATOR FLAT 8, 29
HEATER 243, 268 LOCKING 11, 59, 63, 69
ROTARY 59 LONG
WITH HEATER 247, 273 CABLE GUIDE 69
ADAPTER 29, 43, 82, 119, 199, 231, 253, 290, 298, NYLON-3-3/4 117
299, 369, 383, 391, 431, 435, 451 RETAINER 58
1/4 ORS TEE 383 SHORT
1/4 ORS TO NPTF 44 CABLE GUIDE 69
1/4" 268 SPACER 105
90DEG-O-RING/JIC 267 SQUARE 82
FEMALE BAR 1.75 X 3.5 X 6 9
STRT TH RD 165, 169 BAR LOCKING 393
INPUT SHAFT BAR W/2-.81 HOLES 165, 169
298
PUMP D BARB
298
SAE 8 STRAIGHT 451 HOSE 204
ADAPTER FLANGE SAE 20 BARREL & SLEEVES 329
141
ADAPTERFRT. F NG.CAT3406TA 165, 169 BARREL/AUX SHAFT ASSY 327
ADHESIVE BARREL/SHAFT/CRADLE ASM 309
FLOOR BAR-W/HOLES 441
5
ADPT 90 DFG 167, 171 BASE
AIR CLEAN[ R 211 ENCLOSURE 237
AIREND PIVOT 133
REBUILT WATER INJECTION 434
245
AIREND - HR 2.5 243 BATTERY
ANCHOR 12V-8DW/ELECTROL 185
CABLE BATTERY CABLE NEG 185
59
ANGLE BATTERY CABLE POS 185
421
PINNING BEARING . . 82, 166, 170, 298, 311, 317, 321, 325
166, 170
W/HOLES BALL 121, 166, 170, 298
231
ARM CLUTCH PILOT 166, 170
ASSEMBLY CYL ROLLER 143
58
RETRACT ACTUATOR MOTOR 123
58
ARM ASSY 103 ROD
ARM GUIDE HALF SHELL 434
59
ASSY SUPPORT ROLLER-TAPER 82
117
ATOMIZER S.H. BALL 298
ETHER SELF LUBE 105
C15 227 SINGLE SPHERICAL 61, 65
SPHERICAL 303, 307
SPINDLE 91
B
TAPERED ROLLER 71
B2B 158 THRUST 97
BALL 47, 335 BEARING ASSY 145
CHROMESTEEL13/32DIA 143 BEARING CONE 91
KNOB 375 BEARING CUP 91
VALVE 348 BEARING NUT 91
US021250 index i
BEARING RING
BEARING-SPHERICAL
303
127
Index
BRACKET
"J"
8, 159, 237
236
T3W
•
ACTUATOR 268
BELLOWS
149 AIR FILTER 348
RUBBER
AIR LINE MNT 268
BELT
169 BO BOX 243
ALTERNATOR 53.5"
BREAK OUT BOX 269
BLADE
236 ELEC. BOX 413
FAN
BLANKET ETHER
189 MOUNTING 223
EXH ELBOW
321 ETHER MOUNTING 227
BLOCK
159, 173, 177 FUEL COOLER 219
6MM COMPONENTELEC
268 HAND PUMP 348
FLANGE 2"NPT
165, 169 MOTOR 204
SWITCH MOUNTING
173, 177 MOUNTING 119
UK10 TERMINAL
173, 177 MOUNTING-AMOT 253
UK4 TERMINAL
319 OIL 167
BLOCK-PORT
PILOT VALVE 243
BLOWER
236 PIPE MOUNTING 193
24V
213 PIPE SUPPORT 207
BODY ASSY-AIR CLEANER
351 PUMP DRIVE MOUNT 295
BODY KP-1004C-10
269 RADIATOR INLET 193
BOLT
268 RELAY MOUNTING 166, 170
EYE
RETAINER 204
HUCK-FIT
8 ROD BOX 17
16X45
166, 170 TOWER SUPPORT 11
SHOULDER
307 VALVE 372
BOLT m5x50
BONDED SEAL RING 377 BRACKET ASM
HOSE MOUNT 167
BONNET
SWIVEL W/3"CPLG 91 BREAKER
CIRCUIT-15 AMP 43
BOOM
JIB ASSY 141 BREATHER 82, 298
FUEL TANK 217
BOOT
DUST PRESSURIZED 348
W/PLATE 377 VENT
BOSS DHD PUMP 453
HINGE 105 BRIDGE
PIN 69 ELEC. INSULATED 158
PIVOT 105 U K-4
BOX INSULATED 158
1/4 TURNBUCKLE 173, 177 BULKHEAD UNION-16
4" STONCO W/COVER 421 L45 372
ELEC BUSHING 11, 58, 85, 89, 91, 105, 117, 121, 141, 434
4X6 20"TABLE 105
NEM4 249, 275 CONDUIT 425
ELECTRICAL 243, 269, 413, 417 PIPE 82, 217, 231, 271, 277, 349
MACHINED REDUCING 263, 267
ELECTRICAL 173, 177 QD
T3W TOOLBOX 21 2-3/8 SHAFT 165, 169
TOPHEAD 82 REDUCER 298
BRACE 111 SELF LUBE 166, 170
DUST SHIELD BACK 113 TAPER-1.75 BORE 199
BUSHING ASSY 11
index ii WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250
T3W
C 441
CABLE HEX HEAD 69, 165, 169, 341
90 DEG.PLUG 158 HEX SOCKET HEAD 82
BATTERY 185 HEXHEAD
EXTENSION METRIC 243
4-PIN 243, 269 PLATED 99, 119, 267
6-P1N 269 HX 17, 205, 413
EXTENSION 10PIN 413 SELF LOCKING 166, 170
EXTENSION 12PIN 413 SH 377
EXTENSION 4PIN 243, 387, 413 CAPSCREW (6R8) 268, 295
GROUND-1/0 X 36 185 CAPSCREW W/LOCK WASHER 91
HOSE RESTRAINT 257, 277, 279 CAPSCREW/35A2A166Z1HR 166, 170
SAFETY WHIP 267 CAPSCREW/35A2A225Z1HR 295
STARTER JUMPER 158 CAPSCREW/35A2A377Z1HR 205
CABLE EXTENSION 10-PIN 413 CAPSCREW/35A2A379Z1HR 59
CABLE EXTENSION 4PIN 413 CAPSCREW/35A2D323G 295, 369
CAC CAROUSEL
HEAT EXCHANGER 204 6X4.5 DIA. ROD 99
CAM INSTL
LOCKING 166, 170 T3W 99
CAM SHAFT CARRIAGE SHEAVE ASM 69
WELDMENT 165, 169 CARRIAGE WLDMT
CAM SI ROKER ASSY 331 TRAVELING 69
CAP CARTRIDGE
37 DE ARED 263, 269 CHECK VLV. 199
END 123 CASTING
ENL r 351 FAN END 236
FA, RING -16 373, 401 CHAIN 166, 170
F AL RING - 4 373 ANCHOR 8
FACE -RING -12 372 CHAMBER
FACE LE-RING -6 373 VALVE 434
JACK 29 CHANNEL
JIC-12 435 ANCHOR 8
JIC-4 263 CHECK VALVE 335
JIC-6 268, 290 CLAMP 193, 213, 321
MID JACK L.H. 29 #10 SILICONE 237
MID JACK R.H 29 13.5" DIA 189
RADIATOR 204 2.5"STAUFF
WEATHER 189 RAIL 407
CAP SCREW 83 ASSY 3/4 -STACK 29, 369
CAPSCREW 8, 11, 13, 15, 43, 44, 45, 58, 59, 83, 91, BOTTOM-SINGLETIER 401
117, 119, 133, 141, 149, 165, 166, 167, 169, 170, 171, CABLE 145
181, 189, 193, 199, 204, 207, 217, 219, 223, 231, 243, CABLE-3/4 59
263, 269, 290, 298, 299, 343, 348, 369, 370, 372, 387, CABLE-5/16 101
421, 425, 431 CABLE-7/8 59
AH 95, 253 CONSTANT TORQUE 207, 211
FLANGED 12 PT 82 CUSHIONED 236
HEX 3, 8, 15, 17, 19, 29, 35, 43, 44, 59, 63, 69, 82, EXHAUST PIPE 236
89, 111, 113, 117, 125, 127, 165, 166, 167, 169, EXHAUST-TURBO 189
170, 171, 181, 185, 189, 199, 204, 211, 219, 267, FUEL HOSE 236
295, 299, 348, 349, 369, 370, 393, 413, 421, 435, GEAR #32 236
HOSE 82, 133, 141, 159, 193, 204, 231, 267, 277,
WARNING: This manual contains data -SPECIFIC to the drilling rig with serial number: US021250
index iii
279, 407, 421, 425, 435, 459
HALF 401
Index
CONNECTOR
1/2
43, 44, 158, 237, 401, 421
158
T3W
•
HOSE SUPPORT 348 STR LT
SPRING 16-14 BUTT SPL 159, 425
AIR 236 3 PIN 49, 159
48 CIRCUIT 417
STAUFF
G12 CHRG AIR 207
STACK 372 CORD GRIP 43, 149, 247, 273, 451
58 FEMALE 44
CLAMP 5.75 O.D. FEED CYL
141, 277, 401 HOSE 459
CLAMP ASSY
STAUFF 1.560D 370 MALE
STAUFF1-1/20D 370 37 DEG 167, 171, 175, 183, 435, 459
STAUFF1-1/4OD 167, 199, 372 37 DEG. 268, 290
STAUFF3/4 OD 29, 369 STRAIGHT-1 158
CLAMP GEAR #36 237 STRT THRD 44, 193, 219, 268
CLEVIS TAP TYPE 447
PIN 58 CONNECTOR MALE
ROD 58, 105 PLUG 5PIN 413
T3W DH-50K 141 CONSOLE
CLEVIS ASSY 143 T3W.ASM 35
CLEVIS WELDMENT 63 WELDMENT 43
CLIP 185 CONTACT
WIRE HARNESS 236 14 AWG SOCKET 158
CLIP FRAME 185 CONTRL
CLOSURE CAP 4WAY
MALE 413 JIB 45, 149
CLUTCH LEVER ROT
WELDMENT 166, 170 9A 43
COC CONTROL
HEAT EXCHANGER 204 3POS
COCK S.FEED 43
DRAIN 348 CONTROL CHAMBER 335
COIL CONTROL FITTING
24V 385 ETHER 227
24VDC 309 CONTROLLER
IGNITION 236 NON-PROGRAMD 417
COLLAR COOLER
ROD SPINNER 133 ASSEMBLY 199
COMPENSATOR ASSEMBLY 303, 307 FRAME TOP 204
COMPOUND FUEL
SILICONE 5, 149, 185 QSK19ENGINES 219
COMPRESSOR CORD
24V 237 14/2 43, 421
CONDUIT CORDSET
3/8 NYLON 451 MALE
CONE 47, 337 8PIN 247, 273
COTTER PIN 89
index iv WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250
• COUPLING
FORGED STEEL
44, 237, 271, 434
271
D
DECAL
T3W
HOSE STEM-3 277, 279 AC

LORD 165, 169 WHITE
PIPE 175, 183 25X12 471
Q.D. HALF
AC LOGO
F 348 20.87" 473
QD 459 CAUTION 185
QD HALF
CAUTION-EXCESSOIL 465
M 348 COMP REQ'D MAINT 471
QUICKDISCONNCT 348 DANGER-HAZ. VOLT. 465
RIGID VICTAULIC 257 DHD LUBE SETTINGS 447
SAE HALF 193 DRAIN WATER SEP 465
TORSIONAL DRIVE 166, 170 ENG.FAILURECOOLSY 465
COUPLING ASSY 119 HYD.OIL LEVEL 349
COVER 121, 315, 335 MACHINE-T3W MODEL 471
BAFFLRE PLATE 211 NOTICE 465
CLEAN OUT 348 NOTICE-HYD.FAILURE 465
CLUTCH HOUSING 165, 169 T3W
CONNECTOR 237 7600
•
CONSOLE 51 LT
CONTROL 335 LH 473
FILTER 348 RH 473
FTG/90514L 317 TOGGLE SWITCH 237
JACK 29 WARNING-DONTALTER 465
TERMINAL BLOCK END 173, 177 WARNING-FALL PWRHD 465
CRAD1 335 WARNING-FALL. PIPE 465
253 WARNING-FALLDERRIC
CU! ARBOXILATED 465
434 WARNING-HIGH PRESS
CU1 ,DbY 268, 465
213 WARNING-HIGHPRESS
CYLINDER 465
135 WARNING-HOT FLUID
AIR 465
58, 105 WARNING-NOCLIMBNG
CERAMIC 1.63DIA 465
434 WARNING-POWERHEAD
ETHER 465
223 WARNING-ROT.BLADE
FEED 5"BORE 465
58 WARNING-ROTATINGPT
HYD 465
29 WEB PAGE
HYDRAULIC 471
103, 105, 141, 143, 393 XHP605 OVAL 268
DECAL & MANUAL SET-T3W 465
DECAL WIDTH 23" 473
DECAL WIDTH 23.60" 473
DECALWARNING-COMBUST.GAS 465
DECALWARNING-ROTAT.PARTS 465
DERRICK
WELDMENT
T3W-40K 58
DIODE
•
3AMP
600 VOLT 158, 173, 177
DISC & SPRING ASSEMBLY 434
DOOR 21
DRIVE ASSY-CAROUSEL 117
DRIVE SHAFT 123
DRIVE SHAFT & BEARING 309
number: US021250 index v
DUST SHIELD-FRONT 111 EUROFAST SPLITTER
EXTENSION
T3W
413
457
•
EXTENSION SOCKET 457
E EXTINGUISHER
EAR 13 23
FIRE-2.5LB
MOUNTING 99, 105
EYE
ELBOW 193, 268, 271, 290, 421, 434 58
CABLE ANCHOR
3/16HOSE X 1/8 NPT 236
3/4 HOSE 236
45 DEG.MALE 267 F
90 DEG FACEPLATE
290 BARREL-15/32 323
MALE
291 FAN BLADE-54IN. 8 BLADE 199
90 DEG EXTRA LONG
90 DEG MALE 105, 217, 253, 263, 271, 290, 348, FILLER
TANK-2.5 NPT 217
447, 451
90 DEG STREET 267, 441 FILTER
. .. 43, 103, 243, 253, 451 AIR 237, 348
90 DEG STRT THRD
BASE 245
90DEG
263 CANISTER 349, 369, 457
FORGED STL
44, 243, 253 CASE DRAIN 349, 369
STRT THRD
90DEG MALE 37DGFL 217 COOLANT
231, 435 SERVICE 169
90DEG-EXT/INT NPT
193 FUEL 237
ENGINE COOLANT
189 PRIMARY 169
EXHAUST-6 FLANGED
189 SECONDARY 169
FLEX W/FLANGE-CAT
279 OIL 169
PIPE
RUBBER 193, 211 FITTING 133, 268, 290, 372, 375, 379
211 20 SAEX20 SAE 349
RUBi3ER -45 DEG
STREET 298, 435 24-20
349 CODE 61 379
90DEG
263, 271 45EL 141, 379
ELBOW PIPE
117 BARBED HOSE 204
ELBOW STREET
EL BOW-90DE G BRT
119 040FS X04SAE 373
EXT/INT NPT
263, 401 120FS X12SAE 82
ELBOW-MALE
ELEC BOX ASSY BST
165, 169 160FS X160FS 370
3406E
255 ELBOW 372
ELEMENT
348, 457 FILTER CAP 237
FILTER
OIL FILTER 245, 457 GMCO
213 VICTAULIC 257
PRIMARY
SAFETY 213 HOSE 193, 459
SEPARATOR 267 HOSE 2.00"
STRAINER-HR2 245 STR 407
END HYD 8, 44, 73, 83, 133, 165, 166, 167, 169, 170,
POWER 434 193, 231, 243, 253, 263, 267, 268, 271, 290, 291,
ENGINE
BARE C15/560HP 169
C15
580HP@1800 T3 165
ETHER
KIT
CAT C15 223
EUROFAST CONNECTOR 413
index vi WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250
T3W
349, 381, 389, 401, 435, 441 171, 393

HYD-NPT/JIC 133, 290 LUBE-90 DEG 103, 143
L45 0-RING ADAPTER 299
060FS X06SAE 383 RED ORB24-16 387
12OFS X12SAE 299 REDU 12X060FS 83, 299
16OFS X16SAE 383 RNT
200FS X2OSAE 383 040FS X04SAE 44, 45, 299, 391
L90 060FS X06SAE 369
040FS X04SAE 369 12OFS X12SAE 299, 372
040FS X06SAE . . 44, 375, 383, 391, 431 16OFS X16SAE 199
040FSX04BSPP 379 STL
060FS X06SAE 45, 369, 389 040FS X04SAE 43
060FS X08SAE 369 060FS X06SAE 29
080FS X08SAE 125 STR
080FS X1OSAE 119, 133, 375, 435 040FS X04SAE 44, 299, 369, 375, 381, 383
12 OFS 82 040FS X06SAE 44, 73, 372, 383, 391
12OFS X1OSAE 141 040FSX04BSPP 379
12OFS X16SAE 383, 389 060FS X04SAE 299, 431
16OFS X16SAE 383, 387, 407 060FS X06SAE .29, 82, 141, 143, 369, 391
16OFS X2OSAE 401 060FS X08SAE 369, 383, 389
•
200FS X2OSAE 83, 299 060FSX08SAE 29
240FS X24SAE 370, 387, 389 080FS X06SAE 372
6 OFS 82 080FS X08SAE 125
L90-120FSX12SAE . . 82, 199, 370, 375, 383 080FS X1OSAE 119
L90 160FSX12SAE 375 080FS X12SAE 383, 431
LUBE 29, 58, 85, 103, 117, 127, 141, 143, 167, 12OFS X12SAE .73, 82, 83, 199, 299, 383
12OFS X16SAE 389
16OFS X16SAE ..73, 199, 372, 387, 389
160FSX12SAE 401
200FS X2OSAE 73, 83, 141, 383
240FS X24SAE 369, 387
STR-EXT NPT 268
STR-EXT NPT RUN 231, 268
TEST 299, 383, 387, 431
TUBE 387, 389
FITTING HYD 349
FITTING L90
060FSX1OSAE 375
FLANGE 434
32-24
CODE 61 387
MOUNTING 123
PIPE
COMP VICT 243
RCVR VICT 267
RUN TEE
CODE 62 199
•
STR
16 CODE62 379
WELDMENT 348
FLANGE ADAPTER
STR
20-24 379
index vii
•
T3W
Index
FLANGE HALF GAUGE

SIZE 16-CD62 379 200PSI
379 2" AC 45
SIZE 20-CD61
SIZE 20-CD62 341, 379 4"
400PSI AC 43
FLARE
EMERGENCY 23 400PSI
434 3.5" AC 45
FLUID CYLINDER
FOOT 5000PSI
29 2.5" AC 45
CASTING
29 DISC TEMP AC LOGO 44
JACK
FORK ENG OIL PRES
58 AC 43
ADJ
ENG TEMP AC LOGO 43
FRAME
BOTTOM FUEL
COOLER 204 AC LOGO 43
COOLER PRESSURE 0-160PSI 268
LFT CHANNEL 204 SIGHT 82, 204
RHT CHANNEL 204 TACH
DUST SHIELD BACK 113 AC LOGO 43
HOLD 185 GEAR 121
•
FUEL OUTPUT 82
DIESEL 217 PINION 298
FUSE 447 PUMP DRIVE 298
15A 236 WORM 121
TIME DELAY GEAR SET-1250HR2.5 245
2A 158 GEROTOR 317
GLAND
PACKING 91
G
309 GLASS
GASKET 119, 121, 189, 217, 243, 267
158 SIGHT-RECEIVER TNK
1
158 GLASS KIT
3/4 236
434 SIGHT
BASE
236 GREASE
BLOWER 71
348 RONEX-HD
CLEAN OUT 237
268 GROMMET
COMP DISCHARGE 236
434 CONTROLLER MOUNT
CYLINDER 45
348 RUBBER
FILTER
323 GUAGE
HOUSING 217
319 FUEL TANK
PORT BLOCK 348
158 PREESSURE
SEALING
GUARD
SEAT 185
236 BATTERY
IGNITER
257 DRIVE SHAFT
VITON VICTAULIC 181
T3W
VLV BLK 337
DRIVESHAFT T3WCAT 170
FINGER 56" SYM 204
HELPER SIDE
•
LG 8
HOSE 82
JIB CONTROLLER 149
SHEAVE 58
WIRE TRASH (HALF) 204
index viii WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250
T3W
GUIDE HOLDER 99
4.5 ROD 99 FUSE 447
TOP-ROD SLING 101 WATERPROOF 158
GUIDE ARM LOCKING END 173, 177
UPPER RH FAB 58 HOOK
GUIDE ARM-LOWER FAB RH 59 SUCKER ROD-#9120TON 145
GUIN: ASSEMBLY HOOP
RVLG 59 TOWER PIVOT HOSE 11
GUN HOSE
BLOW AIR & FUEL 236, 237
D 459 AIR-R32 BULK 267
BLOW-WITH 25' HOSE 457 ASSEMBLY 29, 44, 45, 82, 83, 263, 290, 349, 370,
GREASE 457 371, 372, 401, 441
GUSSET 105 BULK 204
BULK 3" GATES HNBR 257
H BULK 3"ID BULDOG GD 277, 279
HANDLE COOLANT 193, 237
BALL 437 HYD-A04 BULK 401
BLACK 263 HYD-A06 BULK 193, 459
VALVE HYD-Al2 BULK 231
10 SPOOL 375 HYD-C16 BULK 435
HANDLE-ROD HANDLINGSLING 101 HYD-C32 BULK 407
HANDLE-SLIP 127 HYD-C40 BULK 407
HANDWHEEL RAD. 193
INDICATING 47 RADIATOR 193
HARNESS 413 SUCTION 435
CAN & POWER 419 UA48
ENGINE 117 OAL
2STR- T1V1,/ 158 VICT 257
GAUGE 419 HOSE ASSEMBLY 29, 44, 83, 125, 370, 371, 372, 401
MAIN INTERNAL 236 HOSE ASSY 29, 44, 82, 83, 125, 133, 141, 167, 171,
POWER 237 199, 217, 219, 253, 263, 268, 290, 348, 370, 371, 372,
SWITCH 237 373, 401, 407, 431, 441, 451
WIRING HOSE HOOP ASSY 372
T3W 158 HOSE HUMP 211
HARNESS CONSOLE/JUNC BOX 158 REDUCING 193, 211
HEAD 107 HOSE STEM-3/4 231, 435
HEAD ASSY HOT OIL SHUT
FILL ER-2.5NPT 217 DR REC 298
HEADCAP 107 HOUSE
HEAT EXCHANGER 236 ASM 323
HEATER HOUSING 123, 337
DIESEL FIRED 231 4X6 LIGHT 43, 421
HINGE A SIDE 377
LH BEARING 91
T3DH 8 ASSM 166, 170
RH END CAP 309
•
T3W-DH 8 JIB BOOM 143
HOC SEAL-ROTARYHEAD 82
HEAT EXCHANGER 204 TRIPLE 298
HOLD DOWN-VANE 335 HOUSING ASSY 325
HOLDDOWN
GEROTOR& BARREL 309
WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250 index ix
•
T3W
HRC JOINT
STRT HANDEL 149 WIRE
STRT HANDLE 43 10
W/BUTTON 43 CLEAR 451
HUB JUNCTION BOX
GEAR 121 6PORTS 413
HUCKBOLT 8
HUCKFIT COLLAR K
16 8 KEY 59
20 8 SHAFT 121
HUCKFIT LCKBLT SQUARE 58, 141, 317
16 WOODRUFF 123
35-45 8 KEY-SQ 83
KIT
I -32 SPLIT FLANGE 407
IGNITER 236 CAB SHEILD INSTL 3
INDICATOR 315 FLARE
24VOLT REFLECTOR 23
RED 43 GASKET-AIR CLEANER 213
RESTRICTION 211 HANDLE 377
INJ ASSY HOLDER
WTR FUSE 236
18 BEAN 431 HR2.5 TUBE 245
INLET 0-RING
AIR 213 HYDRAULIC 457
INPUT PACKING 434
AUXILIARY PCM 236 REBUILD HR2.5 245
INPUT SHAFT 298 RELIEF VALVE 253
INSERT REPAIR 145
3/8"THREADED 204 REPAIR 2B
ACTUATOR 269 CUSHION 105
THREADED REPAIR 2B.NON CUSH 58
3/8" 204 RETAINER PISTON/SHOE 331
INSTL RETAINING RING 309
DRIVE SHAFT GAURD 165 SEAL 29, 107, 123, 199, 369
INSULATION 185 A SIDE
INSULATOR HYD PLT 377
HEAT SHRINK. 425 MANUAL 377
INTAKE B SIDE
COMPRESSOR 211 HYD PLT 377
INTERFACE BOARD 417 MANUAL 377
IQAN MOTOR 135
EXTRACTION TOOL SECTION 377
JPT 417 SEAL - CYLINDER 103
IQAN EXTRACTION TOOL SHAFT(SHAFT
MT 417 BRG
KEY) 199
J SPL FLG 407
J1939 EUROFAST CONNECTOR 413 SPLIT FLANGE 199, 299, 407
VALVE 434
KIT-REPAIR 267
KIT-SHIM 309
index x WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250
T3W
KNOB LUBRICATION
CON T ROL 47 SYSTEM 167, 171
POTENTIOMETER 44 LUBRICATOR
DHD
L 7GAL ASSM 441
LAMP SUB ASM
BACK-UP TURN LH 425 7GAL 447
BACK-UP TURN RH 425 LUG CYL 143
FLOOD-70W HALOGEN 43, 421
LEAD M
IGNITION W/BOOT 236 MAGNET 348
LED MAIN MANIFOLD ASSY 372
24V AC/DC RED 43 MANIFOLD
LEVEL 44 AIR
GA I -;E 298 LP 267
LEVER 58 ALUM-ORING 43, 391
SUE. 58 ANTI-CAV 199
LEVER ,ALVE 271 HRC SHUTTLE 381
LID MAIN DEEP HOLE 383
EN( . OSURE 237 RETURN 389
LIGHT 50PS1 387
LED INDICATOR 447 MANIFOLD ASM
RED 425 HRC 372
LINK MANIFOLD ASSY 372
MASTER 99 RETURN 372
LOCK MANIFOLD BLOCK 75, 339, 385, 387
PA':)DLE 21 MANUAL
LOC -, f ,iii- SAFETY-T3W 465
:t 59 MARKER
LO ' tER WIRE 158
HEL SPR. 401 WIRE LASER PRNTBL 49
LOCKN,.' 7 83, 107, 165, 169 MOTOR 135
BRG 166, 170 HYD
LOCKW,-.SHER 158, 268, 299, 321, 369 12.5" 87
#11 236 HYD.
1/4 237 6 CU. IN 435
HELICAL SPRG 17 HYDRAULIC 87, 119
HEL IC AL SPRNG 8, 181 HYDRAULIC FAN 199
SPRING MOUNT
PLATED 8, 83, 141 ENGINE LEFT 165, 169
LOCKWASHER (METRIC) 243, 269 ENGINE RIGHT 165, 169
LOCKWASHER/14A5C120Z3 369 FLEX-BOLTSANDWICH 158
LOCKWASHER/14A5C76Z3 295 MOTOR
LOCKWASHER/14M5EA12M4HRT 379 ASM 204
LOCKWASHER/14M5EG14Z3 379 MOUNT CYLINDER
LOGO SHORT 58
AC-2'X10 MOUNT KIT
WHITE 471 RUBBER 236
LOWER SUB 91 MOUNTING
LUBRICANT ANTI-VIBRATION 165, 169
DRY MOUNTING RAIL (DIN) 173, 177, 417
SPRAY-ON 166, 170 MTG FLG 329
index xi
•
T3W
Index
MUD FLAP 343, 421, 435

ATLAS COPCO 3 MACHINE
PLATED 425
PLATED 17, 19, 369
N 167, 171, 199, 217
471 STOP
NAMEPLATE
HEX FINISHED
10-SPOOL 43
BRASS 205
COMP DRIVE 166, 171
HEX JAM 15, 58, 59, 253, 337, 451
CONTR HELPER 149
HEX STOP 58, 69, 199
DHD CONTROL 447
HEX-1/4-20 ZINC 370
INSTRUCTIONS 465
JACK 29
JIB MAIN/AUX 45
JAM 69
MAINT/SERVICE 471
LOCK 58
PIN HOLE 166, 171
HEX
UPPER CAM 166, 171
PREV TORQUE 166, 170
NIPPLE 348
MACHINE
NPTF DRYSEAL 267, 290
HEX 413
PIPE 83, 267, 271, 435
MACHINE SC.#6 158
EXTRA STRONG 271
NYLON 236
PIPE 2" AIR 271
PLASTIC GORTEX VENT 149, 417
PIPE FITTIING 279
SELF-LOCKING 237
NIPPLE PIPE 277
SWIVEL-3 277, 279
NOZZLE 181, 204
236 WELD-3/8-16 THRU
FUEL 185, 213
WING
NUT 35, 89, 213, 298, 317, 337
NUT AND RIVIT 145
ELASTIC LOCK 348
NUTS
HEX 3, 44, 45, 58, 59, 133, 141, 165, 169, 170, 185, 237
PANEL
189, 204, 211, 219, 243, 263, 267, 348, 369, 401,
421, 431, 441
BRASS 295 0
FINISHED 15, 17, 43, 44, 59, 111, 113, 149, 0 RING 325, 337
158, 166, 170, 175, 183, 189, 219, 223, 231, O'RING 29, 82, 107, 109, 245, 255, 298, 299, 379, 387,
268, 269, 290, 299, 372, 425, 441 451, 461
PLATED 8, 95, 99, 133, 141, 167, 185, 189, BUNA N 434
193, 199, 205, 207, 253, 263, 267, 295, SPLIT FLANGE (20) 199, 341, 379
OIL
BULK XHP605 263
SAE-30WT
NON-DETERG 435
OIL LINE 401
OIL LINE -12 ORS 401
ORIFICE
.110 SCAVENGE 268
MINIMUM PRESSURE 267
index xii WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250
T3W
0-RING 47, 82, 91, 107, 109, 121, 141, 243, 255, 268, PAGE
298, 303, 307, 309, 315, 317, 321, 325, 329, 335, 337, CAUTION EXCESS OIL 467, 469
377, 387, 434, 461 COVER 467, 469
20A11CM147 317 DANGER HAZARD VOLT 467, 469
25CM-233 91 DANGER ROT.BLADE 467, 469
FUEL FILTER 237 LABEL REFERENCE 467, 469
HYD 461 ORDER INFORMATION 467, 469
NOZZLE 236 TABLE-T3W 467, 469
OVERHEAT 237 WARNING COMBUSTGAS 467, 469
SEAL-LOK WARNING DON'T CLIMB 467, 469
-10 461 WARNING FALL DRLPIP 467, 469
- 16 461 WARNING FALL PWRHD 467, 469
-8 461 WARNING FALLDERRICK 467, 469
-12 461 WARNING HIGH PRESS 467, 469
-20 461 WARNING HOT FLUID 467, 469
-24 461 WARNING POWER HD 467, 469
-4 461 WARNING ROTATING PT 467, 469
-6 29, 461 WARNINGROTAT.PARTS 467, 469
TEMP.SENSOR 236 PANEL
0-RING (5 28X1 78) 377 BOTTOM
O-RING 20P -1 1)M232 407 REAR 204
0-RING S 299 ASM 204
0-RING DEN-671-000 337 BOX DEVICEMOUNTING 173, 177
OUTLET BODY 421 ELECTRICAL BOX 417
GAUGE
P T3W 43
PACKING BOY 91 NAMEPLATE VALVE 43
PAC ' HER 434 TOP
RING 91 REAR 204
,/,SHER 434 ASM 204
PACKING-SWIVEL 91 PETCOCK 217
PAD PICKUP ASM
ANTI-VIBRATION 193, 199, 207 FUEL 237
WEAR 117
WEAR-TRAVEL SHEAVES 69
PADLOCK 51
index xiii
PIN 58, 105, 141, 143, 317, 325, 335, 337
BREAKOUT WRENCH 105
Index
PIPE PLUG
PIPING
315
99
T3W
•
CLAMPING BAR 8 CAROUSEL
COTTER 29, 58, 103, 141, 143, 213, 263 PISTON 47, 107
COTTER-3/16 X 1-1/2 143 PIVOT
CYLINDER 58, 59 LIGHT 43
CYLINDER-RAISING 393 PIVOT PIN 143
DERRICK PIVOT 393 PL.HEXSAE 0.88-14V 375
DOWEL 166, 170, 317, 329 PLATE 11, 58, 143, 309, 317
FAST 166, 170 BASE MOUNTING 237
GRIP 103 BREAKOUT-WELDMENT 105
HINGE 29, 103, 105 BULKHEAD 372
HINGE/TOOL BOX 21 CLUTCH ENGAGEMENT 166, 170
HINGE-1 COOLER SUPPORT 199
DIAX1.13GRP 103 COVER 82, 149, 181, 243
LOCK 145 CREEP 331
MALE 419 DRIVE 165, 169
MODULATING 337 IDENTIFICATION 298
POWERHEAD 82 MOTOR 335
RETAINING MOUNTING
LOWER 127 WELDMENT 165, 169
ROD SPINNER 133 MTG
ROLL 103, 325, 434 VALVE
SIZE 16 49, 159 STEEL 15
SPRING PIVOT
SLOTTED 434 T3W-70K 127
TOWER RAISE CYL 11 PORT-RH 15/32 319
TRAVELING SHEAVES 69 RETAINER 141, 337
WRENCH MTG. 8 RETAINING 127
WRIST 434 ROLLER MOUNTING 135
PIN RETAINING 127 SEAL VANE 335
PIN SHEAVE 143 SIDE
PIN WELDMENT 58 CABLE GUIDE 69
LOWER 63 SPACER 123, 268
PIN WLDMT SPINNER MOUNTING 135
TRAVEL.SHEAVES 69 SWING
PIN-CLEVIS 58 20" OPEN 105
PINION TAPPED 421
INPUT-TOPHEAD 82 TRAVELING SHEAVE 69
PIN-ROLL 337 PLATE COVER 298
PINS 319, 323 PLATFORM
PIPE CENTER
COOLER INLET 193 STEEL 15
COOLER OUTLET 193 STEEL
ENGINE INLET 193 COMPLETE 15
ENGINE OUTLET 193
EXHAUST 236
HARD 277
INLET CAC 207
OUTLET-CAC 207
THD 231
PIPE ASM
ENGINE INLET 193
index xiv WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250
• PLUG
1/4-ORING
123, 129, 317, 321, 325, 329, 335, 337
HEX SOC 193

PUMP ADAPTER C
PUMP DRIVE ASSEMBLY
T3W
298
295
PUSHBUTTON
2 CIRCUIT 223 2-POSITION 43
3 CIRCUIT 419
3 WAY 413 R
6MM COMPONENT 159, 173, 177
RACE
C61-32 407
BEARING 97, 123
ELEC CONNECTOR 158
RADIATOR
EXPANSION 298
HEAT EXCHANGER 204
FACE SEAL 0-RING -8 372
RAIL
FACE SEAL O-RING-6 387
FUEL COOLER FRAME 219
HEX HEAD 383
RB14-14 425
STRT THRD 44, 373, 389
RECEIVER TANK ASSY
JIC -20 83 LP 263
LIFTING-2.7/8 IF 93
RECEPTACLE
MAGNETIC 298
3 WAY 413
1NPT 348
6 CIRCUIT 419
NYLON 107
FEMALE 10PIN 417
PIPE 82, 271, 290, 298, 348, 457
FEMALE 19PIN 45
•
SQ HEAD 119, 253, 290
FEMALE 4PIN 249, 275, 417
SOLID 267, 271
MALE 10PIN 249, 275
PIPE-3/4NPT 271
MALE 12PIN 417
PIPE--SQ HEAD 217, 435
RECEPTACLE FEMALE 12PIN 45
SEALING-SIZE 12 158 RECEPTACLE FEMALE 6PIN 249, 275
SOCKET 59
REDUCER
STRAINER 245
EXPANDER 370
PLUG PIPE 348
0-RING 133, 375
PLUGHEX 337 SAE 0-RING 10-6 141, 143, 375
PLUN, ALR
SAE/ORING 16-8 389
TEFLON 453
SPEED 119
POPPET
REFLECTOR
DUAL & REPL 337 AMBER 471
SEQ 337 RED 471
POPPET KP-3004C-10 351 REGULATOR
PORT BLOCK/HOUSING ASSY 309
AIR 348
POTENTIOMETER
FUEL 236
EAR SYSTEM 49
PRESSURE 268
POTENTIOMETER ASSM. 44 RELAY
POWERVIEW 43 24VDC COIL 173, 177
PUMP
SOLENOID-24VMARINE 158
145CC P3 298 RELIEF 385
60CC P2 FAN 298 50 PSI 387
COOLANT 24V 237 RESISTOR
DHD LUBRICATOR 451
TERMINATION 419
DRIVE 59000 SERIES 298 RESISTOR CF .25W 5.1K 159
FUEL-GEAR 237 RESTRICTOR
•
HAND FILL 348
JIC/JIC .062 175, 183
OIL 245 RETAINER 117, 337
P7
BEARING 325
9A CONT 298
SEAL W/O RING 309
WATER INJ
RETAINER KP-3004C-10 351
PISTON 434 RETAINER PALTE 327
index xv
T3W
Index
RETAINING RING GROUP 331 SCREW 44, 158, 237, 309, 315, 319, 321, 335, 337
RING 317, 321 #5-40UNCX.75LG 44
BACK-UP 107, 109 CAP
FLINGER 82 HEX 268
LANTERN 91 CAP-5/16 X 7/8 123
LOCKING CAP-M6 X 10 MM 44
4 3/4" 93 DRIVE 298, 471
RETAING 315 FLANGE
RETAINING 59, 63, 141, 166, 170, 298, 311, 313, CAP HEX 205
317, 329, 333, 434 HEX FLNG 236, 237
SHEAVE INSERT 61, 65 HEX HD 236
SNAP 298 HEX HEAD
SPLIT COARSE TH 379
4 3/4" 95 HEX H EA D/34 M2AA464 379
TAPERED 95 HEX WASHER HEAD 211
RIVET HEX-M16 X 20 243
1/8 DIA. X .5 POP 173, 177 MACHINE 425
BLIND 51 MACHINE HD 8
DRIVE 465 MOTOR 335
ROCKER AND PLUG 335 ROUND HD 44
ROD ROUND HD- T-UDRIVE 231
CONNECTING E04 434 SET 107, 315, 335
CONTROL SHOULDER 15
BALL VALVE 263 SOCKET 236, 237
ROD BOX 17 TAPPING-1/4-20X1/2 417
ROD SPINNER 133 TAPPING-10-24 X1/2 173, 177
ROD STOP TRUSS HD 413
4.5 PIPE 99 SCREW-HEX M10X1.5X35MM 379
ROLLER SEAL 335, 377, 434
MACH 85 FLEXBLE KP-3004-105 351
ROD SPINNER 135 HOLE 158, 417
ROLLER ASSEMBLY 83 HOUSING 91
ROPE NILOS RING 71
WIRE OIL 82, 119, 121, 298, 434
22MM SHAFT 309
SWAGED 58 SHAFT CARRIER 307
5/16 X 16'5 101 SHEAR 315
RUBBER 44, 111, 113 TRIM 204
BACK 113 WEATHER
FRONT 111 ENCLOSURE 237
RUBBER BELLOWS 45, 149 SEAL ASSEMBLY
SINGLE 303
S SEAL BOX
LOWER 91
SCREEN
236 SEAL HOLDER 434
BLOWER INLET KIT
SEAL KIT 87, 141, 143, 339, 369
STRAINER
435 HYD CYL 393
1.50
434 PUMP 453
STRAINER - 1-1/4
SEAL KIT-MOTOR 123
SEAL RING 377, 434
SEAL VANE 335
SEALING NUT (M8X1) 377
SEAT 47, 337
indcA WARNING! This manual contains data SPECIFIC to the drilling rig with serial number: US021250
• SENSOR
2WIRE-TEMPERTURE
FLAME
243
SHIM
15 GA.
T3W
69, 377
69
236 25 GA. 69
OVERHEAT 236 7 GAUGE
PRESSURE 348 EXHAUST 189
PRESSURE 14.5 PSI 243 COOLER 199
PRESSURE 725 PSI 268 MID JACK 8
TEMP SET 8
0-150DEG C 243, 387 T3WDH 8
TEMPERATURE 236, 243, 387 TOPHEAD 83
SEPARATOR SHIM SET 165, 169
HEAT EXCHANGER 204 BEARING ADJUST 83
SEQUENCE SEAT 337 SHIMSET
SERVICE KIT 268 COOLER SUPPORT 199
SERVO OUTPUT 309 SHOE
SERVO PLATE 309, 335 SUPPORT 143
SERVO SHAFT ASSY 315 SHROUD 204
SERVO-CONT.COVER GASKET 309, 315 ASSEMBLY 204
SET SCREW 91, 337 INLET 211, 213
SETSCREW ROLLED RING 204
•
ADJ. NUT 91 SIDE PLATE 317
SHACKLE SIGHT
CHAIN 99 FLOW 268, 441
SHAFT 121, 434 GAUGE 348
CAM 165, 169 SILENCER 263
CLUTCH 166, 170 6"W/INSULATION 189
CLUTCH ENGAGEMENT 166, 170 SINGLE SEAL ASSEMBLY 307
DRIVE 295, 329 SLEEVE 11, 47, 82
OUTPUT 123 CLUTCH 166, 170
SHAFT ASSEMBLY 303, 307 SLIDE
SHAFT SEAL 303 JIB BOOM 143
SHALE TRAP 82 SLING
SHEAR SEAL 315 ROD 99
SHEAVE ROD HANDLING 99
1 GROOVE 61, 65 SLINGER
2 GROOVE 71 MUD 91
5/8 WIRE ROPE 143 SNAP RING EXT. 52mm 307
LOWER 59 SNAP RING EXT. 80mm 307
SHEAVE & BEARING SNAP RING-EXT. 100mm 303
ASSY 58, 63 SNAP RING-EXT. 108mm 303
SHEAVE PIN 143 SNAP RING-EXT. 35mm 307
SHIELD 5 SNAP RING-EXT. 55mm 303
DUST SNAP RING-EXT. 72mm 303
FRONT SOCKET
ASM 105 EXTENSION-T3DH 457
SHIELD ASM SOCKET ASSY 59
DUST-BACK 105
index xvii
SPACER
CONTROLLER
63, 185
236
Index
SUB
LOWER
T3W
•
INNER 4-1/2X2.88IF 93
CABLE GUIDE 69 UPPER
INNER RACE 71 3 1/2" 93
OUTER SUB 54407309 SHAFT ASM 311
CABLE GUIDE 69 SUB 95934386 CAPSCREW 17
SHEAVE 59 SUPPORT 105, 117
TENSIONER 69 COOLER 199
TRAVELING 69 DHD LUBE 441
VANE 335 FEED CYL 5.75"OD 59
SPINDLE FRONT ENGINE
MAIN-ROTARYHEAD 82 T3W 165
SPINNER FUEL COOLER 219
KNURLED 135 MID JACKS 48 8
SPLIT FLANGE PIPING CAC 207
-16 407 POST 11
SPLITTER 413 TOWER
SPRING 47, 329, 337, 453 T3W 8
99 SWITCH
COMPRESSION 129 FLUID FLOW 451
PIN 1/8" DIA 375 KEY 43
RETAINER 329 ON/OFF
SPRING GUIDE 24V 237
PISTON SEAL 47, 337 PROMIMITY 166, 170
SPRING KP-1004-104 351 PUSH BUTTON 43
SPUD SPST REED 451
FEMALE 277 SPST/ON-OFF 43, 447
MALE 277, 279 TEMP 243
STACK SWIVEL
ENG.INLET 207 25CM
STEM 267, 271 3"CPLG-STR 89
HOSE-1 HOSETO1 NPT 434 90DEG-INTNPT/JIC 219
HOSE-3 279
STEM W/ ORIFICE 267 T
STEP TAB
STEEL 15 ARM 58
STOP 329 TABLE
PLUG 129 RETRACT 99
STRAINER TANK
B STYLE-1-1/4ST 434 7-GAL DHD LUBE 451
STRAINER ASSY-HR2 245 FUEL
STRAINER ASY 337 ALUMINUM 217
STRAINER BODY 245 HYD
STRAP ASM 343
SHROUD 204 HYDRAULIC 348
STROKER SEPARATOR 267
9A ELECTROHYD 309 SURGE 204
STUD 89 TAPE
ADAPTER 298 SPONGE 51
LOCK 185
WELD 8, 141, 413, 421
WELD 1/2-13X1.00 133
index xviii WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250
• TEE
BRT -06
FORGED STEEL THRD
291
83
TUBE
2" SUCTION
T3W
327
407
271 2.5"SUCTION 407
MALE RUN AIR DUCT 211
NPTF 231, 267 AIR-INLET 7 X 70 211
NPT/JIC 290 COMBUSTION 236
PIPE 435 DIPSTICK 298
TEE BRANCH 268 FUEL SIPHON 217
TEE MALE 2 NPT 271 GUIDE-6 ID 101
TERMINAL 158, 413 LEVEL GAUGE 298
12-10 LUBRICATION 175, 183
1/2 RING 158 PRESS 327
16-14 SCAVENGE 268
BULLET 447 VENT 193
16-14 5/16 RING 413 TUBE ASM 327
16-14 BULLET FE 447 TUBE WELDMENT
6 FORK 447 CONSOLE 44
FEMALE PUSHON 159 TUBING
RING 421 CONVOLUTED 49
RING 22-18 AWG 43 ETHER
RING 8GA
•
48" 227
5/16 159
THIMBLE
U
WIRE ROPE-5/16 101 U-BOLT 8, 193, 207, 263, 267, 268
WIRE ROPE-5/8 145
THREADLOCK U-CUP 107, 109
93 UMBRELLA BLACK
THROTTLE 434
UNION
ELECT. i'ZONIC-CAT 43 STRAIGHT THREAD 348
TIE
CABLE 158, 447, 451
TIE DOWN
TOWER BOTTOM 13
TIE DOWN TOWER ASSY 8
TIE DOWN TOWER TOP 13
TIMER
7 DAY DIGITAL 231
DHD LUBRICATOR 451
TIMER KIT INSTALLATION 237
TOOL
ROD HANDLING 127
TOOLBOX
T3W 19
TRAY
FUSE 23
TRUNNION PIN 89
index xix
•
T3W
Index
VALVE ASSY 321, 337

V
43, 290, 451 10-SPOOL 369
VALVE
375 2-SPOOL 372
10-SPOOL M4-12
369 ETHER 227
2-WAY
75, 385 VALVE BLOCK 337
3 WAY
263 VALVE BLOCK ASSY 309
3-WAY
385 VALVE CAGE 434
4 WAY
4 WAY DO3 385 VALVE KIT
290 RELIEF 237
AIR
271 VALVE SEAT 337, 434
BALL
263, 268 VALVE-AIR 290
BALL-1/2
231, 267, 435 VANE HOLD DOWN SPRING 335
BALL-3/4
BLOW DOWN 268 VARNISH
290 INSULATING 447
BRAKE
BUTRFLY 8" FOR EAR 243 VENT
FILTER 453
CARTRIDGE
437 GORTEX 149, 417
2 WAY
75, 243, 339, 349, 385, 435, 451 V-RING 82
CHECK
.25NPT 267, 349, 441
CHECK CARTRIDGE 369
CHECK-DBL PILOTOP 369 WASHER 165, 169, 295, 315, 317
COUNTER BALANCE 75, 125, 369 5/16 237
COUNTERBALANCE
FLOW CONTROL
FLOW REGULATOR
MANUAL SHUTOFF
MIN.PRESSURE
MODULATING
29
135
437
267
267
385
BELLEVILLE
BEVEL
SQ
PLATED
ENG MTG SPACER
165, 167, 169, 171,
59
295
19, 199
169
FLAT 17, 35, 44, 45, 58, 59, 103, 113, 141, 149,
•
PILOT (400 PSI) 337 158, 165, 167, 169, 181, 185, 199, 205, 207, 219,
PO CHECK 385 223, 231, 269, 295, 348, 349, 369, 413, 431
PRESS REDUC/RELIE 385 NARROW 111, 166, 170
PRESSURE REDUCING 385 PLAIN 271, 299, 369
PRESSURE-REMOTE 43 PLATED 9, 59
PROP PRESS CONT. 309 WIDE 3, 8, 9, 17, 117, 166, 170, 189, 193, 199,
REGEN 205, 207, 217, 253, 348, 369
DH 73 FLAT 1/2 . . . 166, 170, 185, 199, 205, 263, 343
REGEN ASSEMBLY 59 FLAT 1/4 413
REL FLAT-HARDENED 82
3750 370 LOCK 11, 44, 59, 69, 83, 89, 99, 117, 119, 133,
REL ELEC PROPOR 369 141, 165, 166, 167, 169, 171, 173, 177, 189, 193,
RELIEF 43, 339, 369, 435 199, 205, 207, 243, 253, 263, 267, 268, 295, 341,
RELIEF CARTRIDGE 2 369 369, 417, 421, 431, 435
ROTARY HELICAL 3, 17, 43, 44, 58, 59, 63, 69, 111,
ON/OFF 437 113, 127, 133, 149, 158, 165, 169, 170, 185,
SAFETY 267 189, 193, 205, 207, 211, 219, 243, 263, 267,
SHUTTLE 385 290, 369, 370, 393, 421, 425, 441
SHUTTLE CART 339 HELICAL SPRG 95, 141, 387
TEMPERATUREBYPASS 253 PLATED 15, 59, 125, 165, 169, 205, 219, 231,
VALVE 2-SPOOL M4-22 379
•
269, 370, 431
VALVE AIR-QUICK EXHAUST 271 LOCK HELICAL 15, 17, 19, 29, 166, 171, 199, 217,
index xx WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250
• 243, 268, 271, 295, 299
LOCK M20
LOCK-5/16
167, 171, 243
WRENCH
BREAKOUT
T3W
99, 105
99
223 BREAKOUT-IMPROVED 103
LOCK-BEARING 166, 170 LOWER 99, 105
NYLITE 309, 315 UPPER BO
PLAIN 141 4.5" 99
FLAT
TYPE A 219
ROLLER
Y
83 YOKE-ASSY FOR 25CMSWIVEL
SEALING 237 89
SPRING LOCK 379
THRUST 83, 127, 141, 315, 331
UMBRELLA 434
WASHPIPE 91
WATER INJECTION MANIFOLD 431
WEDGE
3 PIN 49, 159
CONNECTOR 8 PIN 158
WELDMENT
CLUTCH HOUSING 166, 170
•
FRONT EXHAUST 189
MAINFRAME
T3W 8
REAR EXHAUST 189
RISER PLATE 82
TANK MOUNT 267
WELDMENT ROD LOADER 127
WINCH
18K
HIGH EFF 141
WIPER 107, 109
ROD- 4.5 DIA.ROD 99
WIRE
14AWG-BLACK 159, 419
14AWG-BLUE 419
14AWG-GREEN 158, 419
14AWG-RED 419
14AWG-WHITE 223
18AWG WHITE 49
8AWG-RED 419
ELECTRICAL-14/3 425
GROUND 158
LOCK 69, 117
WIRE ELEC 158, 447
WIRE LINK-9 158
WIRE ROPE 101
WIRE ROPE-3/4 BULK 58
•
WIRE ROPE-5/8 DYFORM-18 145
index xxi
•
T3W
Index
index xxii WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250
• PART NO.
22252043
PAGE
263
PART NO.
50344605
PAGE
69
PART NO.
50816446
PAGE
213
PART NO.
52155033
PAGE
323
T3W
30441570 185 117 50816479 213 52155041 325

35092279 245 50381904 29 50816487 213 52155066 327
35108216 185 50419670 189 50816503 213 52155116 329
35277797 245 50428572 279 50816511 213 52155140 333
35292135 243 50429356 369 50816529 213 52155157 333
35370063 245 50429455 372 50816537 213 52155165 333
35562156 185 50462944 369 50817089 319 52155256 335
35596436 243 50465293 419 323 52155306 335
35609098 245 50469238 189 50817428 82 337
36017549 243 50491729 123 50822964 51 52155314 329
36020055 245 50597442 298 50829605 263 335
36037190 253 50597632 298 268 337
36039519 245 50603869 268 50830199 337 52155322 335
36507820 471 50616028 211 50855923 243 52155330 335
36751295 245 50616390 213 50874833 298 52155348 335
36798973 245 50616408 213 50879246 351 52155363 335
36843720 243 50621796 213 50879253 351 52155371 335
36860336 245 50621986 267 50879261 351
•
52155439 337
457 50625839 425 50879279 351 52155447 337
36860476 245 50625938 158 50879287 351 52155454 337
36861144 245 419 50879295 351 52155488 337
39322748 268 50625946 43 50943240 298 52155512 337
39417118 268 149 50998103 123 52155520 337
39871702 268 247 50998145 123 52155546 337
42428847 245 273 51061661 165 52155603 337
50023910 267 451 169 52155637 337
271 50627918 375 51792323 204 52155645 337
50033414 29 50644269 434 51867901 253 52155660 47
50034826 401 50669027 123 52146883 435 337
50057215 434 50695063 158 52154499 309 52155686 47
50067131 459 50700731 5 52154515 309 337
50112895 231 149 52154580 309 52155751 311
435 185 52154606 309 52155843 329
50212224 231 50707280 290 52154622 309 52172723 267
267 50717743 298 315 52175023 189
435 50717917 434 52154739.. 321 52175809 421
50218627 29 50718089 434 52154770 317 52185832 43
50219518 217 50718121 434 52154788 317 52187861 263
50245281 457 50743731 267 52154796 317 52188851 123
50245299 459 50759455 167 52154887 321 52188885 123
50245307 459 171 52154895 321 52188893 123
50249648 419 243 52154903 321 52188901 123
50249655 159 50791557 417 52154911 321 52193653 435
419 50798891 47 337 52201662 311
50249671 223
•
50798925 47 52154929 321 52201670 327
50258128 263 50805118 349 52154937 321 52201738 309
50258474 185 50810993 349 337 335
50263813 401 50812411 158 52154994 325 52201761 315
50339001 59 50812429 419 52155017 325 52201779 315
50344530 51 50816420 213 52155025 325 52201803 315
WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250 index xxiii
•
T3W
Numeric Index
PART NO. PAGE PART NO. PAGE PART NO. PAGE PART NO. PAGE
52201811 315 54407309 309 54408513 337 56935562 44
52201852 321 54407317 311 54408547 337 56937022 158
52201894 317 54407325 313 54408570 337 56940042 299
52201928 3 17 54407333 313 54408588 337 56940281 199
52201936 317 54407341 313 54408596 337 341
52203627 337 54407358 309 54408612 309 379
52203668 331 54407366 309 54408620 309 56940364 211
52203718 335 54407390 309 54408638 309 56943582 193
52203767 335 315 54408646 309 56944507 349
52204765 323 54407416 315 54409123 315 56946247 243
52204799 319 337 54409776 329 56946734 407
52204815 319 54407457 315 54410741 327 56947104 435
52204831 317 54407473 315 54414743 331 56947112 407
52204856 331 54407481 315 54416946 309 56948565 253
52204864 333 54407648 309 54418090 217 56949084 158
52204872 333 54407671 317 54473335 434 56950447 263
52204880 331 54407739 317 54506738 193 56950579 199
52206604 271 54407762 317 54529623 158 56953045 119
52215415 44 54407796 317 54530985 49 56954365 217
52223070 193 54407812 317 159 56955867 263
52226164 253 54407838 317 54565569 268 56956725 219
52226362 291 54407853 317 54573704 19 56956857 253
52232949 407 54407879 317 199 56964257 167
52235363 167 54407903 317 54596960 166 171
52236551 158 54407945 319 170 56970379 231
52236569 158 54407960 321 54634878 135 56971914 425
52236577 158 54407994 321 54634886 135 56974892 290
52236932 43 54408059 325 54640040 268 56988728 317
52240959 421 54408133 325 54651187 419 56991193 421
52243649 290 54408190 327 54651237 223 56993678 43
52246519 185 54408232 329 56001118 123 56996911 435
52246774 217 54408273 329 56257629 434 56999360 158
52247657 243 54408299 333 56258668 133 57002867 268
52248093 337 54408331 335 56273642 173 57012676 107
52248119 327 54408349 335 177 57012684 107
52249588 47 54408356 335 56280852 207 57020729 44
52249604 47 54408364 335 56773096 145 57027377 323
52249620 47 54408372 335 56780703 447 57032690 105
52249638 47 54408380 335 56790330 42 1 57033508 99
52249646 47 54408398 335 56793243 267 57036881 419
52251766 401 54408406 335 56793599 59 57037517 185
52251816 141 54408414 329 56799844 211 57039521 268
401 54408422 337 56804743 145 441
52262029 105 54408430 337 56883572 407 57039695 107
52263787 243 54408448 337 56883614 379 57040024 82
•
52265311 211 54408455 337 56899669 211 57040032 85
52277431 211 54408463 337 213 57040149 83
52279338 447 54408471 337 56928534 407 57040156 85
54386636 143 54408489 337 56930290 413 57040164 83
54402821 105 54408497 337 56932551 99 57040347 83
54404520 21 54408505 337 56933690 447 57044828 231
ndex xxiv WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250
T3W
57045882 329 57140428 465 57179608 43 57242604 107
57052565 167 57140444 465 447 57245870 165
57052631 309 57140469 465 57181307 335 169
57053183 193 57140477 465 57186728 87 57250276 123
.................459 57141905 47 57187213 82 57251894 277
57058166 ........ 263 57142358 271 57196677 158 57262479 401
57061053 11 57147282 43 173 57262487 141
57061061 11 421 177 401
57063737 337 57147969 159 57198111 298 57264731 143
57064065 ...335 57148389 471 57199085 441 57267528 119
57070278 29 57150617 335 57208852 383 57269649 457
57070286 29 57151144 315 57209520 127 57269698 337
57073546 23 57153090 309 57209728 299 57272551 95
57080251 253 57153108 315 372 57272569 95
57084055 43 57153793 298 57209736 199 57272841 8
57093080 158 57155517 465 57209744 383 57273716 125
57093510 58 57156333 465 387 369
57095143 253 57156465 465 407 57274474 82
57097792 45
•
57156770 167 57209934 471 57274482 82
57097891 . ........ 133 171 57209942 471 57274490 83
57101750 193 57157885 43 57213399 193 57274516 82
57113177 185 421 57216699 43 57277790 127
57114332 298 57163677 465 57216848 425 57279176 58
5712 '-<283 331 57167421 383 57216855 425 57279184 58
57124315 185 57167454 73 57217234 82 57279630 461
105 83 57217416 401 57279648 29
113 141 57217648 393 461
5712492/ 113 383 57221855 173 57279655 461
57124935 113 57167934 82 177 57279663 461
57128720 295 199 417 57279671 461
57128886 105 370 57222143 29 57279689 461
57129785 143 375 57222713 29 57279697 461
57129835 141 383 57224081 107 57283178 387
57130213 143 57167942 73 109 57283186 372
57130270 141 82 57224099 107 57283996 373
57130379 143 83 109 57284002 373
57130403 457 199 57224123 107 57284028 372
57130577 447 299 109 57284036 373
57131732 21 383 57228249 99 401
57134157 243 57167959 82 57229452 166 57291049 175
5713689 -, 291 57167983 299 170 183
57139131 158 57168916 447 57233280 401 57293540 127
57139982 253 57170284 166 57233983 401 57294829 169
57140329 465 170 57235863 393 57296394 375
57140337 465 57170821 253 57237539 58 57296956 129
•
57140345 465 57170839 255 57240749 335 57297137 447
57140352 268 57171910 298 57240756 315 57297228 129
465 57174070 83 335 57299604 467
57140360 465 299 57240764 335 469
57140394 465 57176141 211 57242554 107 57299612 467
57140402 465 57242596 107 469
WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250 index xxv
T3W
57299620 467 57308967 369 57319683 73 57357907 348
469 57309064 370 199 57357915 348
57299638 467 57309650 105 372 57358145 257
469 57310831 465 387 277
57299646 467 57311086 465 389 279
. .. ...........469 57311128 9 57319691 369 57358327 431
57299653 467 57311169 467 387 57358665 189
469 469 57319725 43 57358830 451
57299661 467 57311649 467 57319733 29 57358855 43
469 469 57319774 369 57359523 457
57299679 467 57311656 467 57319782 44 57361412 103
469 469 375 57361982 447
57299687 467 57311730 169 383 57361990 447
469 57313207 170 391 57363251 370
57299695 ....... 467 57313975 465 431 57363350 125
469 57318040 465 57322364 99 57364010 43
57299703 467 57318107 467 57324162 467 57365918 461
469 469 469 57367278 199
57299711 467 57318628 431 57325433 263 57367328 298
469 57318693 465 57325599 339 57367377 298
57299729 467 57318743 82 57326738 127 57367385 298
469 57319410 44 57326795 107 57370439 219
57299737 467 299 109 57371510 185
................469 369 57326803 107 57371528 185
57302143_........... 337 375 109 57377384 141
57303794 ;9 381 57326811 107 143
57303885 434 383 109 57379505 43
5/306268 ... 309 57319592 44 57326829 107 391
57307886 453 73 57328676 299 57380099 370
57307902 309 372 383 371
57308678 45 383 387 57380131 372
369 391 431 57380214 370
389 57319600 299 57329948 83 57380743 371
57308686 369 431 57341604 434 57380776 29
57308702 125 57319618 29 57343402 434 57380834 401
57308710 119 82 57344731 82 57381097 371
133 141 83 57381188 44
375 143 57345316 103 57381212 371
435 369 57345878 465 57381261 29
57308728 141 391 57348476 193 57381329 371
57308736 383 57319626 369 57348997 348 57381337 383
389 383 57350035 103 431
57308751 370 389 57351108 119 57386955 158
387 57319634 372 57351116 119 57391047 267
389 57319642 125 57351892 58 57391773 3
57308793 383 57319659 119 57351900 105 57391781 5
57308892 373 57319675 389 57351942 58 57394348 158
57308959 44 57351959 105 57400004 158
45 57352973 451 57402828 211
299 57353021 451 57404147 379
391 57354342 451 57404261 465
index xxvi WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250
T3W
PART 40. PAGE PART NO. PAGE PART NO. PAGE PART NO. PAGE
57404 381 89 57435075 158 57486375 89 57546160 268
57404 64 145 57436024 199 91 57547580 204
57405 185 341 57438376 91 57487274 319 57547614 204
379 57438384 91 57487423 91 57548182 135
57405 321 ............. 165 57438400 91 57487431 91 57549479 133
169 57438418 91 57487449 91 57549487 133
57406 720 143 57438491 129 57487514 91 57549495 133
57408 353 348 57439275 211 57487548 91 57551947 158
57408 700 141 57439283 211 57487555 91 57551954 158
57408 767 451 57439341 91 57487563 91 57552275 267
57408 775 451 57439937 8 57487571 91 349
57409 104 ............. 243 57440190 143 57487589 91 441
57409 237 91 57440224 143 57487597 91 57554925 89
57409 2 52 91 57440307 143 57487605 89 57554933 89
57403 260 91 57440323 143 57490831 99 57554941 89
57409 278 91 57440356 141 57490849 82 57556565 93
57409 286 91 57440570 211 57491813 43 57560682 453
57411 17[:. ..471 57441982 143 57491862 166 57561037 434
57412 124 165 57441990 143 170 57561045 434
..... ... ..........169 57442477 268 57492324 8 57561060 434
57412 181 141 57442527 189 57492332 8 57561078 434
57412 710 ...158 57442857 441 57492365 8 57561367 434
57416 321; .........91 57443525 173 57493868 43 57561383 434
57416 33'- .325 177 57494049 99 57567182 135
57416 )5e 325 57446411 263 57494510 117 57567190 135
5741-7 - 3' 309 57447237 370 57494619 91 57569758 267
.315 57447245 167 57495368 82 57569923 268
57418 91 199 57497190 217 57575094 105
574 0 91 372 57498339 159 57575102 105
57420 309 127 57447260 29 57502882 372 57575169 8
57421 )34 • . ....... 127 369 57507816 143 57578205 166
57426 126 348 57448425 173 57507857 141 170
57427 325 ............... 58 177 143 57578924 166
57427 341 59 57451536 21 57511255 141 170
57428 765 29 57452666 407 143 57579039 166
57428 173 29 57464018 199 57511933 145 170
57428 114 451 57464208 29 57511941 145 57579179 211
57429 714 .... . ...... 159 369 57511958 145 57580284 165
...... . ..,. ..... ......173 57464430 371 57511966 145 169
177 57470866 370 57512188 317 57580342 211
57429 722 ._ ,. ...... 159 57472698 219 57513293 29 57580359 211
173 57472789 173 57514846 267 57580367 211
177 177 57514895 329 57580474 207
57429 730 173 57472938 173 57514903 329 57580516 207
177 177 57524449 8 57580557 189
5742q '48 173 57475618 111 413 57580581 193
.. ............ 177 57475626 105 57524456 141 57580599 189
574 :23 453 57477317 44 57524522 421 57580649 268
574.;e: 338 271 57477325 383 57531162 193 57580656 268
57 44 57480980 199 57546061 277 57580664 263
158 57481178 451 279 57581563 217
WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250 index xxvii
•
T3W
Numeric Index
57581589 217 57604787 166 57655177 236 57655680 237
57585135 17 170 57655185 236 57655698 237
57586091 298 57606147 8 57655193 236 57655706 237
57587602 193 57608283 407 57655201 236 57655714 237
57587644 267 57609752 370 57655219 236 57655722 231
57590580 435 57609778 44 57655227 236 57655730 237
57593766 8 57609869 370 57655235 236 57655748 237
57593840 243 57609901 370 57655243 236 57656266 169
57594426 217 57609927 370 57655250 236 57656647 189
57594962 271 57611097 166 57655268 236 57657660 199
57595605 91 170 57655276 236 57658833 91
57596108 435 57612038 15 57655284 236 57659633 29
57596942 89 57612061 15 57655292 236 57660029 370
57599532 166 57612079 15 57655300 236 57660227 141
170 57612087 15 57655318 236 379
57599557 165 57613978 8 57655326 236 57660631 165
169 57615338 158 57655334 236 169
57599664 165 57625964 419 57655342 236 57660649 165
169 57628984 370 57655359 236 169
57599672 165 57637894 267 57655367 237 57660680 165
169 57637902 267 57655375 237 169
57599698 166 57642555 372 57655383 237 57660870 372
170 57642647 379 57655391 237 57666000 441
57599714 165 57643827 231 57655409 237 57667453 61
169 57644155 375 57655417 237 65
57599730 166 57644163 133 57655425 237 57668071 419
170 375 57655433 237 57668667 370
57599755 173 57651002 370 57655441 237 57673543 125
177 57654949 236 57655458 237 57676595 141
57599763 166 57654956 236 57655466 237 57678088 49
170 57654964 236 57655474 237 159
57600199 166 57654972 236 57655482 237 57678096 49
170 57654980 236 57655490 237 159
57600843 165 57654998 236 57655508 237 57678328 434
169 57655003 236 57655516 237 57678971 58
57600959 105 57655011 236 57655524 237 63
57602963 99 57655029 236 57655532 237 57678989 61
57604555 166 57655037 236 57655540 237 65
170 57655045 236 57655557 237 57679011 69
57604563 166 57655052 236 57655565 237 57679029 71
17 1 57655060 236 57655573 237 57684433 159
57604571 166 57655078 236 57655581 237 57685026 199
171 57655086 236 57655599 237 57685034 199
57604589 166 57655094 236 57655607 237 57687444 267
171 57655102 236 57655615 237 57688095 193
57604597 166 57655110 236 57655623 237 57689218 370
170 57655128 236 57655631 237 57689846 277
57604738 165 57655136 236 57655649 237 57690695 371
169 57655144 236 57655656 237 372
57604746 166 57655151 236 57655664 237 57690786 371
170 57655169 236 57655672 237 57690950 83
index xxviii WARNING. This manual contains data SPECIFIC to the drilling rig with serial number: US021250
T3W
57691115 401 57734204 69 57765661 8 57780868 219
57692352 371 57736779 204 57766099 45 57782781 204
57692360 371 57736803 204 57766131 371 57782799 204
57692766 58 57736837 204 57766172 371 57782807 204
57692782 29 57736845 204 57766206 83 57782856 204
57692790 29 57736878 204 371 57783458 471
57699613 93 57737132 69 57766222 29 57783466 471
57699621 93 57737140 69 57766230 370 57783532 204
57699639 95 57737157 69 57767014 471 57783565 199
57699647 93 57737165 69 57767279 193 57784910 277
57699670 69 57737173 69 57767790 471 279
57699761 58 57740763 167 57768525 193 57785073 29
57700213 71 171 57769390 453 57785651 135
57700221 69 57740771 175 57770232 309 57785669 135
57700247 61 183 57770240 309 57786360 199
65 57742371 189 57770919 19 57786378 199
57700262 71 57742421 127 57770927 21 57789034 268
57700270 71 57744674 419 57772675 165 57793077 243
57700296 69 57744682 419 57772782 199 57794935 268
57700304 69 57746133 370 57775306 204 57795593 3
57700312 63 57747727 166 57775330 204 57797151 8
57700320 69 170 57775355 204 57799322 298
57700346 69 57752354 451 57775371 204 57799793 465
57700353 69 57752362 447 57775389 204 57799975 58
57700361 69 57752370 441 57775397 204 57799983 59
57700379 69 57752719 158 57775405 204 57807869 243
57701120 189 57753485 393 57775413 204 387
57701229 370 57756041 8 57775421 204 57815433 243
57709149 58 57756058 8 57775439 204 57815458 269
57709693 125 57756520 434 57775447 204 57815516 44
57713042 58 57756538 434 57775488 204 57815540 417
57713141 58 57756553 199 57775496 204 57815623 49
57714396 189 57756561 199 57775504 204 57815649 44
57714701 105 57757312 93 57775520 204 57815656 49
57723645 247 57759102 44 57775538 204 57815912 8
273 57760555 419 57775546 204 57815920 8
57724346 99 57760746 207 57775553 204 57816742 295
57724387 127 57762395 207 57775561 199 57816936 49
57725400 453 57765042 207 57775579 199 57816993 43
57725574 204 57765059 207 57775587 199 57817009 49
57727117 393 57765075 199 57775595 219 57817181 149
57727596 434 57765166 207 57776288 165 417
57728974 166 57765232 193 57777351 268 57817199 149
170 57765240 193 57778276 434 417
57729683 8 57765257 193 57779589 369 57817504 417
57729790 231 57765265 193 57780033 369 57818221 71
57729980 29 57765273 193 57780041 369 57818585 298
57729998 29 57765281 193 57780058 369 57818601 375
57731739 121 57765463 441 57780439 158 57818668 343
57731747 121 57765646 8 57780488 193 57818676 43
57731846 309 57765653 8 57780850 219 57818684 43
index xxix
h1/4
•
T3W
57818692 ...............45 57844011 99 57847436 249 57860884 371
149 57844045 295 275 57860934 372
57818734 383 57844086 8 57847642 431 57861064 44
57818817 387 57844235 181 57847709 401 57861254 141
57818825 .369 57844383 149 57848137 29 57861411 370
57818833 379 57844698 387 57848186 435 57861429 413
57821209 73 57844706 387 57848244 199 57861437 417
57821225 369 57844714 75 57848251 217 57861445 249
57821241 298 57844722 75 57848491 434 275
57828436 348 57844730 75 57848566 387 417
57828451 348 57844748 385 57849366 133 57861452 413
57828469 348 57844755 385 57849374 51 57861494 243
57828477 348 57844763 385 57849713 371 57861510 413
57828493 349 57844771 385 57849770 370 57861528 249
57828501 348 57844789 385 57849796 29 275
57828519 348 57844797 385 57849812 372 57861536 269
57828527 348 57844805 385 57849820 372 57861544 45
57828535 348 57844813 385 57849838 371 57861551 247
57828543 348 57844821 385 57849853 370 273
57828550 348 57844839 385 57849861 370 57861791 290
57828568 348 57844847 385 57849887 372 57861825 290
57828576 348 57844854 385 57849929 372 57861841 243
57828584 348 57844870 339 57849960 372 268
57828600 . . ..... 348 57844888 339 57849994 372 57861874 263
57828618 348 57844896 339 57860009 371 57861957 373
57828626 348 57844904 339 57860025 371 57861981 431
457 57844912 75 57860033 371 57861999 431
57828634 348 57844920 385 57860041 371 57862005 431
57828642 348 57844938 385 57860066 371 57862039 431
57828659 348 57845190 82 57860074 371 57862146 413
57828667 348 57845356 8 57860108 371 57862328 413
57828675 348 57845372 11 57860116 371 57862336 413
57842676 407 57845398 11 57860124 371 57862344 413
57843070 58 57845406 11 57860140 371 57862369 413
57843088 58 57845414 11 57860157 371 57862377 45
57843096 58 57845422 11 57860165 372 57862385 413
57843104 59 57845513 44 57860173 371 57862393 413
57843120 58 57845802 17 57860207 413 57862427 29
57843161 407 57845877 263 57860298 51 57862443 401
57843419 59 57846107 417 57860512 141 57862458 269
57843625 69 57846453 268 57860520 401 57862633 373
57843633 69 57846461 268 57860538 401 57862963 375
57843641 63 57846792 165 57860546 401 57862971 372
57843724 299 57847170 267 57860553 141 57863052 387
57843732 63 57847345 9 57860561 141 57863151 379
•
5784 3740 105 57847352 401 57860637 372 57863169 379
57843807 43 57847360 401 57860645 372 57863193 59
57343815 43 57847386 401 57860652 372 57863201 58
5 7 84 3880 35 57847410 401 57860678 372 57863268 99
57843898 43 57847428 401 57860785 370 57863318 149
r 7 943906..............43 57860793 372
index xxx WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250
T3W
PAR: NO PAGE PART NO. PAGE PART NO. PAGE PART NO. PAGE
r
243 57874265 8 57902009 298 57925455 298
269 57874422 99 57902017 298 57925638 307
5781 243 57874760 372 57902025 298 57925646 307
...... ____269 57875080 413 57902058 298 57925653 307
tCq.1 ..__.....371 57876831 59 57902074 298 57925661 307
5751 1 372 57877201 253 57902082 298 57925679 307
5786355 372 57877417 401 57902090 298 57925687 307
5786:56 413 57877516 379 57902827 227 57925695 307
5751:68 1 379 57878183 407 57902850 223 57925703 307
5786410 1 44 57878217 407 57903015 223 57925711 307
371 57878225 407 57903023 227 57925729 307
578t 258 83 57880684 43 57903031 227 57925737 303
5-1.098 , 379 57880692 149 57903049 227 57925745 303
5'7865008 372 57880825 199 57903064 227 57925752 303
57w)01 , 379 57880833 298 57903098 223 57925760 303
5780:1, 31 401 57880866 141 57903494 165 57925778 303
57K.:15677 413 57880882 381 169 57925786 303
243 57884512 348 57907875 82 57925794 303
5T-" 401 57886301 169 57913303 135 57925802 303
243 57888182 349 57916553 393 57925810 303
..........387 369 57917304 298 57925828 303
, .... 133 57888216 389 57917312 298 57925836 303
...413 57888232 45 57917528 11 57925844 303
....43 57888240 45 57917635 167 57928913 169
_59 57888257 45 57917726 407 57930927 417
290 57888265 43 57918427 371 57930935 417
5 _290 57888273 149 57918468 370 57932535 434
_181 57888364 43 57918476 371 57932543 434
...375 57888513 45 57918484 371 57932550 434
578('1114 375 57889453 267 57918492 371 57932568 434
413 57889594 457 57918500 370 57932576 434
57 413 57890444 169 57918575 371 57932584 434
5 /8698j` 372 57891335 417 57918583 371 57932592 434
5786951 1 ....... . ....158 57892283 263 57918591 371 57932600 434
57869551 [ 349 57892291 263 57918609 372 57932618 434
5786965 372 57895005 249 57918617 371 57932626 434
57869661 372 275 57918781 59 57932634 434
5781 ::967 372 57895039 43 57918799 413 57932642 434
5787056 ) 43 57895047 43 57918922 371 57932659 434
5787172 i 372 57895054 43 57920829 257 57932667 434
57871771[ 83 57895062 44 57920837 257 57936411 257
5781286 s 385 57895088 43 57921637 58 57937880 377
5787306 ) 290 57895112 370 57922213 257 57937898 149
5787309 263 57895120 243 57922254 243 57940009 83
57 ''21 473 387 57922262 267 57940017 83
571, ) 473 57895138 298 57922437 257 58000092 473
5787417 [ 290 57895146 348 57925174 8 58000100 473
5787,118 290 57895278 349 57925182 13 58000357 431
290 369 57925190 13 58000365 167
57'r: - . ..,... .290 457 57925208 370 58000456 437
473 57901993 298 57925430 298 58000464 437
WARNING. This manual contains data SPECIFIC to the drilling rig with serial number: US021250 index xxxi
•
T3W
58000472 437 58039207 119 58056425 58 58183070 268
58000480 437 58039454 99 141 58186321 13
58000522 82 58041187 11 58057274 83 58187121 59
58000530 169 59 58059536 43 58187139 59
58000670 348 63 58060161 101 58192915 121
58000746 82 69 58060187 101 58192923 121
58003989 123 58041302 105 58061367 127 58194903 121
58004011 45 58041310 117 58062985 59 58194911 121
149 58041757 58 58063231 99 58194929 121
58004094 377 58041807 58 58086141 193 58194937 121
58004102 377 58041989 117 407 58194945 121
58004110 377 58042060 165 58087784 298 58194952 121
58004128 377 169 58123100 117 58194960 119
58004136 377 58042235 82 58143348 58 121
58006016 377 58042334 82 58145392 44 58197260 277
58006024 377 58042581 82 58145939 117 279
58006032 377 58042656 277 58146903 193 58203035 44
58006040 377 58042920 99 58147646 43 111
58006057 377 58043001 58 58148339 457 113
58006065 377 58043142 119 58148446 166 58206954 253
58006073 377 58043159 117 170 58212697 87
58006081 377 58043225 117 58149790 298 58212705 87
58006099 377 58043290 117 58150103 43 58214461 82
58006107 377 58044512 82 421 58216391 117
58006115 377 58044561 211 58150111 425 58218280 173
58006123 377 58044744 211 58150160 425 177
58006131 377 58047101 99 58150178 413 58226630 121
58034950 83 105 58150186 421 58227661 119
58035015 58 58047853 435 58150202 159 121
58035056 82 58048919 277 425 58231242 263
58035064 82 279 58150210 425 58234907 185
58035072 82 58048968 277 58150228 159 58234949 185
58035171 82 279 58150244 447 58234972 185
58035189 82 58050782 165 58150251 447 58235128 299
58035320 99 169 58151325 59 58235672 105
58035403 8 58051848 23 58151358 119 59383422 298
58035510 111 58051855 23 58152729 82 59383463 298
58036179 58 58051863 23 58158429 103 59476705 369
58036187 58 58054305 290 58158445 103 59506436 193
58036229 58 58054362 290 58158668 253 459
105 58054370 290 58159088 425 59514976 298
58036260 290 58054537 5 58159377 111 59595629 298
58036336 117 58054602 105 58163536 8 59643718 123
58036534 59 58054610 425 58166224 145 59671081 123
58036542 105 58055062 11 58167743 435 59671107 123
58036575 99 58056029 97 58168352 101 59686451 298
105 58056037 97 58168360 101 59896308 211
58036583 99 58056169 101 58173097 193 59918557 83
105 58056177 101 407 59921056 82
58038761 44 58056185 101 58175514 193 59923482 82
58038910 59 58182767 82
ndex xxxii WARNING! This manual contains data SPECIFIC to the drilling rig with serial number: US021250
T3W
59924019 83 95038212 263 95077772 431 95105110 13
299 267 95077939 35 141
59956466 158 95038634 175 95081642 8 95105243 8
67604298 417 183 95081667 8 223
855017P0344 . .271 95038766 271 117 431
855017P0841-1 .. 447 95040952 349 189 95105300 59
91310128 461 95040986 435 253 95111043 425
91310136 407 95041034 117 95081709 103 95129599 401
92329309 ....... 379 95041091 268 95081717 59 95147674 43
94171873 87 271 95081865 117 383
9500047 ....255 95042289 141 119 391
9500214: ....217 95043162 268 166 95147997 141
.435 299 169 143
95002499 ....... 59 95048179 348 171 375
95002689 ....263 95048906 277 95083051 44 95157731 69
95002697 ....213 95050035 279 401 95169660 219
95006573 ,...435 95054128 217 95086310 317 95200093 17
95013702 82 95055018 141 95086559 82 199
9501372 ....165 95055034 387 95086849 82 205
.169 95055067 253 95087045 121 95201331 58
950137i,,- ....199 95055117 95 95093381 29 253
95017 47 95055315 369 95093399 103 95201547 29
..... ...337 95055406 299 143 58
9501840' ....387 95064192 471 95094280 58 85
95018982 ..143 95064663 413 95094314 9 103
9'1 0222R • 255 95064689 219 17 117
..268 95064697 166 199 127
..263 170 217 141
401 185 95096137 401 143
95033379 271 199 95096350 369 167
9503359`-c 267 205 95097291 271 171
. . ..271 263 95097689 315 393
95033 ;' 119 343 95098760 290 95207429 15
290 95067906 119 95101044 457 95207767 348
9503384 166 95069464 434 95103867 165 95208682 253
.170 95069589 45 169 95208971 103
95033 ...103 95072971 451 95104006 45 143
95035408 17 95073920 158 95104014 119 95208989 393
205 95076725 413 431 95209086 290
...413 95077301 199 95104071 43 95209094 193
95035432 17 95077319 167 45 271
29 171 421 349
95035457 17 199 425 95209391 435
95037339 271 95077590 217 95104147 8 95209409 69
95037438 231 95077608 58 185 133
95037446 82 69 369 167
217 95077665 205 95104204 82 295
95037453 271 95077673 295 95104212 199 95209425 165
95037792 ..434 95077681 149 95104675 59 169
9503R0n .277 95077699 59 95105094 8
349 95077707 58
L_
index xxxiii
PART NO.
95209870
PAGE
29
PART NO.
95257325
Numeric Index
PAGE
263
PART NO.
95287629
PAGE
167
PART NO.
95335394
T3W
PAGE
199
•
387 269 171 95335980 290
451 95257333 263 95293296 44 95338026 271
461 95257341 268 95293387 291 95338356 165
95209888 461 290 95293403 271 169
95209904 166 95261467 185 290 95338372 441
170 95263380 133 348 95338406 290
95210852 141 290 447 95341053 231
95212106 166 95264909 231 451 95343737 461
170 435 95294112 58 95344719 421
95219721 268 95264941 267 95297602 268 95351540 421
290 95264958 231 295 95352415 59
95219739 231 95265088 29 95298428 271 95356721 217
290 105 290 95356853 103
451 95266417 461 95301370 204 95357570 219
95219747 167 95266425 243 95301818 141 95357729 267
435 461 95301834 193 95359329 158
95219853 253 95266433 461 95301842 425 95359600 158
95220844 204 95266441 461 95301883 159 95360608 166
231 95266771 58 193 170
459 95267092 217 204 95364154 243
95220976 119 95267399 58 95302113 290 95364469 267
95223319 141 95268215 401 95302121 291 441
95223475 298 95279097 263 95302642 193 95365078 44
95223582 59 95279105 167 95302733 290 193
63 435 95303335 451 95365094 44
95227682 348 95279162 267 95303350 290 243
95228029 103 95279337 435 95303368 268 253
95228037 103 95279352 8 95303756 461 95365177 253
95231031 268 95279386 271 95306296 82 95366001 267
95235131 435 95279402 217 95309829 82 95366761 205
95235370 268 95279410 268 95313961 267 95367025 291
95237079 205 95279436 167 95315222 167 95368338 421
95239216 451 95279451 263 435 95371209 267
95239521 45 95279477 253 95315404 451 95371258 44
141 95279493 105 95316949 253 133
165 290 95316964 8 95371266 413
169 95279519 165 95316972 459 95372850 263
243 166 95317848 83 267
263 169 95318440 158 95373999 158
267 170 95323358 231 95378626 117
401 95279857 268 268 95378667 341
95242376 59 95279956 291 95323457 268 95379376 434
95242624 271 95279998 267 291 95381158 175
95242988 435 441 441 183
95243200 267 95280541 73 95328530 103 95387346 253
95245072 158 401 95329249 447 95387387 167
95245767 295 95280913 143 95329975 43 171
95245775 167 95285904 83 243 95387890 435
171 95286910 271 95330023 267 95391173 207
95249702 253 290
index xxxiv WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250
• PART NO.
95395737
PAGE
267
PART NO.
95663803
PAGE
387
PART NO.
95920674
PAGE
35
PART NO. PAGE

T3W
95922563 44
290 389 43 173
95396776 348 95666996 44 59 177
95403044 149 373 63 95922639 8
95413449 268 389 69 181
95415667 .,,,...,.263 95670535 165 82 95922894 3
268 169 127 44
95416335 370 95702619 435 181 133
95416871 181 95708293 299 295 165
204 95718060 166 393 169
95417929 166 170 441 170
170 95735346 73 95920682 44 185
95419073 290 389 165 189
95426235 133 401 170 204
375 95746335 279 189 211
9543129z 253 95748562 83 369 219
95445664 133 267 95920724 370 267
954/MA 1 r 263 95748802 158 95921623 173 348
9544 44 451 177 369
9544669(- ....271 95750543 141 95922183 44 421
95452066 59 95754867 381 113 441
141 95754875 243 158 95922902 8
149 95860730 295 348 95
........ . 369 369 95922225 165 99
95457586 .............141 95862876 175 169 133
954579 7 ...167 183 205 167
...271 95865937 59 219 185
9.545: ....343 95893483 44 231 189
95468633 83 95902144 15 95922233 3 193
95469037 83 95915229 461 166 199
95473443 263 95915245 461 170 205
95479044 • ...... 461 95915252 461 189 207
95479739 389 95916821 204 193 253
95481800 193 219 205 263
267 95919197 181 207 267
95484408 ..... 158 95919338 165 348 295
95485074 .... 271 169 369 343
95489050 . ..... 268 95919445 166 95922324 111 421
95489159 193 170 166 435
95505699 59 95919569 141 170 95922910 17
95507612 8 167 95922365 269 19
95528808 431 189 349 369
95568960 243 263 95922373 35 95922928 17
95647798 435 95919619 295 181 59
95650149 370 95919841 369 185 189
95650156 29 95920021 205 95922415 271 268
299 95920047 59 299 299
369 369 95923025 158
95651378 83 95922548 158 95923041 425
95651683 263 95923314 348
95924080 417
WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250 index xxxv
PART NO.
95926861
PAGE
461
PART NO.
95934451
PAGE
99
PART NO.
95934733
PAGE
11
PART NO.
95934774
T3W
PAGE
165
•
95926879 461 119 83 169
95928982 44 267 89 348
165 95934469 435 99 95934782 290
169 95934501 295 117 95934816 111
243 299 119 113
370 95934519 299 141 441
95929006 15 95934550 165 189 95934840 189
171 170 193 95934857 370
231 348 199 95934998 223
95929071 413 369 205 95935003 17
95929097 69 413 207 167
95929121 199 95934568 44 253 207
95929139 167 95934576 8 263 295
171 95934584 11 267 431
95929782 15 165 268 95935037 295
..............166 170 295 95935052 295
170 193 341 95935128 219
.......189 207 369 95935151 133
..219 95934592 3 421 95935201 199
223 82 435 95935227 204
. 231 211 95934741 15 95935235 166
.....269 95934626 165 17 171
372 169 19 95937413 3
T45930723 17 95934642 349 29 43
19 95934659 89 166 44
166 117 171 58
.171 199 199 59
45931242........... 369 267 217 63
95931432 295 421 243 69
95931564 43 95934683 17 268 127
44 95934691 17 271 133
111 59 295 165
113 189 299 169
158 205 95934766 43 170
290 95934717 8 44 185
......425 83 111 189
441 141 113 193
95934170 29 149 205
95934303 15 158 207
59 165 211
125 169 219
165 243 369
169 263 393
205 267 421
•
219 290 441
231 370 95938221 375
269 421 95938544 269
370 425 95939856 383
431 441
_15934378 189
firA xxxvi WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250
• PART NO.
95939948
PAGE
95
PART NO.
Numeric Index
PAGE PART NO. PAGE

PART NO. PAGE

T3W
141
387
95939955 431
95941084 8
141
95943668 125
170
219
369
95952354 267
95952560 15
95958351 44
95958583 44
95958682 413
95958765 231
95958930 372
95959136 417
95959144 223
95971552 369
95972238 348
95972246 9
59
96701198 379
96701958 243
96704564 269
96706189 379
96710942 166
170
96712096 379
96718481 166
170
96720834 379
96726625 379
96727573 243
269
98632888 158
417
•
T3W
index xxxviii WARNING: This manual contains data SPECIFIC to the drilling rig with serial number: US021250
•••
P
A Company Within the Atlas Copco Group
P.O. Box 462288, 2100 North First Street
www.atlascopco.com/drillingsolutions
ATLAS COPCO
• Drilling Solutions
Instruction Manual
MODEL: T3W Upgrade
2100 North First Street
Garland, Texas, 75040
(972)496-7400
Read the instruction manual before operating this equipm

ent.
This manual contains important safety information.
Do not destroy this manual.
This manual must be available to the personnel who opera
te and maintain this machine.
TABLE OF CONTENTS
T3W UPGRADE
PAGE
40
TITLE
1-1
SECTION 1 - INTRODUCTION
1-2
INTRODUCTION 1-2
General Information 1-3
How this manual is organized 1-3
Where to find information 1-4
Procedure when receiving the T3W drill 1-5
Identification Data 1-6
Drill Identification 1-6
Engine Identification 1-7
Carrier Vehicle Identification 1-7
Instruction Manual Location 1-7
Drill Description 1-11
Identification of Major Components
2-1
SECTION 2 - SAFETY
2-2
2-1 SAFETY AND HEALTH 2-2
General Safety and Health 2-2
Safety and Health Statement 2-3
Emergencies 2-3
Important Safety Instructions 2-4
2-2 SAFETY PRECAUTIONS AND GUIDELINES 2-4
• OVERVIEW 2-4
Warnings 2-6
Drill Applications 2-6
Safety Reminder 2-7
Personnel Requirements 2-8
General Guidelines 2-9
Equipment Safety Rules 2-11
Pre-Start Inspection 2-11
Operation Safety 2-15
Maintenance Safety 2-22
Warning of Special Dangers
2-23
2.3 - SAFETY DECALS & NAMEPLATES 2-23
Pre-Operation 2-24
Safety Decals 2-34
2.4 - HAZARDOUS SUBSTANCE PRECAUTION 2-34
General Information
2-35
2.5 - SYMBOL IDENTIFICATION
toc - i
•
TABLE OF CONTENTS
T3W UPGRADE
TITLE
PAGE
SECTION 3 - SPECIFICATIONS
3-1
SPECIFICATIONS
General Description 3-2
Operational Limitations 3-2
Standard Equipment 3-3
Specifications 3-4
Hydraulics 3-5
Hydraulic Pumps 3-18
Motors 3-21
Hydraulic Cylinders 3-23
Derrick 3-25
Miscellaneous 3-28
3-35
SECTION 4 - CONTROLS
4-1
OPERATING CONTROLS
Instruments and Controls 4-2
•
Top of Console 4-3
Upper Console 4-3
Middle Console 4-4
Lower Console 4-10
Under Console 4-13
Helper's Controls 4-15
Auxiliary Controls and Indicators 4-16
4-17
toc
TABLE OF CONTENTS
T3W UPGRADE
PAGE
TITLE
5-1
SECTION 5 - OPERATING
5-2
OPERATING SAFETY 5-2
Safe Operations 5-4
DAILY INSPECTION 5-4
Walk Around Inspection 5-7
PRELIMINARY START INSPECTION 5-7
Pre-Start Inspection 5-16
Driver's Checklist 5-20
STARTING TRUCK ENGINE 5-20
Starting Engine 5-28
STARTING DECK ENGINE 5-28
Deck Engine Starting Safety 5-31
OPERATING 5-31
Operation 5-43
Rotary Drill 5-48
Pipe Handling Procedures 5-60
Down Hole Drill 5-67
Drilling With Air 5-70
Carousel Reloading 5-71
Water Injection 5-73
DHD Hammer Drilling 5-76
Mud Drilling 5-81
Casing 5-83
• SHUT DOWN & DRIVE AWAY 5-83
Shutdown Procedures 5-86
TRANSPORTING THE DRILL 5-86
Transportation Procedures 5-89
TOWING THE DRILL 5-89
Towing Information 5-91
SPECIAL CONDITIONS OF USE 5-91
Special Conditions
toc - iii
TABLE OF CONTENTS
T3W UPGRADE
TITLE
PAGE •
SECTION 6 - MAINTENANCE
6-1
6-1 MAINTENANCE SAFETY
Maintenance Safety and Health 6-2
Maintenance Information 6-2
6-2 MAINTENANCE SCHEDULE 6-8
Schedule Information 6-10
Truck Engine Maintenance 6-10
Deck Engine Maintenance 6-16
6-3 REFILL CAPACITIES/LUBRICANTS/FUEL 6-20
Hazardous Substance Precaution 6-23
Lubrication Table 6-24
Refill Capacities 6-25
Filter Elements and Kits 6-27
Hydraulic Oil 6-28
Lubricant Oil & Grease 6-30
Coolant Specifications 6-31
Diesel Fuel (Cat Engines) 6-37
6-4 MAINTENANCE AS REQUIRED 6-39
•
Maintenance As Required 6-41
Air Cleaners 6-42
Clean the Drill 6-42
Feed Cable 6-49
Cable & Wire Rope 6-50
Receiver Separator Element 6-51
Compressor Air Hose and Clamps 6-56
Fuel Systems 6-57
Rotary Head Swivel 6-57
6-5 MAINTENANCE (8-10 Hours) 6-58
Overpressure Control System Test 6-59
Air Cleaners 6-60
Deck Engine 6-61
Cooling System 6-63
Fuel Tanks 6-65
Receiver Separator 6-68
Hydraulic Reservoir 6-70
Rotary Tophead 6-71
Lubrication 6-73
6-6 MAINTENANCE (50 Hours or Weekly) 6-76
Batteries 6-83
Winch/Sand Reel Cable 6-84
Cat Water Injection Pump 6-85
Pump Drive Gearbox 6-86
•
Winch (Auxiliary) 6-87
6-7 MAINTENANCE (100 Hours) 6-89
Winch (Main) 6-92
John Bean Water Injection Pump 6-93
Deck Engine Oil and Filter Change 6-98
6-99
toc - iv
TABLE OF CONTENTS
T3W UPGRADE
PAGE
TITLE
6-101
Deck Engine Fuel System Filters 6-108
Truck Maintenance 6-110
Compressor 6-113
Water Injection Pump 6-116
Main Winch 6-118
Auxiliary Winch 6-119
Compressor Air Hose and Clamps 6-120
Receiver Tank 6-122
Hydraulic Oil Filters 6-127
Rotary Tophead 6-129
Main Winch 6-130
Water Injection Pump 6-130
•
Carousel 6-131
Engine 6-132
Compressor 6-135
Engine Coolant 6-138
6-13 Torque Specifications 6-138
Standard Torque Values 6-142
6-14 MAINTENANCE (25CM Swivel) 6-142
25 CM Swivel 6-149
6-15 MAINTENANCE (40 RM Swivel) 6-149
40 RM Swivel
• toc - v
TABLE OF CONTENTS
T3W UPGRADE
TITLE
PAGE
SECTION 7 - TROUBLESHOOTING
7-1
7-1 INTRODUCTION
Troubleshooting Information 7-2
Electrical 7-2
Operator Observed Problems 7-2
Pneumatics 7-2
Mechanical Hydraulic Components 7-3
Mechanical Engine 7-3
7-2 ELECTRICAL 7-3
Electrical System Information 7-4
Electrical System Components 7-5
Components 7-5
Engine Electronics 7-6
Gauges and Indicators 7-9
Cat Monitoring System 7-10
Sensors and Electrical Components 7-12
Engine Diagnostics 7-13
MurphyLink PowerView 7-17
•
PowerView Operation 7-22
Faults and Warnings 7-25
Electric Ladder 7-29
Electrical Symbols 7-50
Schematics 7-53
7-3 OPERATOR OBSERVED PROBLEMS 7-54
7-4 COMPRESSOR 7-55
Compressor Fire Prevention 7-59
Pneumatic System Information 7-60
Lubrication System 7-60
Separation System 7-61
Electronic Air Regulation System (EARS) 7-66
Electronic Air Regulation Operation 7-68
Electronic Air Regulation Troubleshooting 7-74
Compressor Related Problems 7-77
Electronic Fan Regulation System 7-93
7-5 HYDRAULIC SYSTEM 7-95
Hydraulic System Introduction 7-97
7-6 HYDRAULIC SYMBOLS 7-97
Fluid Power Symbols 7-98
7-7 HYDRAULIC CIRCUITS 7-98
Rotation Circuit 7-113
Main Manifold 7-114
•
Main Valve 7-117
10-Spool Valve 7-122
Schematic Circuit Symbols 7-125
Mud Pumps 7-129
7-8 DIXON Boss Clamp Selection and Installation 7-135
Safety Information 7-139
General Preparation Instructions 7-139
7-141
toe - vi
TABLE OF CONTENTS
T3W UPGRADE
40 TITLE
Dixon Diameter Tape Procedure
PAGE
7-142
7-145
Boss Clamps 7-149
Installation of Boss 2-Bolt Clamp 7-150
Testing 7-155
7-9 WATER INJECTION 7-155
Cat Water Injection 7-167
Bean Water Injection 7-177
7-10 ENGINE HEATER 7-177
Introduction 7-178
Technical Specifications 7-182
Normal Operating Sequence 7-184
Troubleshooting & Repair 7-185
Function Diagnostic 7-204
Components 7-210
Operational Problems 7-211
Maintenance 7-217
Timer 7-223
7-11 DHD LUBRICATOR 7-223
DHD Lubricator
•
7-223
Timer 7-223
Lube Injection Pump 7-224
Flow Switch 7-225
Diagnostics 7-225
Oil 7-226
Pressurized Air 7-229
DHD Lubricator Diagnostic Summary
8-1
SECTION 8 - GLOSSARY
8-2
GLOSSARY OF TERMS
toc - vii
TITLE
TABLE OF CONTENTS
T3W UPGRADE
PAGE •
toc - viii
•
•
Section 1 - Introduction
• DRILLING SOLUTIONS
1-1
T3W Instruction Manual
INTRODUCTION
General Information
This Safety, Operation and Maintenance Manual has been
developed to present the safety,
operations and preventive maintenance requirements for
safe, effective operation and
maintenance of the Atlas Copco Drilling Solutions T3W
Waterwell Drill.
The primary purpose of this manual is to provide opera
tors and maintenance personnel with
the knowledge of the fundamental rules and criteria to be
followed for on-site use and
maintenance of aT3W Waterwell Drill.
The operator and maintenance personnel must read and

fully understand this Safety,
Operation and Maintenance Manual before opera
ting or servicing the drill. This manual has
been organized to present the safety precautions, opera
tion requirements and appropriate
information needed to:
1. Safely operate the T3W Waterwell drill while achiev

ing optimum production.
2. Understand the operating principal of each system
associated with the T3W
Waterwell drill.
3. React effectively and safely to emergency and alarm condit
ions.
4. Perform the necessary pre-operational and post-operational
checks on the drill.
If any part of this manual cannot be understood, contact your super
visor or local Atlas Copco
Distributor. This is an essential condition for working safely with
the T3W Waterwell drill. The
correct T3W operation, use and regular maintenance are
also essential elements to provide
the highest performance and safety.
NOTE: Always keep the "Safety, Operation and Maintenanc

e" manual on
the drill and available to the operator and helper. The
present manual is
accompanied with an engine instruction manual and
a carrier instruction
manual. Always provide the model of your drill and
it's serial number
when you contact the local Atlas Copco service or parts
office.
1-2
DRILLING SOLUTIONS
How this manual is organized

it has been
Although there is a substantial amount of information contained in the manual,
informa tion needed . The present manual
organized so the reader can easily find the specific
therefor e advised to follow the
is accompanied with a carrier instruction manual. You are
and drill instructi on
operation and maintenance instructions as specified in both the carrier
to the following
manuals. The manual is divided into sections by information based on answers
questions:
1. What are the specific operator responsibilities? (See Section 2)

2. What are the specifications of the drill itself? (See Section 3)
3. What instruments and controls are used by the operator to operate and monitor
the drill? (See Section 4)
5)
4. What are the proper operating procedures for the equipment? (See Section
be
5. What are the maintenance schedules? When and how is maintenance to
performed? (See Section 6)
of
6. What should the operator do when problems arise. What are the types
hydraulic, electric and compressor system s? What is the correct operato r
troubleshooting response? (See Section 7)
8)
7. What do the various terms mean that are used in this manual? (See Section
Where to find information

the
Each manual has a table of contents. If you are uncertain which section contains
step is to
information or where the information is located within a particular section, the first
shown
consult the table of contents. This instruction manual consists of the eight (8) sections
below:
Section 1 - Introduction describing the drill
Section 2 - Safety
Section 3 - Technical Specifications
Section 4 - Operating Controls and Instruments
Section 5 - Operating Instructions
Section 6 - Maintenance Instructions
Section 7 - Systems/Troubleshooting
Section 8 - Glossary
Drilling
If any part of this manual cannot be understood, contact your supervisor or local
Solutions Distributor. This is an essential condition for working safely with the drill.
s
The correct drill operation, use and regular maintenance are also essential element
necessary to provide the highest performance and safety.
1-3
DRILLING SOLUTIONS
Throughout the manual, Dangers, Cautions, Warnings, Notices

and Notes are used to
provide the reader with special noteworthy information. In this manual,
these terms have the
following significance:
A DANGER
DANGER is used to indicate the presence of a hazard which will
cause
severe personal injury, death or substantial property damag
e if the
warning is ignored.
A WARNING
WARNING is used to indicate the presence of a hazard which can cause
severe personal injury, death or substantial property damage if the
warning is ignored.
A CAUTION
CAUTION is used to indicate the presence of a hazard which will
or can
cause minor personal injury or property damage if the warning is ignored
.
NOTICE
NOTICE is used to notify people of installation, operation or mainte
nance
information which is important but is not hazard related. The
hazard
warnings should never be included under the Notice signal word.
Procedure when receiving the T3W drill

Your T3W drill has been tested, accurately checked and prepared for shipme
nt. Every part of
the drill, including the detached parts, has been accurately checked before
being shipped from
the factory.
When you receive the T3W drill. and before unpacking the equipment,
check if damage has
occurred during transport and if any parts are missing.
Check the equipment by consulting the shipment documents.
If the goods are damaged, or if parts are missing, inform the freight agent
as soon as possible.
He will inform you regarding how to proceed in order to make a compla
int.
1-4
DRILLING SOLUTIONS
Section 1 - Introduction T3W Instruction Manual
Identification Data
facilitate
An exact description of the model type and the serial number of your T3W drill will
fast and efficient response from our parts and service support operatio ns.
local Drilling
Always provide the model of your drill and its serial number when you contact the
Solutions service or parts office.
We advise you to enter your drill data on the following lines to maintain drill and engine
service
information necessary to facilitate fast and efficient response from our parts and
support operations.
Model
Drill Serial Number
Chassis VIN Number
Year of Manufacture
Truck Engine Serial Number and Type of Engine
Deck Engine Serial Number and Type of Engine
1-5
DRILLING SOLUTIONS
Drill Identification
The T3W Drill Identification Plate is located on the driller's console as shown below.
Ram arm .66 .,6.466

• fia6.4.4.6 lev
geri••411vo. 111.4
T1/.• r446.•
/\ A'
eon. :•• .664.
• 1.4664•1114.4.6.4
4444 12.••••• 044 re.
4.4
Cd
• •MI 6146•44 .4 L hen ilf4611415 4•••••4. ft V MA..
464.6 ••• 64446 •446* • gooey...NO *maws • vvv. •
Standard Drill Identification Plate Identification Plate to meet

European Community (CE)
requirements
Engine Identification
The engine identification number can be found on the engine identification plate.
The engine
data plate, as shown above, provides the model identification and other important
data about
the engine. Refer to the engine operator's instruction manual for further information
on the
identification information. Have the following engine data available when commun
icating with
an Authorized Repair Location. The data on the data plate is mandatory when sourcing
service
parts:
1. Engine Serial Number (ESN)

2. Control Parts List
3. Model
4. Advertised Horsepower and RPM
1-6
DRILLING SOLUTIONS
Carrier Vehicle Identification

located on the
The carrier vehicle identification number can be found on the identification plate
inside of the carrier cab door.
Instruction Manual Location

cabinet located
The instruction manuals are located within easy reach of the operator. A tool
the operato r's parts and instruct ion manual s. Truck
beneath the oil cooler provides space for
vehicle instructions are located in the truck cab on the driver's side door.
General Information
d concerning
All safety rules in section 2 must be observed. If further information is require
Drilling Solutions
recommended water well drilling applications, contact your local Atlas Copco
distributor.
Atlas Copco Drilling Solutions
Garland, Texas U.S.A.
Telephone: 972-496-7400
Customer Service Parts: 972-496-7382
Fax: 972-496-7427 (Customer Service Parts)
Fax: 972-496-7425 (Customer Service Warranty)
ations without
Atlas Copco Drilling Solutions reserves the right to make any changes or modific
shipped from the
prior notice and without incurring any liability to retrofit machines previously
factory.
1-7
DRILLING SOLUTIONS
T3W Instruction Manual Section 1 - Introduction
Drill Description
T3W Waterwell Drill Description
The Atlas Copco T3W Waterwell Drill is a truck mounted, hydraulic rotary head drive,
deck
engine powered drill, designed primarily for waterwell applications using rotary, mud
drilling
techniques or downhole drilling methods using a high pressure compressor on prepared
(if
necessary) ground that is flat and firm.
Due to the design of the drill, it can be mounted on several different truck frames. It
incorporates four (4) frame mounted leveling jacks to keep the drill level and stable while
drilling.
The standard T3W uses a diesel engine connected directly to a hydraulic pump drive gearbox
on one end. The air compressor is either directly connected to the engine or through a
clutch
on the other end. The power pack is mounted to the drill truck frame.
The derrick is constructed of welded steel tubing. A carousel type drill pipe changer is mounted
inside the derrick and holds either seven (7) or nine (9) drill pipes, depending on the
O.D. of
the pipe. A pipe rack is mounted on the left side of the drill and holds 12 or 16 extra pieces
of
pipe, depending on the O.D. The derrick is raised and lowered by two hydraulic cylinders
.
Drill pipe changing is done by emptying the carousel first, then pulling pipe from the pipe
rack.
Pulling pipe out of the hole is done just the opposite, after replacing one piece of pipe
in the
carousel to stow the rotary head.
All drilling functions are controlled from the operator's console adjacent to the drill table.
The
operating controls and gauges are positioned within easy reach of the operator.
1-8
DRILLING SOLUTIONS
the
To permit optimum performance on a wide range of applications and site requirements,
T3W Waterwell Drill is equipped with:
1. 900 CFM or 1070 CFM HR2.5/1800 rpm over/under screw air compressor
2. Caterpillar C15 Deck engine
3. Hydraulic cylinder driven cable feed system
4. Hydraulic driven, four motor spur gear rotary tophead
5. Seven (7) or nine (9) drill pipe carousel
6. Easily accessed operator's console and platform
7. Drill pipe rack
8. Hydraulic cylinder operated, self adjusting, cam action breakout wrench
9. Retractable table with an air operated bottom holding wrench
10. Four (4) leveling jacks
Engine
.
The T3W Waterwell drill uses a water cooled engine with direct injection and turbo chargers
is standard on all T3W Waterwe ll
Electric starting and belt driven alternator battery charging
,
drill models. The T3W is equipped with dual system air filtration. Dry type 2-stage air cleaners
with optional precleaners, provide clean air to the engine and the compres sor. The engine
by the
power / rpm is controlled by the engine speed control. The engine is shutdown either
removable key "ON/OFF" switch or the emergency stop switch.
Carrier
The T3W Waterwell drill consists of a special truck frame which supports the power pack
assembly (engine/compressor/hydraulic pump drive), the combined engine radiator and
hydraulic oil cooler, drill tower assembly and four leveling jacks.
Derrick
the
The derrick is constructed of welded tubular steel with cross bracing on both sides and
support the feed cables. The derrick
back. A set of sheaves at the top and bottom of the derrick
.
assembly features the hydraulically driven rotary head and the hydraulic drill feed systems
a set of cables
The feed system consists of the rotary head, the hydraulic feed cylinder and
connected to the top and bottom of the rotary head assembly.
rack.
Drill pipe changing is done by emptying the carousel first, then pulling pipe from the pipe
piece of pipe in the
Pulling pipe out of the hole is done just the opposite, after replacing one
carousel to stow the rotary tophead.
1-9
DRILLING SOLUTIONS
Controls
All operational functions can be controlled from the driller's console. All of the controls, with
the exception of the helper's jib boom and jib hoist control located on the helper's side of the
drill table, are positioned for operator convenience on the operator's console. The operator's
console has been designed for convenience, ease of control and safety while providing
maximum visibility to the work area. Full details are provided in Section 4 (Operator Controls)
.
Serviceability
The engine, compressor and hydraulic pump drive are accessible from either side of the drill.
All daily checkpoints are positioned to encourage preventive maintenance. All grease points
can be serviced from the two banks of grease nipples from which hoses provide grease to the
respective components.
A DANGER
Your life may be endangered if the following is not complied with: DO
NOT add attachments to the drill that intrude into operator's protective
area, reduce visibility, restrict emergency exits or add weight exceeding
certification weight. See the operator's manual or contact your dealer for
complete inspection requirements and maintenance instructions.
Standard Features on T3W Waterwell Drill
1. Diesel driven, deck mounted power pack

2. Operator's console mounted to the deck to operate engine and leveling jacks
3. Cooling package rated to 125°F (52°C) ambient temperature
4. Improved breakout wrench
5. Hydraulic powered table slide
6. Jib Hoist and Auxiliary Hoist for drill rod and accessories handling
7. Spur Gear hydraulic powered rotary tophead
8. Four leveling jacks
9. Deck mounted rod box
10. Custom designed two (2) rear axle, diesel driven carrier with a 10-speed
manual transmission.
11. Under cooler storage box
12. Heavy Duty engine silencer/muffler
13. Separate Air intake filters for engine and compressor
1-10
DRILLING SOLUTIONS
Identification of Major Components
SINGLE
ROD LOADER
HYDRAULIC
RESERVOIR
MAIN
HOIST
AUXILIARY
HOIST
NSOLE
OPERATOR
PLATFORM
FUEL
TANKS
BATTERIES
DERRICK
HELPER'S
PLATFORM
AUXILIARY
HOIST
1-11
DRILLING SOLUTIONS
The pictures shown are for reference only.
RECEIVER
TANK
MAIN
HOIST
LEVELING
JACK
WATER
INJECTION
COOLER
PACKAGE TOOL
BOX
DHD
LUBRICATOR
SWIVEL &
YOKE
ROTARY
HEAD
SINGLE ROD
LOADER
CONTROL
CONSOLE
ROD
SPINNER
HELPER'S OPERATOR'S
PLATFORM PLATFORM
1-12
DRILLING SOLUTIONS
•
Section 2 - Safety
2-1
T3W Instruction Manual Section 2 - Safety
2-1 SAFETY AND HEALTH
General Safety and Health

This manual has been published to alert operators, helpers and mechanics to the possible
physical dangers that are present in all phases of operation and maintenance of this drill.
Anyone working around this drill must read and thoroughly understand the precautions
outlined in this manual before attempting to operate or perform work on the drill. In addition,
"SAFETY ALWAYS" must always be the primary consideration of all personnel when working
around this drill under normal or unusual conditions.
Since this manual cannot cover every possible situation, all personnel are expected to
exercise good judgement and common sense when operating, servicing or working near this
drill.
If there is any doubt about the safe operating procedures of the drill, STOP! Review the
information supplied with the drill, ask your supervisor or contact your nearest Atlas Copco
Drilling Solutions representative for assistance.
Make sure all new employees read and understand the decals in the laminated Decal Safety
Manual that is mounted on the drill. Never remove the Decal Safety Manual. Replace the
manual if it becomes lost, damaged or illegible.
Safety and Health Statement

Every employer should have a safety and health philosophy based on the following
statements:
1. We are committed to providing a safe and healthy workplace for all our
employees.
2. We believe that injuries and accidents are preventable and that the well being
of all our employees can be protected in the work environment.
3. We believe that safety is number one. Safety will not be sacrificed for
production.
4. We believe that housekeeping is an integral part of our safety program and the
protection of our employee's health.
5. We believe that all of our employees are responsible for the safety of their co-
workers. Each of us has the duty to listen, watch and act upon hazards that
might injure another.
6. We believe that good safety training is necessary to assist employees in
completing their assigned tasks in a safe manner.
7. We believe that safety is a team effort.
Safety is an integral part of every individual's job responsibility. Every employee must be
committed to these beliefs and must work in a manner that demonstrates that commitment.
2-2
DRILLING SOLUTIONS
Section 2 - Safety T3W Instruction Manual
Emergencies
Emergencies are situations where there is personal injury or property damage, or when there
is imminent threat of personal injury or property damage. It is important for everyone to know
how to respond to emergency situations in order to minimize injury and damage. Each
operator must have a plan to be able to contact 911 or some other form of help, such as Fire
or Medical Emergency Services, immediately. These plans must be known to everyone
around the drill in case someone is injured.
Important Safety Instructions

Personal safety is of prime importance at all times when performing any operations or
maintenance on a drill. While we have no direct control over the way the drill is operated or
maintained, we wish to call your attention to those procedures which are potentially
hazardous. Knowing the guidelines shown in section 2.2 will help provide for your safety, for
the safety of those around you and for proper operation and maintenance of the drill.
2-3
DRILLING SOLUTIONS
2-2 SAFETY PRECAUTIONS AND GUIDELINES
OVERVIEW
Before you operate, maintain, work around or in any other way use this drill: READ and
STUDY this manual. KNOW how to safely use the drill controls and what you must do for safe
maintenance. Failure to follow instructions or heed warnings could result in injury or death.
Ensure that the drill is in good operating condition before operating.
WEAR PROTECTIVE CLOTHING

Anyone working around the drill must wear
APPROVED safety equipment (safety shoes or
protective footwear, safety glasses, hearing
protection, hard hat, gloves, respirator, etc.) when
operating or maintaining the machine. Safety Glasses Hard list Ear Protection
Wear close fitting clothing and confine long hair.
Operating equipment requires the full attention of

the operator. Do not wear radio or music
headphones while operating the machine. Electrically
Insulated Gloves
Respirator
J,
Electrically
Insulated Boots
If you have ANY QUESTIONS about the safe use or maintenance of this drill, ask your
supervisor or contact your nearest Drilling Solutions distributor for assistance. NEVER
GUESS-ALWAYS CHECK!
Safety must always be the most important concern. Do not operate the drill when conditions
are unsafe and consult your supervisor when safety is in doubt.
You must be alert, physically fit and free from the influences of alcohol, drugs or medications
that might affect your thinking ability, judgement, sight, hearing or reactions.
Signals must be given by the operator prior to starting or operating the drill.
Make sure all new employees read and understand the decals in the Decal Safety manual that
is mounted on the drill. Never remove the Decal Safety manual. Replace the Decal Safety
manual if it becomes lost, damaged or illegible.
Warnings
Throughout the manual, Notes, Notices, Cautions, Warnings and Danger symbols are
used
to designate instructions of particular importance. Look for these symbols which point out
items of extreme importance to you and your co-workers' safety. Read and understand
thoroughly. Heed the warning and follow the associated instructions. In this manual, these
terms have the following significance:
2-4
DRILLING SOLUTIONS
NOTE: Note is used for supplementary information not directly effecting

safety or damage to equipment. Note can also refer to special information
on the efficient use of the drill.
NOTICE
NOTICE: Notice is used to notify people of installation, operation or
maintenance information which is important but not hazard-related.
Hazard warnings should never be included under the NOTICE signal
word.
A CAUTION
CAUTION: Caution is used to indicate the presence of a hazard which
WILL or CAN cause minor personal injury or property damage if the
warning is ignored.
91!
A WARNING
WARNING: Warning is used to indicate the presence of a hazard which
CAN cause severe personal injury, death or extensive property damage if
the warning is ignored.
A DANGER
DANGER: Danger is used to indicate the presence of a hazard which WILL
cause SEVERE personal injury, death or substantial property damage if
the warning is ignored.
2-5
DRILLING SOLUTIONS
Drill Applications
The T3W Watewell drill is built in accordance with state-of-the-art standards and recognized
safety rules. Nevertheless, its misuse may constitute a risk to the life and limb of the user or
third parties, and may cause damage to the drill or other material property.
The T3W Waterwell drill must be used in accordance with its designated use as described in
this Instruction manual. The drill must only be operated by safety conscious persons who are
fully aware of the risks involved in operating the drill. Any functional disorders, especially those
affecting the safety of the drill, must be corrected immediately.
Designated Applications
The Atlas Copco T3W is a truck mounted, hydraulic tophead drive, deck engine powered drill,
designed primarily for water well applications.
Non-Designated Applications
The Drilling Solutions T3W Waterwell drills are not designed for use on inclined surfaces or on
soft and unstable ground. Use of the T3W Waterwell drill for purposes other than that
mentioned (such as for towing other vehicles or equipment) is considered contrary to its
designated use. The manufacturer/supplier cannot be held liable for any damage resulting
from such use. The risk of such misuse lies entirely with the user.
11111.11111r
, 1111
WARNING
Set up the T3W Waterwell drill on a level surface. If this is not available,
the site should be adequately prepared prior to drill setup.
Operating the T3W Waterwell drill within the limits of its designated use also involves
compliance with the inspection and maintenance directives contained in the operating manual.
Safety Reminder
physical dangers that are present in all phases of the operation of this drill. Anyone working
around this drill must read and thoroughly understand the precautions outlined in this manual
before attempting to operate or perform work on the drill. In addition, "SAFETY ALWAYS"
must always be the primary consideration of all personnel when working around this drill under
normal or unusual conditions.
2-6
DRILLING SOLUTIONS
exercise good judgement and common sense when operating, servicing or working near the
drill. If there is any doubt about the safe operating procedure of the drill, stop and review the
information supplied with the drill or contact your nearest Drilling Solutions representative for
assistance.
Personnel Requirements
Work on and with the drill must only be performed by qualified personnel. Statutory minimum
age limits must be observed.
Those who operate, maintain and work on T3W Waterwell drill must be competent:
1. Physically competent to react correctly and quickly to avoid accidents.

2. Mentally competent to understand and apply all established rules, regulations
and safe practices and to concentrate on the job to be done.
3. Emotionally competent to withstand stress and prevent mistakes.
Those who operate, maintain and work on T3W Waterwell drill must be experienced:
1. Trained in the operation and maintenance of the T3W Waterwell drill.
a. They should have read and understood the Manufacturer's Instruction

Manuals and know the ratings and capabilities of the drill they are using.
b. They must understand hand signals.
c. They must understand the meaning of various symbols on instruments,
controls and specific parts of the drill.
2. Licensed if required by law.
The individual responsibilities of the personnel responsible for operation, setup, maintenance
and repair of the drill should be stated clearly.
1. Define the drill operator's responsibility with regard to observing site traffic
regulations.
2. The operator should have the authority to refuse instructions by third parties
that are contrary to safety.
3. Do not allow persons being trained or instructed in the operation or
maintenance of the drill to work without permanent supervision by an
experienced person.
4. Work on the electrical system and equipment of the drill must be done only by
a skilled electrician or by instructed persons under the supervision and
guidance of a skilled electrician and must be in accordance with electrical
engineering rules and regulations.
5. Work on the truck chassis, derrick, brake, air and hydraulic systems must be
performed by skilled personnel with special knowledge and training for such
work.
2-7
DRILLING SOLUTIONS
General Guidelines
1. Stow the instruction manuals within easy reach of the operator. Manuals must
always be available at the site where the drill is being used. A tool cabinet,
located beneath the oil cooler, provides space for the operator's instruction
manuals. Truck vehicle instructions are located in the truck cab on the driver's
side door.
2. Observe and Instruct the user in all other generally applicable mandatory and
legal regulations relevant to accident prevention and environmental protection.
These compulsory regulations may also deal with the handling of any
hazardous substances, issuing and/or wearing personal protective equipment,
and traffic regulations.
3. Supplement operating instructions with detailed working instructions covering
the methodology of the working sequences, all individual job responsibilities
and overall supervisory responsibility.
4. Always be sure that persons entrusted with work on the drill have read the
operating instructions and in particular the chapter on safety before beginning
work. Reading the instructions after work has begun is too late. This is
especially important for persons who work only occasionally on the drill, e.g.
during setup or maintenance.
5. Make Certain all personnel are working in compliance with the operating
instructions and are alert to risks and safety factors.
6. Always tie back or otherwise secure long hair. Wear close-fitting garments and
avoid wearing jewelry such as rings. Injury may result from clothing, hair or
jewelry being caught up in the machinery.
7. Use protective equipment wherever required by the circumstances or by the
law. Always wear approved safety equipment while working around the drill.
This includes an approved hard hat, safety glasses, protective footwear,
gloves, a respirator and ear protection.
8. Observe all safety instructions and warnings attached to the drill.
9. Be Sure all safety instructions and warnings attached to the drill are complete
and perfectly legible.
10. Stop the drill immediately in the event of safety relevant malfunctions or
change in drill behavior during operation. Report the malfunction to the proper
authority/person.
11. Never provide service or maintenance to the drill unless all of the truck wheels
are on firm, level ground.
12. Do Not make any modifications to the drill which might affect safety without
having the manufacturer's approval. This applies to the installation and
adjustment of safety devices as well as to welding work on load bearing
elements.
13. Always Adhere to the prescribed intervals and/or those specified in the
operating instructions for routine checks and inspections.
2-8
DRILLING SOLUTIONS
14. Ensure that people, equipment and material not required for the correct
operation of the drill are removed and kept out of the work area. The operator
must never drill while people are around the drill table. Alert people and crew
to stay clear of the hole while drilling is in process.
15. All Personnel who work around the drill must ensure that any unsafe
conditions and practices are corrected or reported to the drill operator and
supervisor.
16. All Personnel who work around the drill, including the support and
maintenance people, must obey all warning signs and must ensure their own
safety and the safety of others.
17. With careful planning, most accidents can be avoided.
a. Have a clear understanding of the work to be done.

b. Consider potential dangers or hazards.
c. Develop a plan to do the job safely.
d. Explain the plan to all personnel concerned.
Equipment Safety Rules

Before starting or working around the drill, read and understand the safety manual, decal
safety manual and labels located on the drill. Follow all directions on the labels. Do not remove
or deface the labels. Replace them if they become damaged or lost.
Do not operate or work on this drill unless the instructions in this manual and the signs on the
equipment are understood. Failure to follow instructions or heed warnings could result in injury
or death. Ensure that the drill is in the correct condition before operating.
Safety must always be the most important concern. Do not operate the drill when conditions
are unsafe and consult your supervisor when safety is in doubt. You must be alert, physically
fit and free from the influences of alcohol, drugs or medications that might affect your thinking
ability, judgement, sight, hearing or reactions.
1. Anyone working on or around the drill must wear approved safety equipment.
This includes an approved hard hat, safety glasses, safety shoes or protective
footwear and hearing protection. They must not wear loose clothing that can
get caught in moving parts. They must wear gloves when handling heavy parts
and tools or any objects that are sharp or pointed. A respirator may be required
in dusty conditions.
2. Keep the operator's platform and work areas clean and free from grease, oil
and other items or tools that could cause a slip or fall.
3. Keep the truck cab and all operator platforms clean. Mud, cans. bottles, tools
and other debris can jam pedals and other controls and cause falls.
4. Keep the work site area clear of cuttings, tools, and other objects.
5. Keep all warning and information labels clean and readable. Replace labels if
they become damaged, torn, painted over or removed.
2-9
DRILLING SOLUTIONS
6. Keep all controls and gauges in good working order. If they become damaged
or broken, replace them before operating the drill.
7. Make a complete walk around inspection of the drill before starting. During
operation, make periodic checks to be sure the drill is operating properly.
8. Watch for leaking or broken hydraulic or air hoses. Replace them before they
cause damage or a fire.
9. Do not operate the drill with excessively worn or broken parts.
10. Tighten or replace any loose or broken fittings, bolts or other connections
before operating the drill.
11. Check the batteries and connections before starting the drill. Tighten terminal
clamps and be sure all batteries have caps. Loose wires can cause fires and
shocks. Spilled fluid can cause burns. Make sure all batteries are charged
properly with correct fluids.
12. Use extreme caution when handling, cleaning, wiring, or recharging batteries.
They can explode and spray acid. Keep battery covers in place all the time.
13. Make sure all controls are in neutral before starting the drill.
14. Make sure all guards are in place on the drill. Replace them if they have been
removed for maintenance. Do Not operate the drill if guards are not in place.
15. Know where your helper or other personnel are at all times. Do Not move the
drill if they are not in sight.
16. Signals must be given by the operator prior to starting or operating the drill.
17. Before moving the drill, make sure there is nothing in the way of travel. Make
sure all the drill pipe is out of the ground and secured before moving.
18. Locate the drill on level ground, if possible. Install cribbing (blocking) under
each jack to insure a stable lifting platform in case the ground is broken or soft.
19. Before raising the derrick, make sure it is clear of tools or objects that could fall.
Check to see that all hydraulic and air hoses do not become snagged during
raising. Watch all hoist cables and keep them clear or spooled properly while
raising the derrick. Make sure helpers or visitors are away from the drill while
raising or lowering the tower.
20. When working on any air compressor hose or receiver tank, relieve all pressure
in the system before removing any cap, plug or hose connection.
21. Never move the drill with the derrick partially raised, unless it is an angle drill
with the proper locking pins in place.
22. Never move the drill with the derrick locking pins removed or unpinned. The
derrick is not designed to be held up by the derrick raising cylinders alone.
23. Make sure all new employees read and understand the decals in the Safety
Manual, mounted on the drill. Never remove the Safety Manual. Replace the
manual if it becomes lost or illegible.
2-10
DRILLING SOLUTIONS
Pre-Start Inspection
1. Inspect your drill daily. Ensure that the routine maintenance and lubrication are
being dutifully performed. Have any malfunctioning, broken or missing parts
repaired or replaced before use.
2. Verify that all instruction and safety labels are in place and readable. These are
as important as any other equipment on the drill.
3. Never fill the fuel tank with the engine running, while near an open flame, or
while smoking. Always wipe up any spilled fuel.
4. Check for Warning or lockout tags placed on the drill. Do Not operate the drill
until repairs have been made and all the Warning or lockout tags have been
removed by authorized personnel.
5. Clean any foreign material from the operator's platform to reduce the danger of
a slip or a fall.
6. Know the location of the Emergency Shut Down control if the drill is so
equipped.
7. Always know the capabilities and limitations of your drill equipment: speed,
gradient, steering and braking.
8. Be Aware of the dimensions of your drill's height, width and weight when
moving the drill.
9. Check for any conditions that could be dangerous: unstable ground condition,
tree limbs, low hanging wires or an overhanging rock face.
Operation Safety
General Information
1. Observe the position of fire extinguishers, if so equipped, and ensure that they
are fully charged and inspected regularly.
2. Avoid any operational mode that might sacrifice safety.
3. Take all necessary precautions to ensure that the drill is used only when in a
safe and reliable condition.
4. Operate the drill only if all protective and safety oriented devices, such as
removable safety devices, emergency shut off equipment, sound proofing
elements and exhausts are in place and fully functional.
5. Start the drill from the driver's seat in the cab only.
6. Watch the indicators during startup and shutdown procedures in accordance
with the operating instructions.
7. Make Sure no one is at danger or risk before starting up or setting the drill in
motion. Personnel can be pinched, entangled or crushed by moving machinery.
While the drill is in operation, crew members must never place any part of their
DRILLING SOLUTIONS 2-11

bodies or clothing on or near any rotating machinery, gears, pinions, ropes,

cables, chains or wrenches.
8. Check to see that braking, steering, signaling and lighting systems are fully
functional before starting work or traveling with the drill.
9. Check that accessories have been safely stowed away and that all leveling
jacks are retracted fully before moving the drill.
10. Always Switch On the lighting system in conditions of poor visibility and after
dark.
11. Make Sure there is sufficient clearance when crossing underpasses, bridges
and tunnels, or when operating under overhead lines.
12. Always Keep at a safe distance from the edges of steep slopes.
13. Avoid any operation that might be a risk to drill stability.
14. Always Secure the drill against inadvertent movement by putting the truck in
gear and engaging the parking brake before leaving the truck cab.
15. Always Secure the drill against all unauthorized use before leaving the
operator's cab.
Setup and Start Safety
1. Always Use handrails and steps to get on and off the drill. Always Maintain a
three point contact when climbing onto or off the drill. Watch for slippery
surfaces when mounting.
2. Read and Follow All instruction decals.
3. Before starting engine or beginning to move, check inside, outside and
underneath the drill for people or obstructions.
4. Before starting the engine, Ensure that the truck parking brake is in the
"Applied" position.
5. Before starting the engine, check that all operating controls are in the stop or
neutral position and the emergency stop button is pulled out.
6. Check for Warning or Lockout tags on the controls. If there is a tag attached to
the start switch, do not start the engine until the warning tag has been removed
by the person who installed it.
7. Always sound the horn before starting the drill to alert everyone in the area.
8. Start the engine from the truck cab only.
9. Always Use Extreme Caution if you have to jump start the engine.
10. Check all the gauges and controls for correct operation. Stop the drill
immediately and replace any that are defective.
11. Check all safety devices. Report any defects immediately.
12. Make sure the drill is on solid, level ground before lowering the jacks and
raising the derrick. Use cribbing (blocking) if you are not sure.
2-12 DRILLING SOLUTIONS

Section 2 - Safety
13. When raising the derrick, make certain there are no electrical power lines within
the operating area of the drill.
14. Listen for unusual noises.
15. Engage hydraulic controls slowly in cold weather to avoid shock loading.
Electrical Power Line Safety
A DANGER
Do not raise the derrick or operate this drill in the vicinity of electrical
power lines. Operating too close or contacting a power line with any part
of the drill can result in electrocution.
Contacting power lines with any part of the drill will cause death! Keep at
least 10 feet (3 meters) away from power lines. If there appears any
danger of wind or other obstruction closing the distance, do not drill in
that area.
1. Place the drill as far as possible from electrical power lines and never work
inside the minimum specified distance set by local, state or federal regulations.
2. Treat all electrical lines as live power lines.
3. Clear the area. Slowly raise and lower the derrick. If the distance to the line has
been misjudged, your reaction time might be too slow.
4. A signal person must be used to guide the drill in the vicinity of power lines. The
signal person and drill operator must be in direct visual contact at all times.
Operating Safely
1. Always make sure that no person or obstruction is in your line of travel before
moving the drill.
2. Never Climb on or off the drill while it is in motion.
3. Use Extreme Caution and be very observant when operating in close quarters
or congested areas.
4. Never carry passengers.
5. Know the area in which you are working. Familiarize yourself with any and all
work site obstructions and any other potential hazards in the area .
6. Know and Use the hand signals required for particular jobs and know who has
the responsibility for signaling.
7. Do Not work in the vicinity of overhanging banks or on grades that could cause
the drill to slide or roll over.

Section 2 - Safety
8. Avoid side hill travel. Always operate up and down slopes.

within the
9. Never allow bystanders, other than authorized persons, to stand
drill's danger (working) area when the engine is running.
travel and
10. Always Look in all directions Before changing your direction of
sound the horn prior to moving.
11. Do Not run the engine in a closed building for an extended length of time.
Exhaust Fumes Can Kill.
Drilling
All Atlas Copco Drilling Solutions drills are equipped with an overpressure control system
which will vent feed pressure if the drill end leveling jacks are not supporting the weight of the
drill. To ensure someone has not disabled the system, each operator must perform the
overpressure control system operational check procedure daily as described in sections 5.6
and 6.5 of this manual.
1. Use the proper tools for the job. Do not attempt to lift drill pipe, subs, stabilizers
or bits without the proper lifting devices.
2. Use the proper technique in loading and unloading drill pipe. If a lifting bail is
used, make sure it can be detached by a helper while standing on the ground.
Use a pipe handling tool if the carousel needs to be filled. Make sure the safety
clip is in place. Never Ride The Rotary Head For Any Reason!!!
3. Do not attempt any repairs to the drill while it is running. Stop the drill to make
repairs.
4. Do not allow anyone to climb the derrick. If repairs must be made, lower the
derrick or use a manlift to reach the repair area.
5. Do not ride the rotary head for any reason. It is not meant to be an elevator.
6. Do not use the hoist cable as a manlift.
7. Do not operate the drill except from the operator's station. Trying to operate
from any other position is a safety hazard and can cause serious injury.
8. Do not hoist or brake too sharply. This can cause premature failure of
equipment and can be dangerous.
9. Don't retract the hoist so far that it slams into the crown block. Continuous pull
on the wire rope can break it and drop the load.
10. Know the limitations of your drill and don't exceed the design limits.
Moving the Drill
1. Make sure all drill pipe is out of the hole before moving the drill.
2. Do not get on or off the drill when it is moving.
3. Lower the derrick if moving a long distance.

Section 2 - Safety
4. Secure all drill pipe and tools before moving the drill.
5. Know the drill's height, width, weight and length before moving
the drill.
6. Check the truck brakes before leaving the job site.
7. If moving with the derrick raised, make sure all locking pins
are in place and the
ground is level and solid.
8. Be careful cornering to allow for derrick overhang.
9. Know where your helpers are at all times. Do not move the
drill if they are not
in view.
10. Know and use proper signals when moving the drill.
Stopping and Shutdown
1. Always park the drill on solid, level ground. If this is not possib
le, always park
the drill at a right angle to the slope and chock the wheels.
2. If the drill is left over the hole, lower the jacks so the wheels touch
the ground.
3. Be sure to relieve all pressures in the systems before leaving
the drill.
4. Place all controls in neutral or park position before leaving the
drill.
5. Avoid leaving the controls with the engine running.
6. Move the engine throttle to low idle position for approximatel
y 5 minutes to
allow the engine to cool down before turning the key switch to OFF.
7. Shut off the engine and remove the keys before leaving the truck
cab.
8. Install the operator's panel cover on the operator's console and
lock it.
9. Raise the folding operator's platform and fasten it.
10. Lock all lockable compartments.
11. USE proper flags, barriers and warning devices, especially when
parking in
areas of heavy traffic.
Maintenance Safety
In any work concerning the operation, conversion or adjustment of
the drill and its safety
oriented devices or any work related to maintenance, inspection
and repair, always observe
the startup and shutdown procedures set out in the operating instruc
tions and the information
on maintenance work.
All personnel involved in setting up drills or handling maintenance
and repairs must know and
practice proper procedures, including lockout and tagout practices.
1. Ensure that the maintenance area is adequately secured.
DRILLING SOLUTIONS
2-15
Section 2 - Safety
and repair work, it must

2. When the drill is completely shut down for maintenance
be secured against inadvertent starting by:
ignitio n key.
a.Locking the principal control elements and removing the
b.Attaching a warning sign to the main starter key switch.
the drill is positioned on stable
3. Carry out maintenance and repair work only if
movement.
and level ground and has been secured again inadvertent
st
to individual parts and to
4. Use Care when attaching and securing lifting tackle
to avoid the risk of
large assemblies being moved for replacement purposes
ion and with adequate lifting
accidents. Use lifting gear that is in perfect condit
capacity. Never work or stand under suspended loads.
ment when performing
5. Always Use the correct tools and workshop equip
maintenance to the drill.
safety oriented ladders and
6. Always Use specially designed or otherwise
working platforms when doing overhead assem bly work. Never use drill parts
as a climbing aid and never climb the derrick.
and ladders free from
7. Keep all handles, steps, handrails, platforms, landings
mud, dirt, snow and ice.
, of any traces of oil,
8. Clean the drill, especially connections and threaded unions
out maint enanc e or repair. Never use
fuel or preservatives before carrying
aggressive detergents. Use lint free cleaning rags.
pressure cleaning) or
9. Before cleaning the drill with water, steam jet (high
detergents, Cover or Tape up all openings which , for safety and functional
or deterg ent penetration.
reasons, must be protected against water, steam
onents.
Special care must be taken with electric motors and comp
rs do not come into
10. Ensure during cleaning of the drill that temperature senso
contact with hot cleaning agents.
cleaning the drill.
11. Remove all covers and tapes applied for that purpose after
fluid lines for
12. After cleaning the drill, Examine all fuel, lubricant and hydraulic
ir or Replace
leaks, loose connections, chafe marks and damage. Repa
defective parts immediately.
been loosened
13. Always Tighten any and all screwed connections that have
during maintenance and repair.
enance or repair
14. Any safety devices that were removed for setup, maint
completion of the
purposes must be refitted and checked immediately upon
maintenance and repair work.
of safely and
15. Ensure that all the consumable and replaced parts are disposed
with minimum environmental impact.
ining the drill with
16. Avoid, whenever possible, the servicing, cleaning or exam
the engine running.
DRILLING SOLUTIONS
2-16
Section 2 - Safety
17. Avoid whenever possible; servicing or providing maintenance to

the drill
unless the wheels are adequately chocked and the parking brake is applied.
18. Do Not alter the engine governor settings from those indicated in the engine
manual and the engine option plate.
19. Always replace damaged or lost decals. Refer to the parts manual for proper
location and part number for all decals.
20. Use only original circuit breakers with the specified current rating. Shut down
the drill immediately if trouble occurs in the electrical system.
21. Work on the electrical system or on electrical equipment may only be carried
out by a skilled electrician or by specially instructed personnel under the direct
supervision and control of an electrician and in accordance with the applicable
electrical engineering.
22. If provided for in the regulations, power supply to parts of the drill on which
inspection, maintenance and repair work is to be carried out, must be cut off.
23. Before starting any work, check the de-energized parts for the presence of
power and ground or short circuit them in addition to insulating adjacent live
parts and elements.
24. The electrical equipment of the drill is to be inspected and checked at regular
intervals. Defects such as loose connections or scorched cables must be
rectified immediately.
25. Welding, flame cutting and grinding work on the drill should only be done if
expressly authorized, as there may be a risk of explosion and fire.
26. Winches and ropes must be inspected frequently for unforeseen wear patterns
and discarded according to certain criteria (refer to ISO 4305).
27. Before beginning welding, flame cutting and grinding operations, clean the drill
and surrounding area from dust and other flammable substances and make
sure that the premises are adequately ventilated (risk of explosion).
28. Check all lines, hoses and screwed connections regularly for any leaks and for
obvious damage. Repair damage immediately. Splashed oil may cause injury
and fire.
29. Depressurize all system sections and pressure pipes (hydraulic, compressed
air) that are to be removed in accordance with the specific instructions before
carrying out any repair work.
30. Hydraulic lines must be laid and fitted properly and correctly. Ensure that there
are no connections that are interchanged. The fittings, lengths and quality of
the hoses must comply with the technical requirements.
31. Observe all of the product related safety regulations when handling oil, grease
and other chemical substances.
32. Be careful when handling hot consumables (risk of burning or scalding).
DRILLING SOLUTIONS
2-17
Section 2 - Safety
Fueling
an open flame or
1. Never fill the fuel tank with the engine running, while near
while smoking. Always wipe up any spilled fuel.
2. Do not spill fuel on hot surfaces.

3. Refuel in a well ventilated area.
ng devices
4. Keep open lights, lighted smoking materials, flames or spark produci
at a safe distance when refueling.
to prevent
5. Keep fuel nozzle in contact with tank being filled, or provide a ground
static sparks from igniting fuel.
6. Turn off cab and fuel heaters.
7. Never mix any other fuel with diesel oil. An explosion can occur.
Batteries
or when
1. Disconnect battery cables when working on the electrical system
welding on the drill.
it be
2. Be Sure the battery area is well ventilated (clear of fumes) should
necessary to connect a jump battery or battery charger. Fumes from the battery
can ignite by a spark and explode.
battery
3. Be Sure battery charger is "OFF" when making the connections if
charging is required.
4. Always wear safety glasses when servicing batteries.
5. Connect the ground cable last when installing a battery.
d
6. Battery acid will burn skin, eat holes in clothing and cause blindness if splashe
into the eyes.
7. Batteries generate a highly explosive mixture. A spark could ignite these gases.
8. Do not short across batteries. The spark could ignite the gases.
9. Keep battery covers in place at all times. Be sure there is no connection
between the battery terminals and the cover.
Wire Rope & Cable

,
1. Winches and ropes must be inspected frequently for unforeseen wear patterns
and discarded according to certain criteria (refer ISO 4305).
2. Wire rope running over drums and through sheaves creates pinch points. Do
not use hands or bars to guide wire rope onto drums; instead, use rope guides.
Keep clothing and all parts of the body away from running rope and from
machinery that moves the rope.
DRILLING SOLUTIONS
2-18
Section 2 - Safety
3. Replace wire rope when it is worn to the following:
a. Six (6) randomly distributed broken wires are found in one lay.
b. Wear of one-third (1/3) of the original diameter of the outside wires.
c. Evidence of any heat damage from any cause.
d. Any kinking or cracking occurs.
4. Make sure all hooks are connected properly.
a. Saddle and nuts must be around lifting side of the cable.

b. Always use a thimble when installing a hook.
c. Always use the correct number of clamps for cable size.
d. All hooks must have lock type dogs to prevent cable from jumping out
of the
hook throat.
5. Do not allow cable to backlash on hoist or drum.
a. Make sure the cable spools properly on hoist or drum.

b. Do not overload the hoist or wire rope.
Hot Oil and Components
The normal operating temperature of hydraulic oil is hot enough to cause

serious burns. Use
precautions when working on any hot fluid lines or changing filters.
WARNING
Hot oil or components can burn. Avoid contact with hot oil
or
components.
Do not allow used oil to drain into the ground. Dispose of used
oil
properly and in accordance with local guidelines.
Cylinder Repairs or Replacement
1. When repairing cylinders. be sure to block them up to prevent dropping or

rolling off the drill.
2. After repairing or replacing cylinders, especially the feed or derrick raising
cylinders, purge all air out of each end of the cylinder before connecting it to
the
drill. Air in one end can cause the derrick or rotary head to fall and cause
an
accident.
3. Loosen feed cables or chains before trying to remove feed cylinders.
DRILLING SOLUTIONS
2-19
Section 2 - Safety
the cylinders to prevent oil

4. Plug all hoses as soon as they are removed from
spills and slippery conditions.
5. Use a hoist to lift the larger cylinders.
Pumps and Motors

and motors.
1. Make sure hoses are plugged when replacing pumps
size and type.
2. Always replace pumps and motors with the same
s.
3. Use the correct adapters when installing pumps or motor
Valves
nt contamination from
1. When working on valves, keep area clean to preve
getting inside the valves.
one removed. Motor
2. Be sure the valve being installed is the same type as the
accident or a failure
and cylinder spools are interchangeable and may cause an
of a component if used incorrectly.
Hoses
capacity. Breakage or
1. Do not replace a hose with one of lesser strength or
leakage could result.
nt before it can be
2. Do not use a "will fit" hose as it may fail and cause an accide
replaced by the correct type.
Coolers and Fans

locked out.
1. Never remove the fan guard unless the drill is shut down and
2. When testing fan speed, do so with the guard in place.
the drill and lockout
3. Do not try to remove debris from inside the fan guard. Stop
the key switch before removing.
rs. Spray can injure
4. Be careful while washing out coolers with pressure washe
eyes.
and moving coolers
5. Coolers are heavy. Obtain a suitable hoist capable of lifting
and/or radiators before replacing.
Guards
service, always replace
1. If any guards must be removed from the drill to perform
them before the drill is started.
DRILLING SOLUTIONS
2-20
2. If a guard becomes damaged or lost, replace or repair it before starting drill.

3. Do not cut out or modify a guard. It was designed to protect people from getting
injured.
Lubrication
1. Never attempt to lubricate the drill while it is running, unless the drill is fitted with
an automatic lube injection system. Stop the drill for all maintenance.
2. To lubricate fittings on the derrick, lay the derrick down and use a manlift to
access hard to reach and inaccessible places. Do Not climb the derrick for Any
reason.
3. To lubricate drive lines, reach through the guards. Do not remove them.
NOTE: If a lube point will not take grease, report it immediately. A bearing
can get hot and cause a fire if not lubricated properly.
Cornpressor
ARNIN%
The normal operating temperature of compressor oil is hot enough to
cause serious burns. Use precautions when working on any hot fluid
lines or changing filters.
Do not attempt to remove any plugs or open the drain valve before
making sure all air pressure has been relieved from the system.
1. Relieve all pressure in the receiver tank and lines before working on the
compressor system.
2. Do not allow tools or air powered equipment to be connected to the drill hoses.
They must be attached to the service regulator and the pressure adjusted to
the working capacity of the tool being used.
3. Do not remove any regulation or control hoses while the drill is running or
pressure is still in the system. High pressure air can cause serious injuries.
4. Be careful when using service air to clean off the working area. High pressure
air can be dangerous.
5. Turn off drill air and exhaust the drill string before unscrewing drill pipe at the
table.
6. Do not turn on high pressure air too quickly when the air hoses are in the vicinity
of people. Hoses can jump and injure people, especially if there is water or oil
inside the hose.

Warning of Special Dangers
Overhead Electric Wires
When working with the drill, maintain a safe distance from overhead electric lines. If work is to
be carried out close to overhead electric lines, the working equipment must be kept well away
from them. CAUTION! DANGER! Check out the prescribed safety distances.
A DANGER
If your drill comes into contact with a live wire,
1. DO NOT step off the operator's platform. DO NOT leave the drill.
2. If the driver is in the truck cab, drive the drill out of the hazard zone.
3. Warn others against approaching and touching the drill.
4. Have the live wire de-energized.
5. DO NOT leave the drill until the damaged line has been safely de-
energized.
Ventilation
A DANGER
Operate internal combustion engines and fuel operated heating systems
only in adequately ventilated premises. Before starting the drill in
enclosed premises, make sure that there is sufficient ventilation.
Grade Limitations
A DANGER
Exceeding the slope or grade limitations of the drill and its configuration
can cause the drill to tip over. Prior to moving the drill into position,
always determine the safe operating grade of the drill with the derrick up
and down. Do not move the drill with the derrick up.

2.3 - SAFETY DECALS & NAMEPLATES
Pre -Operation
Before you operate, maintain, work around or in any other way use this drill, read and
understand the safety decals and safety labels located on the drill. Follow all directions on the
labels. Do not remove or deface the labels. Replace them if they become damaged or lost.
Table 1: Safety Decals List
Ref. Safety Decal Qty. Location
1 Caution: Excessive Oil 1 On Side of Hydraulic Reservoir
2 Warning: Falling Drill Pipe 1 Next to Sliding Breakout Wrench

2 On each Side of Hydraulic Tank
3 Warning: Rotating Fan Blade 2 Cooler Housing
4 Warning: High Pressure 1 Top of Cooler Housing

5 Warning: Hot Pressurized Fluid 1 Cooler Housing
6 Warning: High Pressure 1 Receiver Tank

7 Warning: High Pressure Air 1 Receiver Tank
8 Warning: Combustible Gas 2 Truck & Deck Engine Battery Boxes
9 Warning: Falling Derrick 2 Bottom of Derrick Raising Cylinders
10 Warning: Powerhead 1 Face of Rotary Head
11 Warning: Rotating Shaft 1 Engine Assembly Coupling Guard

12 Warning: Rotating Parts 1 Engine Assembly Coupling Guard
13 Danger: Hazardous Voltage 1 Operator's Control Console
14 Warning: Do Not Modify or Alter 1 Operator's Control Console
15 Warning: Falling Rotary Head 1 Bottom of Feed Cylinder
16 Notice: Hydraulic Failure 1 Top of Hydraulic Tank
17 Warning: No Climbing 2 Both Sides of Derrick
18 Notice: Starting Cold Engine 1 On Tower Rest
19 Decal: Drain Water Daily 1 Receiver Tank
20 Laminated Safety Manual 1 Side of Operator's Console
21 Notice: Avoid Electrical Damage 2 Truck & Deck Engine Battery Boxes

Safety Decals
1. CAUTION DECAL: Excessive hydraulic oil. Can rupture hydraulic tank
and cause injury or property damage.
a. Do not fill hydraulic tank with cylinders extended. Retract all cylinders and
fill tank to indicated level.
A CAUTION
Excessive hydraulic oil.

Can rupture hydraulic
tank and cause injury
or property damage.
C}cr not fiti hydraulic tank
vnth cylinders extended
Retract at cylinders and
till Kink to ,nclicated level
HYDRAULIC TANK
57140477
b. Quantity of one (1) located on side of hydraulic reservoir.

2. WARNING DECAL: Falling Drill Pipe. Can cause severe injury.
a. Securely tighten hoist plug before lifting drill pipe.
b. Quantity of three (3). One located each side of the hydraulic reservoir and
one located next to sliding breakout wrench.

• Section 2 - Safety
3. WARNING DECAL: Rotating Fan Blade. Can cause severe injury.
a. Do not operate with guard removed.

Rotating fan blade.

Can cause severe
injury.
57140469
COOLER ASSY
b. Quantity of two (2) located on cooler housing.

4. WARNING DECAL: Engine Failure. Operation with partially filled cooling
system can damage engine.
a. Refill engine radiator immediately after initial fill up and engine warm up.
tasking
Oporation -An pa rim*, NNW

*yowl can asonalo .34-.4 C.
ÀtilitV1 nod:4i%
•t and cr,rx• warn.c
• 57140444
b. Quantity of one (1) located on cooler housing.

5. WARNING DECAL: Hot pressurized fluid. Can cause severe burns.
a. Do not open radiator when hot.
57140402
b. Quantity of One (1) located on cooler housing.

6. WARNING DECAL: High Pressure. Can cause severe injury or death.
a. Completely relieve pressure before removing filler plug, fittings or receiver

cover.
• 4110.0- • • .11104.11.0100 004... • •
COM
t***41114•f M•.f .4 .1144110•011111
67140352
b. Quantity of one (1) located on receiver tank.

7. WARNING DECAL: High pressure air. Can cause severe injury or death.
a. Reduce regulator pressure to meet service requirements.
b. Quantity of one (1) located on receiver tank.

8. WARNING DECAL: Combustible gas. Can cause severe burns, blindness
or death.
a. Keep sparks and open flame away from batteries.
Combustible gas.
Can cause severe
burns, blindness
or death.
Keep sparks and open
flame away from
batteries
BATTERY BOX ON RIG

57140394
b. Quantity of two (2). One on deck battery box and one on truck battery box.

9. WARNING DECAL: Falling Derrick. Can cause severe injury or death.
a. Purge air from circuit after servicing derrick raising cylinders.
idNng derrick.
Can cause severe
iniury or death.
Puri's •r from emir
ales serecin9 demos
Mee* M1 ridelte)
57140360
b. Quantity of two (2) located at the bottom of each derrick raising cylinder.
10. WARNING DECAL: Falling or crushing hazard. Severe injury or death can
occur from falling from derrick or be crushed between rotary head and
derrick.
a. Do not ride rotary head or climb derrick. Lower derrick to service.
Falling or crushing
hazard. Sever Injury
or death can occur
from falling from
derrick or be crushed
between rotary head
and derrick.
Do not ride rotary
head or climb derrick
LOVA' derrick to
ROTARY HEAD samba
fl1.011,
57155517
b. Quantity of one (1) located on face of rotary head.

11. WARNING DECAL: Rotating shaft. Can cause severe injury or death.
ENGINE ASSYICOUPLING GUARD

57140337
b. Quantity of one (1) per plate.

12. WARNING DECAL: Rotating parts. Can cause severe injury.
Rotating parts.
Can cause severe
injury.
Do rot coerate with
guard removed
ENGINE ASSY/COUPLING GUARD

57140345
b. Quantity of one (1) per plate.

13. DANGER DECAL: Hazardous Voltage will cause severe injury or death.
a. Do not raise, lower or drive derrick into power lines.

b. This Safety label is part of console decal #57406340 but is available
separately.
14. WARNING DECAL: Modification or alteration of this machine. Can result
in severe injury or death.
a. Do not alter or modify this machine without the express written consent of
the manufacturer.
Improper operation of this equipment. Can cause severe injury or death.
a. Read operator's manual supplied with this equipment before operation or

servicing.
b. This Warning label is part of console decal #57406340 but is available
separately.
Modification or anersoon kraploper opataf,on of

or thus mocha* Ulf* equIpment
Can mutt In seven Con cause savor*
injury or dean. Injury Of death
Do not ono or moray thus Rood Opitaloea manual
fractal* withcat the supplied web Oils
ea atoms written Consent Of equernere before
too rnaufacturar operate or sem:ft
•••••••• Mao a
57310831
000 oCv
O 3
c
c> 57348112
-:AFEr." APE FART OF SCN3CLE
CONSOLE

•
15. WARNING DECAL: Falling rotary head. Can cause severe injury or death.
a. Purge air from circuit after servicing feed cylinder(s).
Falling rotary head.

Can cause severe
injury or death.
Purge air from circuit

after servicing feed
cylinder(s).
57140329
FEED CYLINDER
b. Quantity of one (1) located on bottom of feed cylinder.

16. NOTICE DECAL: USING A NON-APPROVED HYDRAULIC OIL CAN
CAUSE HYDRAULIC COMPONENT FAILURE.
a. THIS HYDRAULIC SYSTEM USES AN ISO-32 ANTI-WEAR HYDRAULIC

OIL. ANY OIL USED IN THIS SYSTEM MUST BE INCLUDED ON THE
DRILLING SOLUTIONS APPROVED OILS LIST, NO. RD-3-005. USE OF
ANY OTHER OIL WILL VOID THE WARRANTY OF HYDRAULIC
COMPONENTS.
NOTICE
ulaigt A NON.APPROVIDNIZRAULC
CA. CAN CAUSE ETOIRAULIE
couroAcNT IALUSE.
14S UnStALA.0 SYSTEM USES AN
ECI,V ANTI-WEAR HYDRAJI.JC OIL
WY OZ. .SED IN THIS SYSTEM MUST
BE emcksjoED OA TIE coeRsou.4aukNo
APPROAO 0415 LIST Va RO-3436
USE Or MY On 1ER C'4. *IL VDO
rw. WARRANTY OF KYOSAJU: SYSTEM
CCUPONEMTS
• 57156465
b. Quantity of one (1) located on top of the hydraulic reservoir.

17. WARNING DECAL: Climbing raised derrick. Can cause severe injury or
death.
a. Do not climb raised derrick. Lower derrick completely to service.
Climbing raised derrick.

Can cause severe
injury or death.
Do not dimb raised
derrick.
Lower derrick completely
to service.
73180-10
DERRICK
b. Quantity of two (2). One (1) per each side of derrick.

18. NOTICE DECAL: Starting cold deck engine at 32°F/0°C or below.
a. Compressor air inlet valve must be closed by pulling and locking the handle
located on top of the right front leveling jack.
b. As soon as engine speed reaches 1200 rpm, unlock and release the
handle. The air inlet valve must be opened as quickly as possible to prevent
oil pump cavitation and loss of airend lubrication.
NOTICE
Mg deck impale a 32 deg F/0 deg C or below
Compressor as meet valve must be closed by

puffing and locking the handle located on the
top Of the tot grant leveling rack
As soon as soiwas sow males 1200 rpm.

unlock and release the handle. The air inlet
valve must be opened as (ruddy as possible
to prevent oil pump cavitation and loss of
airend lubricator,
c. Quantity of One (1) located on tower rest.

19. DECAL: DRAIN WATER DAILY FROM RECEIVER-SEPARATOR TANK.
DRAIN WATER DAILY FROM RECEIVER-SEPARATOR TANK
a. Quantity of one (1) located on receiver tank.

20. LAMINATED SAFETY MANUAL
safety VanJa
a. Quantity of one (1) located on side of operator's console.

21. NOTICE DECAL: To avoid damage to the rig's electronic components,
disconnect both battery positive (+) and negative (-) cables prior to welding.
Attach the welding ground cable as close as possible to the part being welded.
If necessary to weld close to an electronic component, it is recommended that
the electronic component be temporarily removed.
NOTICE
To avoid damage to the rig's electronic
components, disconnect both battery positive
(+) and negative (-) cables prior to welding.
Attach the welding ground cable as close as
possible to the part being welded. If
necessary to weld close to an electronic
component, it is recommended that the
electronic component be temporarily
removed.
a. Quantity of two (2). Locate one each on the truck battery box and the deck
engine battery box.

2.4 - HAZARDOUS SUBSTANCE PRECAUTION
General Information
The following information is provided to assist the owners and operators of Atlas Copco Drilling
Solutions Equipment. Further information may be obtained by contacting your Atlas Copco
Drilling Solutions Equipment Distributor.
The following substances are used in the manufacturing of this machine and may be
hazardous to health if used incorrectly.
Table 2: Hazardous Substance Precaution
Substance Precaution
Anti-Freeze Avoid ingestion, skin contact and breathing fumes
Hydraulic Oil Avoid ingestion, skin contact and breathing fumes
Engine Lubricating Oil Avoid ingestion, skin contact and breathing fumes
Compressor Oil Avoid ingestion, skin contact and breathing fumes
Preservative Grease Avoid ingestion, skin contact and breathing fumes
Rust Preventative Avoid ingestion, skin contact and breathing fumes
Engine Fuel Avoid ingestion, skin contact and breathing fumes
Battery Avoid ingestion, skin contact and breathing fumes
SAE Gear Oil Avoid ingestion, skin contact and breathing fumes
The following substances may be produced during the operation of this machine and may be
hazardous to health.
Table 3: Hazardous Substance Precaution
Engine Exhaust Fumes Avoid breathing fumes
Engine Exhaust Fumes Avoid buildup of fumes in confined spaces
Electric Motor Dust Avoid breathing in dust during maintenance

(Brushes/Insulation)
Brake Lining Dust Avoid breathing in dust during maintenance

• Section 2 - Safety
2.5 - SYMBOL IDENTIFICATION

The following drill symbol information is provided to assist the owners and operators of Atlas
Copco Drilling Solutions Equipment. Further information may be obtained by contacting your
Atlas Copco Drilling Solutions Equipment Distributor.
Caution Read Inspect/Test/Check On/Start

Operator's
Manual
A
wi 4 I
Off/Stop On Off Battery Plus/Positive
Condition
— +
0
• Minus/Negative
ammummo kY4
Horn Hourmeter
11
Seat (Lap) Belt
AN
Volume Empty Volume Volume Full Circuit

Half— Full Breaker(s)
IC) e
CiiIii? l
Work Light Primer Gas Inject

Tram (Propel) (Start Aid) (Cold Start)
Light
....
goo'
.....D I kJ_ .
;IQ
/ ar/ / 1
I
• DRILLING SOLUTIONS 2-35

Section 2 - Safety
Engine Start
Engine Electric Engine Bypass Start Switch
Preheat (Crank Engine)
0 fil
6:b
Engine Engine Oil Engine Oil

Engine On/Run Rotations (RPM) Level
n min
0 0
Engine Oil Engine Oil Engine Oil

Engine Oil
Pressure— Temperature Filter
Pressure
Failure
0 0
....
4 0 I.
Engine Air Engine Engine Coolant
Filter Coolant Coolant Level Temperature
Engine STOP and Engine Fault

Emergency Engine Datalink Warning
Electrics ON/OFF
Engine Stop Test Point (Diagnostic)
1 - CP Q cus,
STOP /3
+

Increase/Decrease Incremental
Adjustment Filling — Fuel (Diesel)
Increase/Decrease
Emptying
+ ■
r,3,..1 E-j
4.•
$
D
Fuel Level Fuel Filter Hydraulic Oil Hydraulic Oil
Level
.11=
i.
b ...... 6 t> 0
Hydraulic Oil Hydraulic Oil Hydraulic Oil Main Pump
Pressure Temperature Filter Supercharge
Hydraulic Pressure
-L ..L .1..
c) O a
4i 6
1- - - 1
T .16_ii,,
Drill Rotation Drill Pulldown Drill Pullback
Hydraulic Hydraulic Hydraulic Pressure
Pressure Pressure Drill Feed
S'CP
40, -L
Speed/Direction
A
1
46 6 I UP/STOP/DOWN
Drill Feed Drill Feed

(aD Pulldown Force Pullback Force Main Pump
Drill Feed
STCP
A Speed/Direction MP
130 CW/STOP/CCW
43'

Control Lever- Clockwise Counter

Dual Direction Clockwise Drill Mode
Rotation
Rotation
4
0
II
4° 0
Carousel - Rotate Carousel - Rotate

Drill Rotation Drill Rotation Clockwise
ise
(Clockwise) (Counter Clockwise) Counterclockw
--"
Itri
• • • 0
Rod Changer- Rod Changer-

Rod Changer Swing into Load Swing into Stowed
Rod Indexer Swing
_p Position Position
4-- E-- -*
0 • • •
• •• 0 * ilto
Nk__...-/ •
____... --io 10 io 7
.
To Lower Leveling To Raise Leveling

Jack or Leveling Jack Jack Jack
Support Point t 1 t
ia
ifk
0
t 17.7. I
I
Oil Lubrication Lift Point t

i
Grease Point Point Angle
Drill
"‘.......>t
'CI 1 Rod
Support
IP I

Tower Locking Tower Locking

Extend it i
t/ Pin Engaged Pin Disengaged
Hydraulic Retract
Cylinder Hydraulic
Cylinder
010 •
Tower Locking
Pin Disengaged Tower Raise/Lower Lower Derrick Raise Derrick
Warning Light >
Ad O *
dr _IN
li t
.
1i,
Pneumatic Compressor Intake Compressor Intake

Compressed
Energy Air Pressure Closed (Cold Start Open (Run Position)
Position)
*
@ (0 0
I Drilling Air Drill Air Tie—Down

(..., Drill Air Flow Pressure Throttle Valve Points
Adjustment
IIIIV
IIII
(Zero to
Maximum) gi:t€42
0 i_.i
I,
5!
Air Lubrication
(Air Flushing with Oil) Transverse Longitudinal Linear
4 Angle Angle Increase

Rotational Parking Brake Brake On Brake Off

Increase
P
Winch Lower Winch Raise
(Spool Out) (Spool In) Breakout Wrench Breakout Wrench
Disengage Engage
1111111 MC
--> IC
T I \l/
t•%
ir Pipe Water Injection Fluid Flushing
Dust Collector (Water (Injection)
kto Wrench
Chain ___0.
if Wrench r/
J--1
-.,!„.„. 4 #tt /I\
Rear Window Front Window

Wiper
4 II
Lubrication
Oil
Injection
Wiper
H H
Heat ON
i 14o
/1\ • Indicator (c) L V L
Light 111 : 1 -331-
1:1
0 0

•
Section 3 - Specifications
DRILLING SOLUTIONS 31
T3W Instruction Manual Section 3 - Specifications
SPECIFICATIONS
General Description
The Atlas Copco T3W Waterwell Drill is a truck mounted, hydraulic rotary head drive, deck
engine powered drill, designed primarily for waterwell applications using air or mud drilling
techniques. An opening up to 20 in. diameter / 508 mm (depending on carousel option), is
clear all the way up the derrick.
Due to the design of the drill, the T3W can be mounted on several different truck frames.The
standard carrier used on a 30K/40K T3W water well drill is an International Navistar Model
7600, 6X4 truck powered by a Caterpillar C13 diesel engine. The standard carrier used on a
55K/70K T3W water well drill is an International Paystar Model 5600, 6X4 truck powered by a
Caterpillar C13 diesel engine.
The T3W is equipped with a high pressure asymmetrical over/under compressor, available in
two sizes (900/350 and 1070/350), for high performance downhole (DHD) drilling.
The T3W incorporates four (4) frame mounted leveling jacks to keep the drill level and stable
while drilling. The derrick is constructed of welded steel tubing. The mid jacks behind the truck
cab provide optimum stability and more balanced drill and truck frame load distribution. The
derrick is raised and lowered by two hydraulic cylinders.
The drill pipe carousel is contained in the derrick in a fixed position and indexed in both
directions from the console by the hydraulic motor. The carousel holds nine (9) 3.5" x 20'
(89mm x 6.1m) drill pipe or seven (7) 4.5" x 20' (114mm x 6.1 m) drill pipe. The rear half of the
drilling table retracts hydraulically while the front half swings away from either side of the table
and provides a large 20 inch (508 mm) opening to accommodate large casing and tools
The T3W rotary head can be retracted and positioned over either the center of the hole or the
internal carousel. Retracting the head allows drill pipe to be loaded out of the carousel and
allows casing to be handled more easily inside the derrick.
In conjunction with the retractable rotary head, a 12,000 lb. (5443 kg) standard drawworks is
available for 30K/40K drills and an 18,000 lb. (8,165 kg) standard drawworks is available for
55K/70K drills. The jib boom swings and extends to position drill pipe, tools and casing directly
over the hole, reducing the amount of labor required.
Drill pipe changing is done by moving drill pipe in and out of the carousel and rotary head. The
rotary head is used to move all drill pipe in and out of the hole. All drilling functions are
controlled from the operator's console adjacent to the drill table. The operating controls and
gauges are positioned within easy reach of the operator.
Built to last, the structural components and integrity of the T3W separate this drilling rig from
all of its competitors. This truck mounted, tophead drive drill for water well applications
provides a pullback force of up to 30,000 Ibf. (122.45 kN), 40,000 Ibf. (177.93kN), 55,000 Ibf
(244.65 kN), or 70,000 (311.38 kN) depending on the drill configuration.
The standard spur gear drive tophead provides 5,500 ft-lb. (7,458 Nm) of torque @ 145 RPM
single speed rotary.

Section 3 - Specifications T3W Instruction Manual
The T3W Waterwell drills are built in accordance with state of the art standards and recognized
safety rules. Nevertheless, their misuse may constitute a risk to the life and limb of the user or
third parties and may cause damage to the drills or other material property.
The T3W Waterwell drill must be used in accordance with its designated use as described in
the operating section of this manual (See Section 5). The T3W Waterwell drill must only be
operated by safety conscious persons who are fully aware of the risks involved in operating
the drill. Any functional disorders, especially those affecting the safety of the drill, must be
corrected immediately.
Designated Applications
The T3W Waterwell drills are truck powered, hydraulic tophead drive, multi-pass rotary drills
specifically designed for drilling water wells using either rotary, mud drilling techniques or
downhole drilling methods using a high pressure compressor on prepared (if necessary)
ground that is flat and firm. The carousel holds seven (7) pieces of 4.5 in. (11.4 cm.) O.D. x 20
ft. (6.1 m) long drill pipe or nine (9) pieces of 3.5 in. (89mm) O.D. x 20 ft (6.1m) long drill pipe.
The table opening is hinged to swing out to provide an opening up to 20 inches (508 mm),
depending on carousel option, for large casing and tools.
Non Designated Applications
The T3W Waterwell drills are not designed for pioneering/earth moving applications. The T3W
Waterwell drills are not designed for use on inclined surfaces or on soft and unstable ground.
Use of the T3W for purposes other than that mentioned (such as for towing other vehicles or
equipment) is considered contrary to its designated use. The manufacturer/supplier cannot be
held liable for any damage resulting from such use. The risk of such misuse lies entirely with
the user.
,A WARNING
Set up the T3W Waterwell Drill on a level surface. If this is not available,
the site and the way to the site should be adequately prepared prior to
drill setup.
Operating the drill within the limits of its designated use also involves compliance with the
inspection and maintenance directives contained in the instruction manual.
Operational Limitations
Ambient Temperature Range:
The drills come equipped for an ambient temperature working range between limits of 125°F
(52°C) maximum and 15°F (-9°C)° minimum.

Operating Conditions For Stability
Stability is affected by the derrick position and orientation of the drill, surface stability (bearing
strength), and wind conditions.
WARNING'S
Set up the T3W Waterwell drill on a level surface. If this is not available,
prepare the site and the way to the site before set up and drilling with the
T3W.
Do not move or transport the T3W Waterwell drill with the derrick in the
raised (up) position.
Travel at a safe speed relevant to surrounding conditions.
Contact your local Drilling Solutions distributor, dealer or service office for further information.
Standard Equipment
1. Retractable Table
2. Top and bottom air actuated breakout wrenches
3. Hydraulic draw works for drill pipe and accessory handling
4. Lockable Steel Tool Cabinet
5. Cooling package rated to 125°F (52°C) ambient temperature
6. Carousel for Seven 4.5" (114 mm) x 20 ft. (6.1 m) or Nine 3.5" (89 mm) x 20 ft
(6.1 m) Pipe
7. Drill Pipe Rack for (24) 3.5 in. (89mm) or (15) 4.5 in. (114mm) drill pipe
8. Hydraulic Powered Pipe Wrench
9. Four Leveling Jacks provide optimum stability
10. Backup alarm
NOTE: Specifications represented are calculated values at 100%

efficiency.

• Section 3 - Specifications
A DANGER
Your life may be endangered if the following is not complied with. DO

NOT add attachments to the drill that intrude into operator's protective
area, reduce visibility, restrict emergency exits or add weight exceeding
certification weight. See the operator's manual or contact your dealer for
complete inspection requirements and maintenance instructions.
Specifications
General Information
The T3W is a hydraulic tophead drive drill for waterwell applications using either rotary or down
hole hammer drilling as well as mud drilling methods. The rear half of the drilling table retracts
hydraulically while the front half swings away from either side of the table to provide a clear
•
working space for large casing and tools. An opening up to 20 inches (508 mm), depending
on carousel option, is clear all the way up the derrick.
Carrier
The standard current production 30K/40K T3W Waterwell drill is mounted on a Navistar 7600,
6X4, powered by a CAT C13 ACERT diesel engine. You must look at your carrier manuals,
located in the driver's door storage pocket on the drill, to determine the exact configuration of
your carrier.
Table 1: Navistar Truck Specifications
Model 7600 Standard 6X4 Truck Chassis
Model Description: Navistar Model 7600

Gross Vehicle Weight Rating: 66,000 lbs. (29,937.6 kg)
Wheelbase: 232 inches (589.2 cm); Cab to Axle 164.9 inches
(418.8 cm); Axle to Frame 59 inches 149.8 cm)
254 inches (645 cm); Cab to Axle 186.9 inches
(474.7 cm; Axle to Frame 59 inches (149.8 cm)
Diesel Engine: Caterpillar C13 ACERT, 50 state, 380 HP (283 kW)
@ 2100 RPM, 1450 lb/ft torque @ 1200 RPM, 2100
•
RPM governed speed; 395 peak HP (max) and with
electronic controls and ADEM A4E4 ECM.
Manual Transmission: Fuller FRO-14210C, 10 speed manual, with
overdrive, with air shift.

Model 7600 Standard 6X4 Truck Chassis
Clutch: Eaton Fuller EP15521 Easy Pedal Plus, two plate,

cast angle spring; ceramic, 15.5" diameter, soft clutch
7-spring damper, mechanical pull-type control, with
Kwik-Adjust (manual) feature,1700 lb/ft torque
capacity.
Axle, Front Non-Driving: Meritor MFS-20-133A Wide Track, I-Beam type,

20,000 lb. capacity.
Axle, Rear, Tandem: Meritor RT-46-164EH Single Reduction, Standard

Width, 46,000 lb. capacity, with Driver Controlled
Locking Differential in Forward Rear and Rear-Rear
Axle and 200 Wheel Ends Gear Ratio: 4.89.
Cab: Conventional
Front Tire: (2) 425/65R22.5 XZY-3 (Michelin) 465 Rev/Mile,

Load Range L, 20 Ply
Rear Tire: (8) 11R22.5 XDE M/S (Michelin) 498 Rev/Mile, Load
Range G, 14 Ply.
Suspension, Rear, Tandem: Hendrickson RT-463, Walking Beam Type 54" Axle
Spacing; 46,000 lb. capacity with bronze center
bushings.
Frame Reinforcement: Outer "C" channel, heat treated alloy steel (120,000
psi yield); 10.813" x 3.892" x 0.312"; (274.6 mm x
98.9 mm x 8.0 mm); 480.0" (12192 mm) maximum
OAL.
The standard current production 55K/70K T3W Waterwell drill is mounted on a Paystar5600i,
6X4, powered by a CAT C13 ACERT diesel engine. You must look at your carrier manuals,
located in the driver's door storage pocket on the drill, to determine the exact configuration of
your truck carrier.
Table 2: Paystar Truck Specification
Model 5600i 6X4 Truck Chassis
Model Description: Paystar Model 56001, 6X4
Gross Vehicle Weight Rating: 68,000 lbs. (30,844.28 kg)
Wheelbase: 254 inches (645 cm); Cab to Axle 192.0 inches

(487.68 cm); Axle to Frame 68 inches 172.72 cm).
Diesel Engine: Caterpillar C13 ACERT, 50 state, 380 HP @ 2100
RPM, 1450 lb/ft torque @ 1200 RPM, 2100 RPM
governed speed; 395 peak HP (max) and with
electronic controls and ADEM A4E4 ECM.


overdrive, with air shift.
capacity.
Axle, Front Non-Driving: International I-220S, I-Beam type, 22,000 lb. capacity
Axle, Rear, Tandem: Meritor RT-46-160) Single Reduction, 46,000 lb.
capacity, with Driver Controlled Main Locking
Differential in Rear-Rear Axle and 200 Wheel Ends
Gear Ratio: 4.89.
Cab: Conventional.
Load Range L, 20 Ply.
Range G, 14 Ply.
bushings.
psi yield); 12.934" x 3.687" x 0.312" x 415.5 OAL;
(328.5 mm x 93.6 mm x 7.9mm x 10553.7 mm) OAL.
Model Description: Paystar 5600i 6X6

Gross Vehicle Weight Rating: 6800 lbs. (30,844.28 kg.)
Wheelbase: 254 inches (645 cm); Cab to Axle 192.0 inches
(487.68 cm); Axle to Frame 68 inches 172.72 cm).
Diesel Engine: Caterpillar C15 Export, 435HP @ 2100 RPM, 1550
lb/ft torque @ 1200 RPM, 2100 RPM governed
speed; 450 peak HP (max).
overdrive, with air shift, with internal lube oil pump.


capacity.
Axle, Front Driving: Meritor MX-23-160, Single Reduction, 23,000 lbs.

capacity with S-Cam brakes and hub piloted wheel
mounting.
Axle, Rear, Tandem: Meritor RT-46-160, Single Reduction, 46,000 lb.

capacity, with Driver Controlled Main Locking
Differential in Rear-Rear Axle and 200 Wheel Ends
Gear Ratio: 5.38.
Cab: Conventional.

Load Range L, 20 Ply.
Range G, 14 Ply.
bushings.
psi yield); 12.934" x 3.687" x 0.312" x 415.5 OAL;
(328.5 mm x 93.6 mm x 7.9mm x 10553.7 mm) OAL.
Due to the design of the drill, it can be mounted on several different truck frames. You must
look at your carrier manuals, located in the driver's door storage pocket on the drill, to
determine the exact configuration of your truck carrier.
Table 3: Peterbilt Truck Specifications
Peterbuilt Model 365 Truck Specifications
Unit: Model & Type: Model 365, Full Truck
Type: Platform w/Devices
Length: 20 ft. (6.09 m)

Height: 12 ft. (3.65 m)
Max. Laden Weight: 5000 lbs. (2267.9 kg)

Chassis: Front Axle Load: 22000 lbs. (9979 kg)

Rear Axle Load: 46000 lbs. (20865 kg)
Gross Carrier Weight: 68000 lbs. (30844.28 kg)
Wheelbase: 254 in. (6456.6 mm)
Front Axle to BOC: 68.9 in. (1750 mm)
Cab to Axle: 185.1 in. (4701.54 mm)
Cab to EOF: 244.1 in. (6200.1 mm)
Frame & Equipment: 11-5/8" Steel Rails, Steel Xmbrs, To 444", 3/8" Rail
Thickness. 10-3/4" x 3/8" Full Steel Liner. Peterbilt Front
Wheel Mudflaps.
Front Axles & Equipment: Dana Spicer D2200F 20,000 to 22,000 lb., 3.5 inch drop.
Standard Track. Dana Spicer ES cam brakes, 11-1/4"
bolt circle.
Taper Leaf Springs with Shocks 23,000 lbs.
Power Steering TRW TAS85 Dual for use with 16,000
lbs. or greater front axles. Power Steering Reservoir
Cowl Mounted for use with 18,000 to 20,000 lb. front
axles.
PHP10 Iron Hubs, Cast Drums, 16.5 x 6 Cam Brakes.
20,000 to 22,000 lb. front axles. Includes Dana Spicer
EES1200/410 brake linings, non-asbestos.
Standard Oil Seals
Haldex/Dana Auto Slack Adjusters.

Rear Axle & Equipment: Dana Spicer D46-170HP 46,000 lb.

PHP10 Alum LMS Hubs, Cast Drums, 16.5 x 7 Brakes.
46,000 lb. maximum, tandem axle, Dana Spicer ES
brakes.
MGM TR-T 3030 in. Parking Brakes, Both Axles.
Haldex/Dana Auto Slack Adjusters, Tandem Axles.
Chicago Rawhide Scotseal Plus XL Oil Seals, Tandem.
Brake Dust Shields, Tandem Axles.
Dana Spicer Full Lock Diff Lock, Both Axles (46,000 to
60,000 lbs for use with D46-170 (P/H), D52-190P, D60-
190P, DS4636.
Bendix 4S4M ABS, SBM Valve, ABS-6. Synthetic Axle
Lubricant, All Axles. Ratio, 4.78 Rear Axle. Hendrickson
RT-463 46,000 lb., 54 in. Axle Spacing. 6 inch saddle
height. RT463-503.
Engine and Engine CAT C13, 350/2100, 420 @1600, 1550 @1200 (2007)
Equipment:
PACCAR 130 amp alternator, brushless with voltage
regulator. Immersion type pre-heater 110-120V Phillips.
PACCAR 12V Starter.
(3) Optima DT31T Batteries, 2700 CCA Threaded stud
type terminal. AGM (Absorbent Glass Material).
CAT Compression Brake. 16.1 Compressor.
Spin-On Fuel Filter, frame mounted.
High Efficiency Cooling System.
(1) Donaldson air cleaner, firewall mounted.
Exhaust - Single RH side of cab. 36 inch ht., 7 inch dia.,
chrome plated stl standpipe.
Transmission and Clutch: Fuller FRO15210C 10 speed, includes iron bell housing,
external water-to-oil cooler and internal pump, direct shift
pattern and synthetic lubricant.
1810 HD Driveline with single midship bearing w/4.5 inch
x.180 wall tubing.
Eaton Fuller 15.5 inch Clutch, Ceramic 7-spring
dampened/3600# plate/1650 torque.
Manual Adjust Clutch with Grease Bearing.

Tires and Wheels: FF: BR 20 Ply 425/65R22.5 M844F.

RR: BR 14 Ply 11R22.5 M711.
Code-Rear Tire Qty 08.
FF: Alcoa 833640 PLT 22.5 x 13.00 Alm Whl, pilot mount
RR: Accur 28408 STL Inner/Alcoa 883640 Outer AIm
Whl, 22.5 x 8.25 pilot mount.
Code-Rear Rim Qty 08.
Fuel Tanks: 26 in. Aluminum 80 Gallon Fuel Tank LH U/C.
26 in. Aluminum 60 Gallon Fuel Tank LH BOC.
(1) Non-Slip Fuel Tank Step LH U/C.
Fuel Cooler.
Dual Top Draw, Dual Top Return without shut-off valves.
Bumper: Alum Bumper Swept Back Polished w/o FEPTO with
center tow hook and step plates on top of bumper.
Heavy Duty External Tow Eye.
Cab and Equipment: Refer to truck information located in driver's side door.
Unit: Model & Type: Model 367, Full Truck

Type: Flatbed
Length: 20 ft. (6.09 m)
Height: 13.5 ft. (4.11 m)
Max. Laden Weight: 40,000 lbs. (18,143.6 kg)
Chassis: Front Axle Load: 22,000 lbs. (9979 kg)
Rear Axle Load: 48,000 lbs. (21,790.58 kg)
Gross Carrier Weight: 50,040 lbs. (22697.76 kg)
Wheelbase: 262 in. (6654 8 mm)
Front Axle to BOC: 76.8 in. (1950.72 mm)
Cab to Axle: 185.2 in. (4704 mm)
Cab to EOF: 244.2 in. (6202.6 mm)

Frame & Equipment: 11-5/8" Steel Rails, Steel Xmbrs, To 444", 3/8" Rail
Thickness. 10-3/4" x 3/8" Full Steel Liner. Peterbilt Front
Wheel Mudflaps.
Front Axles & Equipment: Dana Spicer D2200F 22,000 lb., 3.5 inch drop. Dana
Spicer ES cam brakes, 11-1/4" bolt circle.
Taper Leaf Springs with Shocks 23,000 lbs.
Power Steering TRW TAS85 Dual for use with 16,000

lbs. or greater front axles. Power Steering Reservoir
Cowl Mounted for use with 18,000 to 20,000 lb. front
axles.
PHP10 Iron Hubs, Cast Drums, 16.5 x 6 Cam Brakes.

20,000 to 22,000 lb. front axles. Includes Dana Spicer
EES1200/410 brake linings, non-asbestos.
Chicago Rawhide Scotseal Plus XL Oil Seals
Haldex/Dana Auto Slack Adjusters.
Rear Axle & Equipment: Dana Spicer D52-190P 52,000 lb.
PHP10 Iron LMS Hubs, Cast Drums, 16.5 x 7 Brakes.

52,000 lb. maximum, tandem axle, Dana Spicer ES
brakes.
MGM TR-T 3036 in. Parking Brakes, Both Axles.
Haldex/Dana Auto Slack Adjusters, Tandem Axles.

Chicago Rawhide Scotseal Plus XL Oil Seals, Tandem.
Brake Dust Shields, Tandem Axles.
Dana Spicer Full Lock Diff Lock, Both Axles (46,000 to

60,000 lbs for use with D46-170 (P/H), D52-190P, D60-
190P, DS4636.
Bendix 4S4M ABS, SBM Valve, ABS-6. Synthetic Axle

Lubricant, All Axles. Ratio, 4.78 Rear Axle. Hendrickson
RT-523 52,000 lb., 54 in. Axle Spacing.

Engine and Engine ISX 550/2000, 550@1800, 1850@1200 (2007). Includes

Equipment: Alum Flywheel Housing.
PACCAR 130 amp alternator, brushless with voltage
regulator. Immersion type pre-heater 110-120V Phillips.
PACCAR 12V Starter.
(3) Optima DT31T Batteries, 2700 CCA Threaded stud
type terminal. AGM (Absorbent Glass Material).
18.7 Compressor furnished on engine. Intebrake
furnished on engine.
Spin-On Fuel Filter, frame mounted.
Engine Protection Shutdown includes oil pressure, oil
temperature, coolant temp. and intake manifold temp.
High Efficiency Cooling System. Effective January 1,
2007 includes silicone radiator hoses and extended life
coolant.
(1) Donaldson air cleaner, under hood mounted. (engine
mounted).
Exhaust - Single RH side of cab. 36 inch ht., 7 inch dia.,
chrome plated stl standpipe.
Transmission and Clutch: Fuller FRO18210C 10 speed (2007), includes iron bell
housing, external water-to-oil cooler and internal pump,
direct shift pattern and synthetic lubricant.
1810 HD Driveline with single midship bearing w/4.5 inch
x.180 wall tubing.
Eaton Fuller 15.5 inch Clutch, Easy Pedal VCTPIus,
Ceramic 4000# plate/1860 torque/vibration control
technology.
Manual Adjust Clutch with Grease Bearing.
Tires and Wheels: FF: BR 20 Ply 425/65R22.5 M844F.
RR: BR 16 Ply 11R22.5 M711.
Code-Rear Tire Qty 08.
FF: Alcoa 823640 PLT 22.5 x 12.25 Alm Whi, pilot mount
RR: Accur 28408 STL Inner/Alcoa 883640 Outer AIm
Whl, 22.5 x 8.25 pilot mount.
Code-Rear Rim Qty 08.
DRILLING SOLUTIONS
3-13
Fuel Tanks: 26 in. Aluminum 80 Gallon Fuel Tank LH U/C.

26 in. Aluminum 60 Gallon Fuel Tank LH BOC.
(1) Non-Slip Fuel Tank Step LH U/C.
Center Fuel Tank Fill.
Fuel Cooler.
Dual Top Draw, Dual Top Return without shut-off valves.
Bumper: Alum Bumper Swept Back Polished w/o FEPTO with

center tow hook and step plates on top of bumper.
Heavy Duty External Tow Eye.
Cab and Equipment: Refer to truck information located in driver's side door.
Powerpack
ly (engine
The T3W consists of a special truck frame which supports the power pack assemb
combine d cooler package , drill derrick assemb ly and
/ compressor / hydraulic pump drive), the
four leveling jacks.
to an air
The power pack (or power train) consists of a diesel engine directly coupled
pump drive on the other end. This complet e power
compressor on one end and a hydraulic
drive train configur ation maximiz es
pack assembly is mounted to the rig frame. The in-line
mechanical efficiency.
e two stage
A heavy duty engine/muffler is provided to reduce engine noise emission. Separat
release dust drop covers, as
dry type engine and air compressor air cleaners have quick
standard, for easy maintenance.
and air to air
Coolers are provided for the hydraulic oil, compressor oil, diesel engine coolant
one package and each section can be
aftercooler. All coolers are mounted side by side in
cooling package is rated for 125°F
individually removed for easy maintenance. The engine
high water tempera ture or high
(52°C) ambient at sea level. Low oil pressure, low coolant level,
compressor temperature will shut down the engine.
Table 4: Power Pack Selections
Power Pack 1 (900 CFM @ 350 PSI)
Deck Engine: Cat C15 Diesel engine, 475 hp (354 kW) @ 1800 rpm.
Compressor: IR HR2.5 Over/Under screw compressor, 900 CFM LPS

Flow, direct coupled.
120 psi to 350 psi (8.3 Bar to 24.1 Bar Pressure)

Power Pack 2 (1070 CFM @ 350 PSI)
Deck Engine: Cat C15 Diesel engine, 565 hp (421 kW) @ 1800 rpm.
Compressor: IR HR2.5 Over/Under screw compressor, 1070 CFM LPS
Flow with in/out box.
120 psi to 350 psi (8.3 Bar to 24.1 Bar Pressure)
Deck Engine
The T3W uses a water cooled engine with direct injection and turbo chargers. Electric starting
and belt driven alternator battery charging is standard on all T3W models. The T3W drill is
equipped with dual system air filtration. Dry type 3-stage air cleaners provide clean air to the
engine and the compressor. The engine power / rpm is controlled by the engine speed
(throttle) control. The engine is shutdown either by the removable key "ON/OFF" switch or the
Emergency Stop switch.
Engine Specifications
11 AiRE frAENER
11— i
- ,
. ,,,
,s,,,.„„,,,,,.„
...„
EN
Table 5: Deck Engine Specifications
Make / Model: Cat C15, 475 HP (354 kW) @ 1800 RPM

Cat C15, 580 HP (432.5 kW) @ 1800 RPM
Engine Cooling Package: Rated at 12°5F (52°C) ambient at sea level
Exhaust System: Silenced for reduced noise levels
Engine Silencer: Aluminized steel
Fuel Capacity: 160 gallons (605 liters)
Electrical System: 24 Volt
Optional Power Pack In/Out Box: Manual engage/disengage between airend and
engine
Auto Shutdown: Low oil pressure, low coolant level, high water
temperature, high compressor temperature

Air Compressor
asymmetrical rotary
Air compressors used on the T3W Waterwell drills are of the oil flooded
loads.
screw design. Tapered roller bearings are used to handle thrust and radial
_COMPRESSOR
Ai-)wi
416_...,01
_, - AIR CLENER
A
.
't..fr
Oidi.. ~
....-.. _ 0...
0,-4 ••. War
il
1....
AIREND 1 c ii'0,
;,. •44.,:t.d'll
. , .f , ...,
4Nti
Standard equipment for the air compressor includes a separate three-stage air cleaner,
includes
electronic air regulation and full instrumentation and controls. The lubrication system
ion air receiver and oil separato r
an oil cooler, bypass valve, oil filter, oil pump and combinat
tank. A safety shutdown system is provided for high discharge air temperat ure.
This greatly
The oil pump allows the operator to close the intake valve when no air is required.
reduces the engine load which saves fuel and facilitates cold weather starting.
Table 6: Compressor Specifications
Make/Model: 900HR2 @ 350 psi
1070HR2 © 350 psi
Type: High pressure two stage, over/under, oil flooded

asymmetrical rotary screw
Electronic Air Regulation: Variable air pressure and volume control allow you to
increase or decrease both pressure and volume as
needed.
Volume: 900 cfm @ 350 psi, (25.5 m3/min. @ 2413 kPa)
1070 cfm @ 350 psi, (30.3 m3/min. © 2413 kPa)
Pressure Range: 120 psi to 350 psi (827 kPa to 2413 kPa)
Operational RPM: 1800 RPM
Receiver Capacity: 28.5 gallon (107.8 liter)
Power Source: Direct drive from diesel engine with compressor drive
engage/disengage. (Optional In/Out box on 1070 CFM)

Cooling Package
A four section cooling package is provided to cool the Charge Air Cooler, Radiator, Hydraulic
oil and Compressor oil. The coolers are mounted side by side in one package and each
section can be individually removed for easy maintenance. This package provides 125°F
(52°C) ambient cooling with a single motor assembly and large fan rotating at relatively low
speeds. This design is more efficient and produces less noise than dual cooler arrangements.
HYDRAULIC FAN
_
54 INCH
DRIVE MOTOR
SUCTION FAN
e
m• 11111=1,41 MO
111:.,fa
....,.._..,,,,,,
. . ..--..
,......ii,...
Iii 7.4 . _... .vi iil
• ,....
.
Table 7: Cooling Package Specifications
Type: Four (4) section cooling package (CAC, Radiator,

HOC and COC).
Fan Drive: Axial Piston hydraulic motor (6.0 in3/rev.)
Rating: 125°F (52°C) ambient at sea level
Fan Blade: 8-blade fan, 54" blade
Cooling Fan: Variable Controlled. The fan only runs as fast as
needed to maintain optimal fluid temperature.
Function: Cools hydraulic oil and compressor oil

Hydraulics
General Information
All drilling functions on the T3W are hydraulically powered. The hydraulic system consists of
a 100 gallon (378.5 liter) hydraulic reservoir with 3-micron filtration, hydraulic pumps mounted
on a three hole gearbox and various valves, cylinders, pipes, hoses, filters and gauges. A
hydraulic oil cooler assures cool oil temperatures to maximize system deficiency and
component life.
Hydraulic Reservoir
LOCATION OF
HYDRAULIC
RESERVOIR
l.-
Table 8: Hydraulic Reservoir Specifications
System Capacity: 100 gallon (378.5 liter)
Filtration: Three 3-micron in-tank return filters and one 10 micron case
drain filter.
Quantity/Location: Located on helper's side rear side deck.
Standard Equipment: Oil level sight gauge and oil temp gauge, three in-tank return
filters, one air filter and one tank breather.

Utilizing axial piston pumps with on-demand technology provides 10-15% increase in
productivity and supports up to 150 ft./min. feed speeds, and 165 ft./min. winch speeds.
The hydraulic pumps are mounted for convenient service access on a single three-hole
gearbox driven off the deck engine through a drive shaft. There are four basic configurations.
1. 30K / 40K Model with no Mud Pump.

PUMP DRIVE
COVER
PLATE
MAIN
ROTATION
HOT OIL
SHUTTLE
MANIFOLD
2. 30K / 40K Model with Mud Pump.
PUMP DRIVE
ROTATION HOT OIL

r SHUTTLE
MANIFOLD

3. 55K / 70K Model without Mud Pump.
PUMP DRIVE
AUXILIARY
ROTATION
HOT OIL
SHUTTLE
VALVE
4. 55K / 70K Model with Mud Pump.
PUMP DRIVE
AUXILIARY
ROTATION
HOT OIL
SHUTTLE
VALVE

Hydraulic Pumps
Rotation Pump
Table 9: Rotation Pump Specifications
Quantity: One
Location: Mounted on 3-hole main hydraulic drive gearbox.
Type: Variable displacement, axial piston, bi-directional, 9A Stroker
Control
Displacement: 7.25 in3/rev. (118.8cc), 2500 RPM, 78.5 GPM (297 liter/minute)
Function: Supplies oil to the rotary head motors.
Main Pump
Table 10: Feed Pump Specifications
Quantity: One
Location: Mounted on 3-hole main hydraulic drive gearbox.
Type: Variable displacement, piston pump, uni-directional (cw rotation).
Control Type: Load Sensing Control.
Displacement: 8.54 in3/rev. (145 cc), 2500 RPM, 95.8 GPM (362.6 liter/minute).
Function: Supplies oil to the main manifold.
Fan Pump
Table 11: Fan Pump Specifications
Quantity: One
Location: Mounted piggy-back on the main pump which is mounted on 3-hole
main hydraulic drive gearbox.
Control Type: Pressure Compensation Control.
Function: Supplies oil to the cooler fan motor.

Auxiliary Pump (55K / 70K Only)

to
On T3W Models with 55K/70K pulldown, an Auxiliary pump is used to provide additional oil
the main valve.
Table 12: Auxiliary Pump Specifications
Quantity: One
Location: Mounted in upper center position on 3-hole main hydraulic drive
gearbox.
Control Type: Load Sensing Control.
Function: Supplies additional oil to the main manifold.
Mud Pump (30K / 40K Only)
On T3W Models with 30K/40K pulldown, the pump that supplies oil to the mud pump is
mounted in the upper center position on the 3-hole main hydraulic drive gearbox.
Table 13: Mud Pump Specifications (30K/40K)
Quantity: One
Location: Mounted in upper center position on 3-hole main hydraulic drive
gearbox.

Control Type: Load Sense & Pressure Control.
Function: Supplies oil to the mud pump option.

Mud Pump (55K / 70K Only)
On T3W Models with 551</70K pulldown, the pump that supplies oil to the mud pump is
mounted piggy-back on the auxiliary pump located in the upper center position on the 3-hole
main hydraulic drive gearbox.
Table 14: Mud Pump Specifications (55K/70K)
Quantity: One
Location: Mounted piggy-back on the auxiliary pump located in upper center
position on 3-hole main hydraulic drive gearbox.
Control Type: Load Sense & Pressure Control.
Function: Supplies oil to the mud pump option.
Motors
Rotary Head Motor
Table 15: Rotary Head Motor Specifications
Rotary Head Motor Specifications
Type: Hydraulic Motor, Bi-Directional, Fixed Displacement

Displacement: 9.9 in3/rev. (162.3 cm3/rev.)
12.5 in3/rev. (204.9 cm3/rev.)
15 in3/rev. (254 cm3/rev.)

Function: Rotate Drill String

Fan Motor
Table 16: Fan Motor Specifications
Quantity: One
Type: Hydraulic Motor, Uni-Directional
Displacement: Fixed displacement, 6.0 in3/rev. (1100 rpm)
Function: Cooler Package Fan Motor
Carousel Motor
Table 17: Carousel Motor Specification
Quantity: One
Type: Hydraulic Motor, Bi-Directional
Displacement: 22.6 in3/rev.
Function: Rotates the carousel to index drill pipe under rotary head
Mud Pump Option Motor
Table 18: Mud Pump Option Motor Specifications
Quantity: One, Fixed Displacement, Bi-Directional
Capacity: 3 x 4 Mud Option: 3.32 in3/rev.
5 x 6 Mud Option: 15.0 in3/rev.

Function: Operates the Mud Pump
Rod Spinner Option
Table 19: Rod Spinner (Option) Motor Specifications
Quantity & Type: One, Fixed Displacement,6.0 in3/rev., Bi-Directional

Hydraulic Cylinders
Leveling Jack Cylinders
The T3W Waterwell drill utilizes a four-point leveling jack system with 18 in (45.7 cm) O.D. jack
pads. The standard mid jacks behind the truck cab provide optimum stability and more
balanced drill and truck frame load distribution. Note that on the Paystar 5600i truck two 5.75
inch (146 mm) bore x 48 inch (1219 mm) stroke hydraulic jacks are part of the front truck
bumper assembly.
Table 20: Hydraulic Leveling Jacks Specifications
Type: Hydraulic cylinder with double holding valves

Quantity: Four (4)
Non-Drilling End: Two - 5.75 inch bore x 48 inch stroke x 4.5 inch rod diameter
(146 mm x 1219 mm x 114 mm)
Drilling End: Two - 5.75 inch bore x 36 inch stroke x 4.5 inch rod diameter
(146 mm x 914 mm x 114 mm)
Jack Pad Diameter: 18 inches (457 mm)
Function: Raise and level the drill off the ground

Derrick Raising Cylinders
The derrick is raised and lowered by two hydraulic cylinders. Derrick pinning is a manual
operation.
Table 21: Derrick Raising Cylinders Specifications
Quantity/Type: Two, Hydraulic Cylinder
Bore x Stroke x Diameter 5 in. x 36 in. x 3 in. (127mm x 914.4mm x 76mm
Function: Raise and lower the derrick
Feed Cylinder
1. The T3W Water Well with the 30K/40K derrick drill uses a single hydraulic
cylinder cable feed system.
2. The feed system on the 55K/70K derrick is powered by two hydraulic feed
cylinders that raise and lower the rotary head smoothly and positively by way
of a cable feed system.
Table 22: Feed Cylinder Specifications
Type: Hydraulic Cylinder

Quantity: 30K/40K - One 5 in. bore x 165.5 in. stroke x 3.5 in. dia.
(127 mm x 4203.7 mm x 88.9 mm)
55K/70K -Two 5 in. bore x 165.5 in. stroke x 3.5 in. dia.
(127 mm x 4203.7 mm x 88.9 mm)
Function: Raise and lower the rotary tophead
Retract Table Cylinder
The retract table is retracted by a hydraulic cylinder.

Table 23: Retract Table Cylinder Specifications
Quantity/Type: One, Hydraulic Cylinder
Bore x Stroke x Diameter: 3.5 in. x 10 in. x 1.75 in. (89mm x 254mm x 44.5mm)
Function: Retracts table to provide working space for casing and
tools.

Breakout Wrench Cylinder
A 3.5 inch (89 mm) bore x 10 inch (254 mm) stroke hydraulic cylinder operates the self-
adjusting, cam action breakout wrench which is suitable for 3.5 inch (89 mm) and 4.5 inch (114
mm) O.D. drill pipe.
Table 24: Breakout Wrench Cylinder Specifications
Quantity/Type: One, Hydraulic Cylinder

Bore x Stroke x Diameter: 3.5 in. x 10 in x 1.5 in. (89mm x 254mm x 38mm)
Function: Used for breaking drill pipe joints
Jib Boom Swing Cylinder
The jib boom swing cylinder controls the movement of the boom arm to position the cable
directly over the rod loader/carousel to load and unload drill pipe.
Table 25: Jib Boom Swing Cylinder Specifications
Quantity/Type: One, Hydraulic

Bore x Stroke x Diameter: 3 in. x 14.125 in. x 1.5 in. (76.2mm x 358.7mm x 38mm)
Function: Swings drill pipe over carousel when loading and
unloading drill pipe
Jib Arm Extend Cylinder
Table 26: Jib Boom Extend Cylinder Specifications
Quantity/Type: One, Hydraulic

Bore x Stroke x Diameter: 3 in. x 14.125 in. x 1.5 in. (76.2mm x 358.7mm x 38mm)
Function: Extends jib arm when loading pipe from rod rack
Bottom Holding Wrench Air Cylinder
The bottom holding wrench, also called the sliding breakout wrench, is used to hold the drill
pipe flats at the table when breaking joints.
Table 27: Bottom Holding Wrench Air Cylinder Specifications
Quantity/Type: One, Air Cylinder

Size: 2 in. x 5 in. x 1.0625 in. (50.8mm x 203mm x 27mm)
Function: Slides forward on drill table to engage the flats on the drill pipe.

Upper Holding Wrench Air Cylinder
The upper holding wrench is used when breaking joints at the rotary tophead when loading
and unloading the carousel.
Table 28: Upper Holding Wrench Air Cylinder Specifications
Quantity/Type: One, Air Cylinder
Size: 4 in. x 6 in. x 1.75 in. (101.6mm x 152mm x 44.45mm)
Function: Engages drill pipe flats when loading and unloading carousel.
Derrick
General Information
The derrick is constructed of welded tubular steel with cross bracing on both sides and the
back. The fabrication is constructed by Drilling Solutions in a special roll-over fixture that helps
provide optimum welds. A set of sheaves at the top and bottom of the derrick support the feed
cables. The derrick assembly features the hydrostatic driven rotary head and the hydraulic drill
feed systems. The feed system consists of the rotary head, hydraulic feed cylinder(s) and
cable connected to the top and bottom of the rotary head.
The derrick is designed to hold the rotary head as it goes up and down carrying the drill string.
It is built to withstand the torque exerted by the rotary head during the drilling operation.
Table 29: Derrick Specifications
T3W 30K/40K T3W 551V70K
Derrick Construction: Welded cold finished steel tubing
Capacity: 45,000 lbs (20,412 kg) 75,000 lbs. (34,820 kg)
Length: 35 ft. 6 inches (10,820 mm main chords)
Head Travel: 27 ft. 4 inches (8,330 mm)
Width: 36 inches (914 mm)
Depth: 28 inches (711 mm)
Retract Channels: Pneumatic foot pedal control at platform

Table: Retractable table with swing out front

Swivel
t
a *IP A
re
Table 30: Swivel Specifications
Tower Hose Lower

Type
Connection Connection
30K/40K 25CM Swivel, 3" CPLG-STR. 3" NPT 3.5" IF Pin
55K/70K 40 RM Swivel 3" NPT 3.5" IF Left
Hand Modified
Pin
Rotary Head
The rotary head (also called tophead drive) is used to rotate the drill bit and to add and remove
drill pipe from the drill string. The drill string is connected to the rotary head and all rotation and
feed pressure is exerted through the rotary head.
Four hydraulic motors power the rotary head. The rotation pressure gauge, located on the
control console, shows the amount of hydraulic pressure being applied to the rotary head
motors. The standard rotary head drive has 3" (76 mm) swivel and air piping.
Table 31: Rotary Head Specifications
Single Speed Standard Rotary Head
Type: Single Speed, Four Motor Spur Gear, Rotary Tophead

Hydraulic Motors: (Four) 9.9 in3/rev. (162.3 cm3/rev.)
Torque: 5500 ft-lbs. (7458 Nm) @ 145 rpm, Single speed rotary head
Swivel/Piping 3 inch (76 mm) air piping with 3 inch (76 mm) I.D. spindle

Single Speed Heavy Duty Rotary Head
Hydraulic Motors: (Two) 9.9 in3/rev. (162.3 cm3/rev.)
(Two) 12.5 in3/rev. (204.9 cm3/rev.)
Torque: 6250 ft-lbs. (8475 Nm) @ 134 rpm, two speed rotary head
Single Speed High Torque Rotary Head
.Hydraulic Motors: (Two) 12.5 in3/rev. (204.9 cm3/rev.)
(Two) 15 in3/rev. (254 cm3/rev.)
Torque: 8000 ft-lbs. (10,848 Nm) @ 105 rpm, Single speed rotary head
Two Speed Standard Rotary Head
Type: Two Speed, Four Motor Spur Gear, Rotary Tophead
Hydraulic Motors: (Four) 9.9 in3/rev. (162.3 cm3/rev.)
Torque: 5500 ft-lbs. (7458 Nm) @ 145 rpm, Two speed rotary head
Second Speed: 4000 ft-lbs. (5424 Nm) @ 195 rpm

2 Speed Heavy Duty Rotary Head
Type: Two Speed, Four Motor Spur Gear, Rotary Tophead

Hydraulic Motors: (Two) 9.9 in3/rev. (162.3 cm3/rev.)
(Two) 12.5 in3/rev. (204.9 cm3/rev.)

Torque: 6250 ft-lbs. (8475 Nm) @ 134 rpm, Two speed rotary head

• Section 3 - Specifications
Type:
Hydraulic Motors:
2 Speed High Torque Rotary Head
Two Speed, Four Motor Spur Gear, Rotary Tophead
(Two) 12.5 in3/rev. (204.9 cm3/rev.)

(Two) 15 in3/rev. (254 cm3/rev.)
Torque: 8000 ft-lbs. (10,848 Nm) @ 105 rpm, Two speed rotary head

Drill Pipe Carousel
The drill pipe carousel is contained in the derrick in a fixed position. It is rotated by a hydraulic
motor, in both forward and reverse directions, and is controlled from the control console. The
rotary head retracts to load and unload the drill pipe.
• —
4 11011
0 -
.
1
Table 32: Carousel Specifications
Location: Fixed position inside derrick
Carousel Indexing: Hydraulic, forward and reverse
Capacity: Nine (9) 3.5" x 20' (89mm x 6.1m) drill pipe

Seven (7) 4.5" x 20' (114mm x 6.1m) drill pipe
Dual Wall Carousel: Seven (7) 4.625" x 20' (117.475 mm x 6.1 m) drill pipe.
4.5 inch spindle (114 mm).
Function: Positions drill pipe under the rotary head for drill pipe
loading and unloading

Retract Table
The T3W table is designed to open and retract to provide a clear working space for large
casing and tools. The rear half of the drilling table retracts hydraulically while the front half
swings away from either side of the table to accommodate up to 16" (406.4 mm) casing.
Bottern Fielding Wrench
Table Opening
Erm lJ
111111_
a __ Table Base
Retractable Table
Table 33: Retract Table Specifications
Retract: Hydraulic Cylinder: 3.5"x10"x1.75" (89mm x 254mm x 44.5mm)

Table Base: Two half plates. Rear half retracts and front half is hinged to
swing out to an opening up to 20 inches (508 mm), depending
on carousel option.
Bottom Holding An air operated wrench fits either 3.5" (89mm) or 4.5" (114mm)
Wrench: drill pipe flats.
Pneumatic Breakout (Holding) Wrenches
Drill pipe breakout is accomplished by upper and lower air actuated holding wrenches, coupled
with the rotation power of the rotary tophead. In addition, a hydraulic cylinder operates a self
adjusting, cam action breakout wrench which is suitable for 4.5 inch (114mm) O.D. diameter
drill pipe.
Feed System
1. The 30K/40K T3W Water Well drill is powered by a single inverted feed cylinder
cable feed system that raises and lowers the rotary head smoothly and
positively by way of single cable for pulldown and pullback.
2. The 55K/70K T3W Water Well drill is powered by an inverted dual feed cylinder
cable feed system that raises and lowers the rotary head smoothly and
positively by way of single cable for pulldown and pullback.
3. The feed pressure gauge located on the operator's console shows the amount
of hydraulic down pressure being exerted on the bit by the feed (cylinder)
system.

• cY" ---''.-
4,- ..-
------ .--_-..- .4,+ .,

_,-
, --- ___--------
-,->' -
, .
_
_,-------- ,..
0..
'C,---- _.-:1V41E
-P
CABLE LAYOUT OF
FEED SYSTEM
( --
Table 34: Feed Specifications
30K 40K 55K 70K

Type: Single Cylinder, Cable Feed Double Cylinders, Cable Feed
No. of Cylinders: One Two
•
Hyd. Cylinders: 5 inch bore x 165.5 inch stroke x 3.5 inch diameter. (127 mm bore x
4293.7 mm stroke x 88.9 mm diameter)
D to d Ratio: 1:28 Ratio between sheave and cable, 7/8 inch / 22 mm cable
Pulldown: 25,000 Ibf. (111.21 kN) 30,000 lbf. (133.45 kN)
Pullback: 30,000 Ibf. 40,000 lbf. 55,000 lbf. 70,000 lbf.
(133.45 kN) (177.93 kN) (244.65 kN) (311.38 kN)
Drill Feed Rate: 20 ft. / min. (6.1 m/min.)
Fast Feed Up and 150 ft. / min. (45.7 m/min.)
Down:
Function: Raises and lowers the rotary tophead (drill string)
Pre-stretched cables offer the strength of a chain when the rotary tophead retracts. The feed
cables, anchored on swivel yokes to the rotary tophead, absorb drilling shocks. Feed
cylinders mounted on top of the derrick ensure maximum performance and increase the
available pullback power.
•
Winch
Table 35: Main Winch Specifications
Type: Hydraulic motor, bi-directional, single line, bare drum.
Description: 12,000 lbs. (5,443 kg): Fixed displacement 6.4 in3/rev. motor,
Line speed of 120 ft./min. (37 m/min.) first wrap.
18,000 lbs. (8,165 kg): Fixed displacement 7.63 in3/rev. motor,

Line speed of 165 ft./min. (50 m/rnin.) first wrap.
30,000 lbs. (13,608 kg): Fixed displacement 5.5in3/rev. motor,

Line speed of 150 ft./min. (45 m/min.) first wrap.
Jib Boom: Swings and extends hydraulically so that it can be positioned
over the hole or over the pipe rack.
Function: Facilitates drill pipe and accessories handling.
Table 36: Auxiliary Winch Specifications
2000 lbs. (High

Specifications: 4000 lbs.
Capacity)
Type: Hydraulic motor, bi-directional, single line, bare drum.
Gear Ratio: 39:1 34:1
Motor Displacement: 1.64 in3/rev. displacement 4.0 in3/rev. displacement
Maximum Recommended 2000 psi (138 bar)

Operating Pressure:

Miscellaneous
Drill Pipe Rack
Mounted on the left side of the deck, this storage rack holds sixteen 3.5 inch (89mm) drill pipe
or twelve 4.5 inch (114mm) drill pipe. A pipe slide is included as standard equipment. Stand-
off ribs at the end of the rod box allow for convenient use of the sling and hook.
-i,
- —
,-------------
Tool Box
The tool box is mounted under the cooler package and below the deck. Construction is all steel
with locking hatches.
Table 37: Tool Box Specifications
Tool Box
Width: 58 inches (1473.2 mm) wide
Height: 23.8 inches (604.52 mm) high
Depth: 24 inches (609.6 mm) deep
Door Assembly: Swings open 90° from closed position

Operator's Console and Platforms
Console
Drill operations are controlled from the control panel located at the right rear side of the drill.
The slim profile and quick opening side panels provide easy access to the console for service
and maintenance.
The operator and helper are provided with heavy duty steel mesh folding working platforms on
each side of the table area that fold up for transport. Two pneumatic foot pedals are mounted
in the operator's platform to operate the retract gates and upper breakout (holding) wrench. A
steel insert drops in between the two platforms, converting the separate platforms into one
continuous surface. An aluminum platform option between the operator's platform is available.
Injection Line Oiler Option
The DHD lubricator pump forces Rock Drill Oil down the drill string to the DHD for lubricating
purposes. You must use a DHD lubricator when using a DHD drill. Note: Follow actual
manufacturer's lubrication instructions when using DHD hammers.

Water Injection
The water injection system injects a regulated quantity of water into the air flow to the drill pipe.
The water content suppresses the dust created by the drilling operation. The water injection
system has a hydraulic motor drive.
Table 38: Water Injection Specifications
Type Size Capacity Pressure Foam

Cat 12 GPM. 0-12 gpm (0-45 L/min.) 550 PSI Optional foam
(3792 kPa) injection pump
CAT 25 GPM 0-25 gpm (0-95 L/min.)
maximum available
John Bean 18 GPM 0-18 gpm (0-68 L/min.) 750 PSI
(5170kPa)
John Bean 25 GPM 0-25 gpm (95 L/min.)
maximum
John Bean 35 GPM 0-35 gpm (0-132) Urnin.) 480 PSI
(3309 kPa)
maximum
Mud Pump
Mud pump packages are available on the T3W Waterwell drill. All Mud Pump packages are
supplied with suction hose and foot valve/strainer.
Table 39: Mud Pump Specifications
Type: Capacity:
3 x 4 Centrifugal Mud Pump. 300 gpm (1136 Ipm) @ 145 psi (1000 kPa)
Mounted in a vertical position next
to the non-drilling end leveling jack
on the operator's side of the drill
behind the truck cab.
5 x 6 Duplex Piston Mud Pump. 150 gpm (568 Ipm) @ 310 psi (2137 kPa)
Mounted behind the truck cab.
7.5 x 10 Duplex Mud Pump. 300 gpm (1136) L/min.) @ 400 psi (2758 kPa)
Mounted behind the truck cab.
Hub Odometer Option
The hub odometer attaches to a truck wheel hub and is used to record road miles.

Pipe Spinner Option
The option Pipe Spinner attaches and detaches drill pipe. It can be used with a single rod
loader.
Table 40: Pipe Spinner Specifications
Pipe Spinner Option
Pipe Size: 3.5 inch (89 mm) 4.5 inch (114 mm)
Design Type: Hydraulic motor / pneumatic cylinder design
Torque: 80 ft/lbs. (284.7 Nm) 80 ft/lbs. (284.7 Nm)
RPM: 395 395
Range: 3.125 inch to 3.5 inch 4.125 inch to 4.5 inch

(79.375 mm x 88.9 mm) (104.775 mm x 114.3 mm)
Location: Mounted on rear bumper next to retract table
Drill Pipe
Table 41: Drill Pipe Specifications
Drill Pipe Specifications
Size: Connections: Flats:
3.5" (89 mm) OD x 20 ft. 2-3/8 inch (60 mm) IF box 2-3/4 inch (70 mm) wrench
(6.1 m) long external flush: up/pin down connections. flats on box end of drill pipe
approx. 240 lb (109 kg).
4.5" (114 mm) OD x 20 ft. 2-7/8 inch (73mm) IF box 3-1/5 inch (89 mm) wrench
(6.1 m) long external flush: up/pin down connections. flats on box end of drill pipe
approx. 345 lb (156 kg).
Standard Tools & Accessories
1. Rod Wiper
2. Hoist Plug for drill pipe
3. Drill pipe centralizer bushings
4. Breakout Wrench
5. Feed Cable Socket Wrench
6. Fire Extinguisher
7. Road Hazard Kit
8. Rod Handling Sling

9. Control Panel Cover

10. Three CD ROM serial Parts manual and Safety, Operation and Maintenance
manual; Three serial number paper Parts manuals and three paper Safety,
Operation and Maintenance Manuals.
Options
1. Mud Pumps
2. Floating Spindle Sub
3. 6x6 Heavy Duty Trucks
4. Drop-down Axle
5. Pipe Spinner
6. Sand Reel
7. Water Injection
8. Deck Engine Starting Aid
9. Single Pipe Loader
10. Service Hoist
11. Down-hole Injection Lube
12. High Pressure Air Piping
Weights and Dimensions
Table 42: Weight and Dimension Specifications
Dimensions and Weights for Shipping

Width: 8 feet (2.4 m)
Length (Derrick down): 426 inches (10.8 m)
Height (Derrick down): 13 feet - 6 inches (4.1 m) depending on
options
Height (Derrick up):
Derrick: 426 inch L x 36 inches W x 28 inches D
(10.8 m L x 914 mm W x 711 mm D
Gross Weight (less drill pipe and mud 66,000 lbs. (29,937 kg) GVWR
pump): (International Navistar 7600, 6x4)
68,000 lbs. (30,844 Ig) GVWR
(International Paystar 5600, 6x4

Performance specifications are based on maximum computed values and are subject to
revision without notification. Nothing in this manual is intended to extend any warranty or
representation, expressed or implied, regarding the products described herein. Any such
warranties or other terms and conditions shall be in accordance with Drilling Solutions
standard terms and conditions of sale for such products, which are available upon request.
These machine specifications are those in effect at the time of this printing. However, Atlas
Copco is constantly striving for product improvements and enhancements. Accordingly, the
right is reserved to make such changes in specifications and design that the Company
considers in conformity with this policy or are due to unavailability of materials or assemblies.
Final confirmation of current specifications should be made by contacting Atlas Copco Drilling
Solutions, Garland, Texas, USA.

•
Section 4 - Controls

T3W Instruction Manual Section 4 - Controls
OPERATING CONTROLS
General Information
WARNIN
Read and understand Section 2 -- Safety Precautions and Guidelines
before you operate or perform any maintenance, service or repairs on the
drill.
Safety should be the main concern for anyone working on or around the drill. Do not perform
any function that could put someone in danger.
Always wear correct safety gear while working on or around the drill. This includes Approved
Hard Hat, Safety Glasses, Steel Toe Shoes, Gloves, Respirator and Ear Protection. Do not
wear loose fitting clothing that can become caught in rotating components.
WARNING
If you are not experienced with the drill's controls and instruments, read
and understand Section 4 - Operating Controls & Instruments.
Unexpected drill motion or moving parts can cut or crush. Shut down
engine before working on the drill.
The following operational hints should be observed:
1. Do not increase engine speed to high idle until all components have been
warmed up.
2. Always chock the tires if there is a possibility of uncontrolled movement.
3. Do not lubricate the drill while the engine is running.
4. Always perform safety checks prior to starting operating or maintaining the drill.
5. Always operate the drill at full engine power when drilling.
6. Never drive or stop the drill on a slope or surface that is liable to collapse.
7. Before starting the truck engine, make sure that the parking brake is applied.
8. Before starting the deck engine, make sure all operator console controls are
either in "OFF" or "NEUTRAL" positions.
9. Always sound the horn before moving the drill in either direction to alert
personnel and to allow sufficient time before putting the drill in motion.

Section 4 - Controls T3W Instruction Manual
Instruments and Controls
Introduction
The instruments and controls section of this manual provides basic information about the
operating controls, instruments and indicators located on the console and around the drill.
All drilling operations are controlled from the operator's console located at the right rear side
of the drill. The slim profile and quick opening side panels provide easy access for
maintenance and service.
The following pages will describe the controls on the console.
Top of Console
The T3W Water Well drill has control levers and a gauge on top of the operator's console.
DOWN HOLE AIR

DRILL STRING PRESSURE GAUGE
AIR ON/OFF
CONTROL
MUD PUMP
BALL VALVE
CONTROL
Drill String Air On/Off Control

The Drill String Air On/Off Control lever (sometimes called Drill Air Throttle) controls the air
flow from the rotary screw compressor. It is used to open and close the ball valve to allow
variable air pressure to the drill string. The ball valve must be closed (pulled out) before
starting the compressor. Push in (open) the ball valve lever after the compressor has built up
air pressure to allow air into and through the drill string. Pull the ball valve lever to restrict air
to the drill string.

Down Hole Air Pressure Gauge
The Down Hole Air Pressure Gauge indicates down hole air pressure supplied to bit.
Mud Pump Ball Valve Lever (Option)
The Mud Pump Ball Valve controls the off/on mud flow from the standpipe to the drill bit. Push
in to open the mud flow. Pull out to stop the mud flow. Note: Always shut off the mud pump
before closing the mud pump ball valve.
Upper Console
The components of the upper console, using PowerView Monitoring System used with Tier Ill
engines, are identified below reading clockwise from the Receiver Pressure Gauge.
EMERGENCY INTERSTAGE OIL PRESSURE
CIRCUIT TACHOMETER FUEL
ENGINE PRESSURE GAUGE / GAUGE
BREAKERS SHUTDOWN GAUGE
RECEIVER
PRESSURE DISCHARGE
GAUGE TEMP
GAUGE
MAXIMUM
PRESSURE WATER
CONTROL - - TEMP
KNOB GAUGE
COMPRESSOR
ON/OFF
SWITCH
POWERVIEW
DIAGNOSTICS
EARS VIEWER
DIAGNOSTIC
LIGHT START
BUTTON
FLOW - ON-LOCK
CONTROL KEY SWITCH
KNOB
/ ECM
ROTATION DRILL FEED THROTTLE LIGHTS ETHER
PRESSURE STRING PRESSURE FILTER BUTTON
GAUGE VENT GAUGE BYPASS
Receiver Pressure Gauge
The Receiver Pressure Gauge (also called discharge pressure or bit air pressure gauge)
shows the amount of pressure being discharged from the compressor and available to the drill
bit on high pressure drills. Drill pressure depends on the size DHD (down hole drill) being used,
drill bit size and the choke size inside the DHD.
This pressure is adjusted by turning the air pressure regulator control adjustment knob
clockwise to increase and counterclockwise to decrease the compressor discharge air
pressure.

NOTICE
Ensure that the pressure is adjusted to the type of downhole hammer
being used.
Circuit Breakers
The Circuit Breakers are mounted between the electrical current producer (batteries or
alternator) and the devices they protect. In the event of an overload of a circuit, press in the
tripped circuit breaker.
Table 1: Circuit Breakers
Breaker Circuit
Breaker 1 (CB1) Engine and Compressor Starting Circuit

Breaker 2 (CB2) Drill and Operating Lighting Circuit
Breaker 3 (CB3) Drill Functions Circuit
Breaker 4 (CB4) Engine Monitoring System (EMS) Circuit
Breaker 5 (CB5) Electronic Air Regulation Circuit
NOTICE
If there is a re-occurrence, call for service assistance to correct the cause
of the overload in the circuit.
Engine Tachometer
The Tachometer shows the RPM of the engine while the engine is running. The tachometer is
calibrated in RPM x 100 with a range of 0 to 30.
Since engine speed controls pump speed, it is important to maintain certain rpm speeds when
performing various functions.
Emergency Engine Shut Down
The Emergency Engine Shut Down has a red light that comes on when the fuel system is
energized. If the light goes out, it normally means that the engine fuel system is not operating.
Pushing the Emergency Engine Shut Down shuts off power to the fuel valve which stops fuel
flow and shuts the engine down. Turning the key switch off does the same thing. All engines
are "energized to run", which means the fuel system must be energized in order to pump fuel.

Fuel Level Gauge
The Fuel Level Gauge monitors the level of fuel in the fuel tank for the deck engine. Note that
the fuel level gauge for the truck engine is on the truck dashboard. The fuel gauge is shown in
increments of EMPTY, 1/4, 1/2, 3/4 and FULL. The tank should be filled when the indicator
needle moves to below the 1/4 mark.
Interstage Pressure Gauge
High pressure compressors use two stages to obtain the 350 psi discharge pressure.
Interstage pressure is the pressure developed by the first stage as it goes to the second stage.
The Compressor Interstage Gauge shows the pressure between the first and second stages
of the air end when the compressor is working. It normally operates between 80 to 120 psi.
(5.52 to 8.16 bar).
Engine Oil Pressure Gauge
The Engine Oil Pressure Gauge shows the pressure that is required to circulate oil inside the
engine. This gauge should not read less than 10 psi on LOW idle nor less than 27 psi on HIGH
idle.
NOTICE
There is a pressure monitoring system on the engine that will shut down
the engine immediately in the event that the oil pressure drops below 10
psi on LOW idle or less that 27 psi on HIGH idle; otherwise the engine
could be severely damaged. Check the oil level according to the
instructions provided in the Maintenance Instructions. Refer to engine
diagnostics section for checking engine problems in the Trouble
Shooting section.
Discharge Temperature Gauge
While compressing air, heat is formed. Oil is pumped into the air end to cool this air. The
Discharge Temperature Gauge (sometimes called the air receiver temperature gauge) shows
the temperature of the oil and air leaving the air end. Normal operating temperatures are 180°
to 220°F (82° to 104°C). This gauge also contains a switch that will stop the engine if the oil
temperature in the compressor exceeds 248°F (120°C).
Water Temperature Gauge
The Engine Water Temperature Gauge shows the temperature of the engine coolant system
in both °F and °C scales. Normal operating temperature is from 150° to 208°F (65° to 98°C).
The system will shut down if the temperature exceeds 210°F (99°C).

PowerView Diagnostic Viewer
The PowerView system is comprised of the PowerView and MLink PowerView Gauges. It is a
multifunction tool that enables the operator to view many different engine parameters and
engine service codes. It includes a graphical backlit LCD screen and has excellent contrast
and viewing from all angles. Back lighting can be controlled via menu or external dimmer
potentiometer. The display can show a single parameter or a quadrant display showing 4
parameters simultaneously. Diagnostic capabilities include fault codes with text translation for
the most common fault conditions. Enhanced alarm indication with ultra bright alarm and
shutdown LEDs (amber & red).
Deck Engine Key Switch
The Engine "ON/LOCK" Key Switch turns on all electrical power to the engine and controls
stopping and run operations.
The engine "ON/LOCK" key switch also activates the ECM (Electronic Control Module) that
controls all aspects of the engine, including most shutdown devices.
NOTICE
Always stop the engine and remove the key when leaving the drill
unattended and/or performing certain maintenance procedures.
Engine Start Button
The Engine Starter Button switch energizes the starter motor and engages the starter motor
solenoid to crank the engine for startup. Press the engine starter button switch to start the
engine. Once the engine starts, release the engine starter button switch immediately.
NOTICE
Do not engage the starter motor solenoid longer than 30 seconds at a
time or it will overheat and burn up the starter motor. If the engine does
not start, WAIT 3 minutes to allow the starter to cool before trying again.
Ether Button
The Ether Button is not used.
Drill Lights
The drill lights control switch is an "ON/OFF" toggle switch that controls all the drill work lights,
including the operator's control panel light located above the control panel. Move the switch to
the ON position to turn on all the lights and illuminate the working area.

Throttle
The engine throttle regulates the speed (RPM) of the engine. The engine has an idle speed of
1200 rpm and a high idle of 1800 rpm. The engine should always be run at low idle for 5
minutes before shutdown. This allows the turbocharger to cool down.
NOTICE
Always ensure that the engine speed is at operating RPM before drilling.
Full power is necessary to obtain the proper component operation and
maximum rpm for greatest efficiency.
Filter Bypass
The Filter Bypass Light indicates that oil is bypassing the return filter elements. This indicates
that it is time to change the return filter elements. Refer to Section 6 - Maintenance for
instructions to change the return filter elements.
ECM Indicator Light
The ECM (Engine Control Module) Indicator Light signals fault codes of the engine protection
system, plus battery voltage above or below normal. Diagnostics will be explained further in
the Electrical section of TROUBLESHOOTING.
Feed Pressure Gauge
The Feed Pressure Gauge (sometimes called pulldown pressure) shows the amount of
hydraulic down pressure being exerted on the bit by the feed (cylinder) system. Increase or
decrease the pulldown pressure in the feed cylinder(s) with the Feed Pressure Control. Note:
Adjustments with the Feed Pressure Control (also called pulldown regulator) have a direct
affect on the readings of both the Feed Pressure Gauge and the Rotation Pressure Gauge.
Drill String Vent Toggle
When the drill is stopped, there is still air under pressure trapped in the drill string. The Drill
String Vent Toggle opens the blowdown solenoid valve to relieve the pressure in the drill
string. Push the toggle up to open the blowdown valve and push the toggle down to close the
blowdown valve.
Rotation Pressure Gauge
The Rotation Pressure Gauge shows the amount of hydraulic pressure being applied to the
rotary head motors. It corresponds to the amount of torque developed by the rotary head
during operation. It is used in conjunction with the feed rotation pressure control to obtain the
best penetration rate.

Air Volume (Flow Control) Knob
The Air Volume (Flow Control) Knob is a variable electronic input into the electronic controller.
When the compressor On/Off switch is on it adjusts the flow into the compressor between the
minimum flow (required to prevent damage to the compressor) and maximum flow (full open
on the butterfly valve).
(EARS) Diagnostic Light
The (EARS) Diagnostic Light is normally off but will flash a signal if an error is detected in the
compressor Electronic Air Regulation System circuit.
Compressor On/Off Switch
The Compressor On/Off Switch is used to select the source of the flow and maximum pressure
commands. When the switch is On, the Flow Control and Maximum Pressure Control are
active and control the compressor. When the switch is Off, the Flow Control is set to the
minimum flow required to prevent damage to the compressor and the Maximum Pressure
Control pressure is set to the minimum holding tank pressure (setting the switch to Off has the
same effect as setting the flow and pressure knobs to the minimum positions.
Air Pressure (Maximum Pressure) Control Knob
The Maximum Pressure Control Knob is a variable electronic input into the electronic
controller. When the compressor On/Off switch is On it adjusts the maximum pressure in the
receiver tank between the minimum holding tank pressure and the maximum working pressure
of the compressor system.

Middle Console
The Middle Console contains the controls for the feed and rotation of the rotary head as well
as controls for most options. The controls on the middle operator's panel are identified below
reading clockwise from the Rotation Controller.
2 SPEED TORQUE FAST
LIMIT SLOW
HEAD FEED FEED
ROTATION \ FEED
PRESSURE
MUD
PUMP
%..P I. • •
• VOLUME
wormanee *1,0010 •11140
FOAM
WATER SLIDE
JIB
DHD INJECTION
HOIST WRENCH
LUBE
Rotation Control
The Rotation Controller controls the direction and speed of the drill pipe rotation. To rotate the
drill pipe in either the clockwise or counterclockwise direction, gradually move the controller in
the required direction and speed of rotation will progressively increase. To stop rotation, move
the controller into the STOP position where the indent should click into place.
2 Speed Head
The 2 Speed Head switch changes the flow from all four motors to provide higher rotation
speed or the highest torque.
Torque Limit Control (Option)
The Torque Limit Control controls the amount of pressure being applied to the rotary head
rotation motors. It can be adjusted to aid in connecting steel threaded casing or to limit torque
on the bit during difficult drilling conditions.
Rotation Pressure is increased by turning the control to the right. Rotation Pressure is
decreased by turning the control to the left.

• Section 4 - Controls
Slow Feed Control

The Slow Feed Control is used to engage pulldown and pullback modes while drilling. Push
the control away from operator for pullback (up) mode. Pull the control toward the operator for
pulldown (down) mode.
Fast Feed Control
The Fast Feed Control is used to raise and lower the rotary head by directing the hydraulic oil
flow from the fast feed pump to the feed cylinder(s).
Fast feed is used to move the rotary head up and down quickly during non-drilling functions,
such as adding or removing drill pipe. It is not used for actual drilling. Drilling is done with the
drill feed circuit. NOTICE: Fast Feed is used for non-drilling functions only.
Feed Pressure Control
The Drill Feed Pressure Control valve controls the pressure to the feed cylinder(s) while doing
actual drilling.
•
Turn the control clockwise to increase feed pressure. Turning the control counterclockwise will
reduce the feed pressure.
NOTICE: When using downhole hammer drilling, use only sufficient feed pressure to match
the rate of penetration.
Mud Pump Control (Option)
The Mud Pump Control Option is used to increase or decrease mud pump flow. Turn the
control to the right to increase mud pump volume. Turn the control to the left to decrease mud
pump volume. The control remains in the position that it is moved to.
Slide Wrench Control
The Slide Wrench (Table Sliding Wrench) Control is used to retract or extend the table wrench
and to hold the drill string in the table. Retract (in) the wrench by pushing the lever away from
the operator. Extend (out) the wrench by pulling the lever toward the operator.
Water Injection System
The Water Injection System (option) utilizes three controls.
1. The Water Injection Control is used to activate and deactivate the water
injection pump. Activate the water injection pump by turning the control knob
•
clockwise. Deactivate water injection pump by turning the control knob counter
clockwise.

2. The Water Injection Flow Control adjusts the flow rate of water into the air
stream to keep down dust and prevent collaring in the hole when the water
injection pump is running. Rotate the switch clockwise to increase or
counterclockwise to decrease the water flow rate.
3. The Foam Control is used to adjust the amount of drill foam added to the water
injection flow. Foam volume is increased by turning the control to the left. Foam
volume is decreased by turning the control to the right.
Jib Hoist
Moving the Jib Control In (up) or Out (down) extends the jib boom while moving the jib control
left and right swings the boom to the side and back to aid in loading drill rod.
DHD Lubricator
The DHD Lubricator Switch is an "ON/OFF" switch for the DHD lubrication system. The DHD
Lubricator Indicator Light will illuminate to confirm that the lubrication system is in service.

Lower Console
The Lower Console Controls functions are from left to right: Winch Control, Auxiliary Winch
Control (option), Carousel Index Control, Breakout Wrench Control, Retract Table Control,
Rod Spinner Control, Derrick Raising Control, Left Front Leveling Jack Control, Right Front
Leveling Jack Control, Left Side (Helper's side) Drill End Leveling Jack Control, Right Side
(Operator's Console side) Drill End Leveling Jack Control and the Drill Bubble Level.
0 0
SAND REEL
MAIN OPTION
WINCH BUBBLE
CONTROL LEVEL
• CAROUSEL
INDEX BREAKOUT RETRACT ROD DERRICK
WRENCH TABLE SPINNER RAISE
LEVELING
JACKS
Winch Control
The Winch Control is used to raise and lower the hoist cable. Raise the cable by pushing the
control forward (away from the operator). Lower the cable by pulling the control towards the
operator. A remote Winch Control is also located on the helper's side and will be discussed
later.
Sand Reel (Option)
The Sand Reel (option) Control is used to raise and lower the Sand Reel cable. Raise the
cable by pushing the control forward (away from the operator). Lower the cable by pulling the
control towards the operator. A remote Sand Reel (option) Control is also located on the
helper's side and will be discussed later.

Carousel Index
The Carousel Index valve spool controls the rotation of the carousel to move drill rod under
the drill string when drill pipe needs to be added to the drill string. Also the carousel can be
indexed to load drill pipe onto the carousel when pulling pipe out of the hole. Raise the control
for Counter clockwise rotation. Lower the control for Clockwise rotation.
Breakout Wrench Control
The Breakout Wrench valve spool operates the breakout wrench cylinder used with the
breakout wrench when loosening the threaded joints between the drill pipe and the rotary head
and/or other drill pipe at the table, and also during bit replacement. Raise the control to
unscrew pipe. Lower the control to reset wrench.
Retract Table
The Retract Table valve spool operates the table retract cylinder used to retract the table to
allow bushings to be changed or to install large casing. Retract the table by lifting the control
and Close the table by lowering control.
Rod Spinner
The Rod Spinner valve spool operates the hydraulic motor that activates the rod spinner used
to attach or detach drill pipe to or from the drill string. The Rod Spinner Control must be pushed
down (away from the neutral position) to turn on the Rod Spinner. Raise the control to the
neutral position to turn off the Rod Spinner.
Derrick Raising
The Derrick Raising valve spool is used to raise and lower derrick. Raise the derrick by pulling
the control up. Lower the derrick by pushing the control down.
NOTICE: Feather the Derrick Raising valve spool handle when derrick approaches vertical
position. Do not slam derrick against stops.
Leveling Jacks
The Leveling Jack valve spools control the two drilling end jacks and the two non-drilling end
jacks. These valve spool handles are used in conjunction with the bubble level on the console
to level the drill. Raise the jacks by lowering the control handles. Lower the jacks by lifting the
control handles. Lift and lower the jacks a little at a time to keep the drill as level as possible
at all times.
Drill Bubble Level
The Drill Bubble Level gauge is used when leveling the drill in both directions. The derrick is
designed to be vertical when the bubble is centered. The bubble must be centered before
drilling begins.

Under Console
Below the console are two foot pedal controls. The left foot control is the Upper Breakout
Wrench foot pedal. The right foot control is the Powerhead Retract foot pedal.
OPERATOR'S
FOLDING
UPPER , . PLATFORM
BREAKOUT * s. ,
a..:..,Vu
WW,.- IoNo.
WRENCH
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? 1 1 1,1 1 1 1 N
POWERHEAD 4 i 10 Jo if ;.7 )9 71 /7 )1/ P.))/00*I'”OSs iNliN.S*Ail
RETRACT ire 0e."/0;4
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Upper Breakout Wrench
The Upper ((Holding) Breakout Wrench foot pedal controls the air cylinder operated top
breakout wrench (on the top plate above the carousel). Stepping on the left foot pedal (out
position) moves the upper breakout wrench out and onto the drill rod flats when breaking a
joint between the rotary head spindle and the drill pipe. Releasing the left foot pedal
disengages the wrench.
Powerhead Retract
The foot operated Powerhead (also called Rotary Head or Tophead) Retract foot pedal
activates the air cylinders that open the retract gates on the derrick retract channels when
bringing the powerhead into retract position. The Powerhead Retract foot pedal is used to
assist in loading/unloading of drill pipe. Springs return the gates to their normal position when
the pedal is released. Depressing the foot pedal opens the gates to allow loading/unloading of
drill pipe. The powerhead must be raised into the retracted position. Releasing the foot pedal
returns gates to normal position. Note: The powerhead is also retracted when loading casing
into well, and for transport.

Helper's Controls
JIB MAIN SAND REEL

BOOM HOIST OPTION
Jib Boom Control
1. The Helper's Side Jib Boom Control is used as a swing control to swing the jib
boom, mounted on top of derrick, from side to front when adding and removing
drill pipe. Push the control to the left to move the jib boom to the left side. Push
the jib boom control to the right to move the jib boom to the right when loading
drill rod.
2. The Helper's Side Jib Boom Control is also used as an extend/retract control
used to extend and retract the jib boom when loading or unloading drill pipe.
Remote Main Winch Control
The Remote Main Hoist Control controls the hoist's direction and speed when raising or
lowering the cable that picks up the drill pipe during loading into or unloading from the carousel
and when handling DHD's. To use the hoist in either Raise or Lower operations, gradually
move the control in the required direction. To slow and stop the hoist, move the control slowly
to the STOP position. A spring applied brake will automatically apply when the control is
released in the STOP position.
Remote Auxiliary Winch Control (Option)
The Remote Sand Reel Control (option) controls the Sand Reel direction and speed when
raising or lowering the Sand Reel cable. To use the Sand Reel in either Raise or Lower
operations, gradually move the control in the required direction. To slow and stop the Sand
Reel, move the control slowly to the center position.

Auxiliary Controls and Indicators

The following controls, instruments and gauges are not located on the
control console. They

are located at various places on the drill. Auxiliary Controls are not used
but are needed to perform functions that aid in the drilling procedures.
to do actual drilling,
In/Out Box Actuation Control
•
The In/Out Box Actuation Control engages and disengages the compre
ssor from the engine
to save fuel and wear when the compressor is not needed. Move the
control away from the
console end of the truck to engage the in/out box and move the control
toward the console end
of the truck to disengage the in/out box.
A CAUTION
• Stop engine before engaging or disengaging the In/Out Actuator

compressor.
DRILLING SOLUTIONS
with the
4-17
Service Pressure Regulator

e pipe to
A pressure regulator and a ball valve are connected to the main air discharg
accommodate tools and equipment that use air power.
PRESSURE
GAUGE
operating
The pressure regulator is used to lower the high operating pressure to the tool
load on the regulator
pressure, usually around 100 psi. The ball valve is there to reduce the
when it is not being used.
, since most air
NOTICE: Do not operate the service air pressure at normal discharge pressure
tools are rated for no more than 100 psi.
Proportional Vent Valve and Actuator
Actuator
Proportional
Vent Valve
r. It can
The proportional vent valve and actuator is controlled by the electronic controlle
vented to atmosph ere through an air silencer.
release air from the receiver tank. The air is

Receiver Tank Oil Level Gauge

The receiver tank contains the lubricating oil for the compressor. The oil is remove
air by centrifugal force, gravity, velocity and filtration.
d from the
OIL LEVEL
GAUGE
•
The receiver tank has an Oil Level Sight Glass that shows the oil level. The sight
glass should
be at least half full when the drill is shut down and oil must show in the glass when
the drill is
running.
Hydraulic Oil Level Gauge
The Hydraulic Oil Level Gauge is located on the side of the hydraulic tank. The
hydraulic oil
level should be monitored with the hydraulic oil level gauge and the level maintain
ed at the
proper level. Failure to maintain this level will result in the malfunction of the hydrauli
c system,
overheating of circuit components and the destruction of hydraulic pumps and
motors.
OIL LEVEL
SIGHT
GAUGE
OIL
•
TEMP
GAUGE
DRILLING SOLUTIONS
4-19
Hydraulic Oil Temperature Gauge

the
The Hydraulic Oil Temperature Gauge is located on the side of the hydraulic tank below
oil level sight gauge and indicates the operating hydraulic oil tempera ture.
the engine and call
NOTICE: If the indicated temperature exceeds 220°F (104°C), shut down
for service assistance to correct the problem.
Compressor Air Filter Indicator

when
The Air Filter Indicator measures the restriction of the air cleaner and alerts the operator
filter replacement is required.
AIR CLEANER
INDICATOR
Fuel Tank Filler Cap
DECK ENGINE
FUEL FILLER CAP
The
The fuel filler cap is located is located above the fuel tank mounted under the truck deck.
fuel tank should be refilled when the indicator on the fuel gauge on the operator 's console
moves to below 1/4 tank.

Rotary Tophead Gearbox

The Tophead Drive Gearbox lube level should be checked daily. When the derrick is raised
(vertical position), the lube level should be halfway on the sight gauge in the front gearbox
cover.
TOPHEAD
•
GEARBOX
OIL LEVEL
SIGHT GLASS
Cab instruments and Controls
•
For information on truck vehicle features, instrument panel controls and gauges, refer to the
OEM Operator's Manual located in the compartment in the driver's side cab door.

Air Transfer Valve
The air transfer valve allows air to move from the deck engine compressor to the operator's
console, isolating the truck chassis air brake system. This configuration allows the truck to be
driven if an air leak occurs in the drilling rig air control system.
The deck engine air compressor provides air to operate the rotary head retract gate air
cylinders, the upper holding wrench air cylinder and the sliding breakout wrench air cylinder.
AIR
TRANSFER
VALVE
The air transfer valve is mounted on the truck frame behind the cab, above the lubricator as
shown above. The air transfer valve lever must be turned to a horizontal position for air to
transfer back to the operator's console.
A WARNING
The air transfer valve must be in the vertical (off) position when driving
the T3W on the road to meet with federal regulations.

•
Section 5 - Operating
• it

T3W Instruction Manual Section 5 - Operating Instructions
OPERATING SAFETY
Safe Operations
Introduction
ARNING
Read and understand Section 2 - Safety Precautions and Guidelines
drill.
PrWARNING
Always wear the correct safety gear while working on or around the drill.
This includes an approved hard hat, safety glasses, steel toe shoes,
gloves, respirator and ear protection. Do not wear loose fitting clothing
that can become caught in rotating components.
and understand Section 4 - Operating Controls and instruments before
you operate or perform any maintenance, service or repairs on the drill.
A WARNING
Unexpected drill motion or moving parts can cut or crush. Shut down the

Section 5 - Operating Instructions T3W Instruction Manual
General Information
1. Do not increase the engine speed to high idle until the engine has been warmed
up.
2. Always chock the wheels if there is a possibility of uncontrolled movement.
4. Always perform safety checks prior to starting, operating or maintaining the
drill.
personnel and allow sufficient time before putting the drill into motion.
6. Always use safe judgement when driving on unstable surfaces where there
may be a risk of overturning or when loading onto a transporter where there is
a risk of overturning. Always use a spotter.
7. Always use approved protective clothing such as gloves, steel toe shoes,
goggles, ear protection and safety helmet when performing service
maintenance. Do not wear oil stained or damaged garments.
10. Never stop the drill against a high wall that is liable to collapse or cause a
crushing risk.
11. Before starting engine, always check to see that the control levers and drill feed
are at stop, neutral or off position and that the parking brake is applied.

DAILY INSPECTION
Walk Around Inspection
FYI (For Your Information)
Before every shift and prior to starting the drill, a walk around inspection of the overall drill
should be performed. This is in addition to the 8 hour daily routine maintenance procedures.
Performance of this inspection can result in longer life and maximum productivity from the drill.
Hydraulic System
A careful inspection of all hydraulic components (hydraulic oil cooler, pumps, motors, valves,
hoses, fittings, etc.) should be made to detect any signs of oil, possible oil leaks or any
irregularities. This is particularly important when the drill is new. Drills have been equipped at
the factory with a hydraulic oil containing a blue colored dye which will aid in early detection of
leaks.
Hot oil and hot components can cause personal injury. Do not allow hot
oil or hot components to contact the skin.
Compressor System
A careful inspection of all compressor components (compressor oil cooler, air end, air end
pump, valves, hoses, fittings and filters) should be made to insure that there are no
compressor oil leaks or any irregularities. This is particularly important when the drill is new.
IA WARNING'
High pressure can cause severe injury or death. Completely relieve
pressure before removing the filler plug, fittings or receiver cover.

Coolant System
The deck engine radiator and the carrier engine radiator should be checked for leaks daily.
Failure to cool the deck engine and carrier engine properly can result in engine failure or
severely reduce engine life.
A WARNIla
Injury can occur when removing the radiator cap. Steam or fluid escaping
from the radiator can burn. Inhibitor contains alkali. Avoid contact with
skin and eyes. Always shut down the engine and allow it to cool down
before removing the radiator cap. Remove the radiator cap slowly to
relieve pressure. Avoid contact with steam or escaping fluid.
Air Hose Leaks
Inspect the flexible air hoses for wear/tear conditions. Check the air system connections for
loose connections. Make sure the air hose safety chains are secure.
Wheels and Tires
Check the tires for damage or unusual wear. Check and maintain tire pressure. Check the
wheel nuts and retighten them after the first 100 miles (161 km) and every 200 miles (322 km)
thereafter.
Fuel Systems
The fuel systems should be checked on a daily basis for possible leaks. Maintain the fuel tanks
at a high level to minimize water condensation inside the tank. This is best accomplished by
filling the fuel tanks at the end of each day. Because of the potential fire hazard, leaks must
be corrected as soon as they are spotted. Select the proper grade of fuel oil in accordance with
the information in the 6.3 "Refill Capacities/Lubricants/Fuel"section of this manual.
WARNING
Fuel is flammable. May cause serious injury or death. Shut down the
engine, extinguish all open flames and do not smoke while filling fuel
tanks or draining fuel filters. Always wipe up any spilled fuel.

General Checks
Other general checks should be made at this time for any wear and tear on the drill. Check for
broken or cracked welds, loose or missing bolts, broken or inoperative gauges or any other
irregularities which could lead to more costly breakdowns.
Check all bolted assemblies for tightness. Inspect the entire drill for any loose, worn or missing
parts and replace them as needed. Inspect fluid lines, hoses, filler openings, drain plugs,
pressure caps, tires, derrick cables, hoist wire cables, muffler, engine, safety shrouds and the
area under the drill for signs of leakage.
Pay attention to the U-joint and flange bolts, rotary tophead mounting bolts, retract table
mounting bolts, air compressor mounting bolts, transfer case mounting bolts, mud pump gear
box bolts, leveling jack bolts and cable sheave pin locks.
NOTICE
Frequently walk around the drill and inspect for leaks, loose or missing
parts, damaged parts or parts out of adjustment. Perform all
recommended daily maintenance.
Operator's Areas
Keep operator's areas clean! Clean windshields, mirrors and all lights. Check that all lights
function.
Make sure the operator's areas, steps and grab rails are clean. Oil, grease, snow, ice or mud
in these areas can cause you to slip and fall. Clean your boots of excess mud before getting
on the drill.
Remove all personal items or other objects from the carrier cab and the operator's platform
area. Secure these items in the tool box, tool cabinet or remove them from the drill.

PRELIMINARY START INSPECTION
Pre-Start Inspection
FYI (For Your Information)
Before starting the drill, a pre-operation inspection of the overall drill is very important. This
inspection should be performed before each shift and at every startup. These are in addition
to the 8 hour daily routine maintenance. Performance of this inspection can result in longer life
and maximum productivity from the drill. The following are checks and verifications of the
overall drill that should be performed prior to starting the drill. Refer to the instructions given in
Section 6 "Maintenance Procedures"for the correct maintenance procedures and oil
specifications.
Engine Oil Level
Check the engine oil level on both the truck engine and the deck engine. Check the engine oil
level by viewing the engine dipstick. The drill must be level when checking the oil level to be
sure the measurement is correct. Wait at least 5 minutes after shutting off the engine to check
the oil level. This allows time for the oil to drain into the oil pan. If the oil level is low, add oil
through the fill cap to the full mark on the dipstick.
Hot oil and hot components can cause personal injury. Do not allow hot
oil or hot components to contact the skin.
A CAUTION
Never operate the engine with the oil level below the "L" (low) mark or
above the "H" (high) mark.

Truck Engine Coolant Level
A CAUTION
Engine coolant must be properly maintained to protect against engine
damage. Coolant must be tested at regular intervals to ensure it can
provide adequate protection against freezing, boiling and corrosion. It is
the owner's responsibility to know the type of coolant used and to
maintain it properly.
Removing the radiator cap on a hot engine can cause scalding coolant to
spray out and burn you badly. If the engine has been in operation within
the previous 30 minutes, be very careful in removing the radiator cap.
Protect face, hands and arms against escaping fluid and steam by
covering the cap with a large, thick rag. If you see any steam or coolant
escaping, don't try to remove it until the radiator cools down. If you see
nothing escaping, still remove the cap very slowly and be careful. Be
ready to back off if any steam or coolant begins to escape. Inhibitor
contains alkali. Avoid contact with skin and eyes.
WARNING
Always shut down the engine and allow to cool before removing the
radiator cap. Remove cap slowly to relieve pressure. Avoid contact with
steam or escaping fluid.
Top off a cooling system when coolant is no longer visible in the sight glass of a surge tank (if
equipped) on a cold engine. With the engine cold, top up with premixed coolant of the desired
freeze protection concentration. Add coolant through the pressure cap neck of the surge tank.
Pressure cap = 7 psi (.48 bar) for CAT engines, 15 psi (1.03 bar) for Cummins engines.
NOTE: If the coolant level is below the minimum level, the low level probe
will activate the engine shutdown. In the case of repeated low level
shutdowns, call for service to investigate the cause of coolant loss.
If coolant must be added, use a reliable brand of permanent antifreeze in a 50-50 mixture. It
must be used year round in all climates. Refer to instructions in Section 6 "Maintenance
Procedures" for the correct procedures.

• Section 5 - Operating Instructions
Deck Engine Coolant Level

Check engine coolant level on the radiator sight glass. The level should be maintained so fluid
can be seen in the sight glass.
SIGHT GLASS •
•a
II 1
a
4111111 ,1*.a.mr
401
Nit
•
•
0
4.6 .4
If the coolant level is low, refer to the instructions given in the Maintenance Procedures section
of Section 6 MAINTENANCE.
rA WARNING
Injury can occur when removing the radiator cap. Steam or fluid escaping
from the radiator can burn. Inhibitor contains alkali. Always shut down
the engine and allow to cool before removing the radiator cap. Remove
cap slowly to relieve pressure. Avoid contact with steam or escaping
fluid.
Fuel Level
Check the truck fuel level on the fuel level gauge on the truck dashboard. Check the deck
engine fuel level on the fuel level gauge on the operator's console. The tanks should be refilled
when the indicator needles move to below 1/4 tank. Refer to the Maintenance Procedures
section in Section 6 MAINTENANCE. Select the proper grade of fuel oil in accordance with the
instructions given in the Fuel Specifications section of Section 6 MAINTENANCE.

OPERATOR'S CONSOLE
FUEL
GAUGE
FUEL LEVEL
DISCHARGE WATER
TEMPERATURE [how man 'sir
TRUCK DASHBOARD
Maintain fuel tank(s) at a high level to minimize water condensation inside the tank(s). This is
best accomplished by filling the fuel tanks at the end of each shift or day. Check fuel tanks
and fuel lines for possible leaks. Because of the potential fire hazard, leaks must be corrected
as soon as they are spotted.
Fuel is flammable. May cause serious injury or death. Shut down engine,
extinguish all open flames and do not smoke while filling the tank. Always
wipe up any spilled fuel immediately.
1. Check the fuel level by reading the fuel level gauges.

2. Never allow the fuel tanks to completely empty, otherwise the entire fuel system
will require bleeding.
3. If the fuel level is low, add clean, filtered fuel.
4. Fill tanks with the correct grade of fuel. Refer to Section 6.3 Fuel Specifications
for more fuel details.
Fuel Filter/Water Separator
The fuel filter/water separators (if equipped) should be monitored daily for signs of water and
sediment. If water is present, drain the water and sediment from the filters/separators. Refer
to instructions given in 6.5 Maintenance Procedures for further information.
Fuel is flammable. May cause serious injury or death. Shut down engine,
extinguish all open flames and do not smoke while filling the tank. Always
wipe up any spilled fuel immediately.

Compressor Oil Level

Check the compressor oil level in the receiver tank. With the drill in a level position, the oil level
should be in the middle of the sight gauge.
OIL
LEVEL
SIGHT ,
GAUGE \.,it
• DRAIN VALVE
DRAIN VALVE
UNDER TANK
IA WARNING
High pressure can cause severe injury or death. Completely relieve
pressure before removing filler plug, fittings or receiver cover. Hot oil or
components can burn. Avoid contact with hot oil or components.
If necessary, add fresh, clean (filtered through a 10 micron filter) XHP605 synthetic oil through
the fill cap to bring the oil level to the middle of the sight gauge. If oil is required, follow the
instructions in Section 6.5 Maintenance Procedures for the correct procedures. Refer to
Section 6.3 Refill Capacities/Lubricants/Fuel for oil details.
Receiver Tank
•
When compressing air, water will condense in the receiver tank and mix with the compressor
oil. If allowed to accumulate, the water will significantly reduce bearing life. Follow the
instructions in Section 6 Maintenance Procedures for the correct procedure to relieve water
from the system.

lbw
BLEEDER VALVE
High pressure can cause severe injury or death. Do not attempt to remove
any plugs or open the drain valve before making sure all air pressure has
been relieved from the system. Hot Oil or components can burn. Avoid
contact with hot oil or components.
Batteries
Check the battery posts and cables for corrosion on the truck engine batteries and the deck
engine batteries. Check and keep the electrolyte levels above the battery plates or to the
bottom of the fill holes. See Section 6 Maintenance for the correct procedures.
DECK ENGINE BATTERIES
Batteries contain an acid and can cause injury. Battery fumes can ignite
and explode. Do not smoke when observing battery fluid level. Skin and
eye contact with battery fluid can cause injury. Avoid skin and eye
contact with battery fluid. If contact occurs, flush area immediately with
water.

Pump Drive Gearbox
Check the oil level in the Pump Drive Gearbox. The oil level must be level with the oil level plug
opening shown in the drawing below. Refer to Maintenance Procedures section of Section 6
MAINTENANCE.
BREATHER
AND FILL --------
PLUG
OIL
LEVEL ,
PLUG ----
DRAIN
PLUG
kA WARNING"
Rotating shaft can cause severe injury or death. Do not operate with
guard removed. Hot oil or components can burn. Avoid contact with hot
oil or components.
1. Move the drill to a level surface.

2. Stop the engine before checking oil level or adding oil.
3. Clean around the breather and oil fill plug before adding oil.
4. Check the oil level within the gearbox.
If it is necessary to add oil, refer to Section 6 Maintenance for the correct procedures.
Hydraulic Reservoir Oil Level
The hydraulic oil level should be checked by the sight gauge on the hydraulic tank. The oil level
in the hydraulic tank depends on the extended or retracted positions of the hydraulic cylinders.
It is important to follow the instructions in Section 6 Maintenance for the correct procedures
when reading the oil sight level gauge.

HYDRAULIC
OIL
SIGHT
GAUGE
OIL
TEMPERATURE
GAUGE
1. The oil level with all hydraulic cylinders retracted, derrick down, jacks up and
rotatytophead in retract position should be 1 inch (25.4 mm) from the top of the
oil level sight gauge.
2. The top of the oil level MUST be visible when the engine is running AND when
the engine is not running. There must be oil showing on the gauge at all times.
NOTE: If no oil is showing on the sight gauge, stop the engine

immediately. Call for service assistance to investigate the cause of oil
loss.
Add oil to bring oil to the level defined above by following the directions in the Section 6
Maintenance Section. Select the proper grade of oil in accordance with the information given
in the Section 6 Lube Specifications Section.
A CAUTION
Excessive hydraulic oil can rupture the sealed hydraulic tank and cause
injury or property damage. Do not fill the hydraulic tank with hydraulic
cylinders extended. Retract all cylinders and fill tank to indicated level.
A CAUTION
Any drill defects should be reported to the proper personnel. Defects
must be corrected before operating the drill.

NOTICE
Dirt in the hydraulic system will lead to premature component failure. A
clean, contaminant free system is extremely important to the drill's
proper function. Take extra care when working around or on the hydraulic
system to ensure its complete cleanliness.
Drain Hydraulic Tank Moisture
Some hydraulic tanks have a moisture bleeder valve underneath the hydraulic tank. Push this
bleeder up to drain moisture from the tank. Release the bleeder when the moisture has been
drained.
BLEEDER VALVE
Operator's Areas
1. Clean windshields, mirrors and all lights. Check that all of the lights function.
2. Make sure the operator's areas, steps and grab rails are clean. Oil, grease,
snow, ice, clay or mud in these areas can cause you to slip and fall. Clean your
boots of excess mud before getting on the drill.
3. Remove all personal items or other objects from the floor of the carrier cab and
operator's platform area. Secure these items in a tool box, tool cabinet or
remove them from the drill.
Verify Controls
Before starting the drill, a check to verify that the Warning Lights, Backup Alarm. Horn and
Emergency Stop controls are functioning properly is very important. This inspection should be
performed before each shift and at every startup.

A CAUTION
If any controls, instruments or devices do not function correctly, refer to
Section 7 TROUBLE SHOOTING or report any drill defects to the proper
personnel. Defects must be corrected before starting and operating the
drill.
Driver's Checklist
Safe Vehicle Operation
To keep your vehicle in top shape and to maintain its high level of safety for you and the drill,
make a thorough inspection every day before you drive. You'll save maintenance time later
and the safety checks could help prevent a serious accident. Please remember, too, that
Federal law requires a pre-trip inspection.
You aren't expected to become a professional mechanic. The purpose of your inspections is
to find anything that might interfere with the safe and efficient transportation of yourself and
your drill. If you do find something wrong and can't fix it yourself, please have a qualified
mechanic fix it right away.
For your safety, as well as those around you, be a responsible driver:
1. If you drink, do not drive.

2. Do not drive if you are tired, ill or under emotional stress.
Much has gone into the manufacturing of your carrier, including advanced engineering
techniques, rigid quality control and demanding inspections. These manufacturing processes
will be enhanced by you, the safe driver, who observes the following:
1. Knows and understands how to operate a vehicle and all of its controls.
2. Maintains the vehicle properly.
3. Uses driving skills wisely.
Do not drink and drive. Your reflexes, perceptions and judgement can be
affected by even a small amount of alcohol. You could have a serious, or
even fatal accident, if you drive after drinking. The use of alcohol, drugs
and certain medications will seriously impair perception, reactions and
driving ability. These circumstances can substantially increase the risk of
an accident and personal injury.

The daily checks listed below are the foundation of your overall preventive maintenance
program.
Vehicle Check
1. Check the overall appearance and condition. Are windows, mirrors and lights
clean and unobstructed?
2. Check beneath the vehicle. Are there signs of fuel, oil or water leaks?
3. Check for damaged, loose or missing parts. Are there parts showing signs of
excessive wear or lack of lubrication? Have a qualified mechanic examine any
questionable items and repair them without delay.
Check Under Truck Hood and Cab
With the engine stopped:
1. Check the engine oil level; top off as necessary. Refer to your engine's
operating manual for the type of oil to use.
2. Check the engine coolant level while the engine is cold. Top off as necessary
with premixed coolant. Refer to instructions for adding coolant to the proper
level.
3. Check the engine belts. Refer to the instructions to check belt condition and
adjust tension.
4. Check brake lines and hoses.
5. Check all other accessories, controls, belts, hose and wiring for condition and
adjustment.
6. Check the windshield washer fluid level; top off if necessary.
7. Check the power steering fluid reservoir; top off if necessary.
8. Check the steering components (pitman arm, draglink, power steering hoses,
etc.)
9. Drain the fuel/water separator.
10. Check the fire extinguisher charge.
11. Check the road emergency kit. Is it complete?
12. Check the windshield washer fluid level; Top off if necessary.

Check Outside the Vehicle
A WARNING
Diesel fuel in the presence of an ignition source (such as a cigarette)
could cause an explosion. You could be seriously injured. A mixture of
gasoline or alcohol with diesel fuel increases this risk of explosion. Use
only the fuel recommended for your engine.
A WARNING
Hot fuel vapors are combustible and can cause an explosion or fire
resulting in injury or death. Do not remove a fuel tank cap near an open
flame.
1. Be sure all wheel nuts and cap nuts are secure. Check wheel cap nut torque
weekly; refer to the instructions.
2. Check tires for condition and proper inflation.
3. Check the front wheel bearing lube level.
4. Check the parking (spring) brakes as to the condition and tightness of air lines,
breathers, clamp rings & bolts, mounting studs and release bolts.
5. Check turn signal operation.
6. Check emergency flashers and exterior lamps.
7. Check the fuel tanks. Is there enough fuel? Are the tank caps secure?
8. Visually inspect the fuel tank mounting hardware. Are the tank straps tight? Is
the webbing in place?
9. If equipped with fuel tank mounting steps: are they damaged or broken? Is the
grommet / windlace in place between the tank and side plate? Are bolts missing
or loose?
10. Check the air cleaner(s) and muffler(s). Are they tight and secure?
11. Check for loose or missing suspension fasteners.
12. Check springs or other suspension parts for damage such as cracks, gouges,
distortions, bulges or chafing.
13. Check the air system. Are there leaks?

14. Drain excess moisture from all air supply tanks. Make sure the drain cocks are
closed. This procedure is also required for air supply tanks equipped with
automatic drain valves.
15. Check that cab latch or hood holddowns are hooked.
In-Cab Check
A CAUTION
To avoid injury while entering or leaving the cab, keep your feet in contact
with the steps and your hands on the handhold. Always have three points
of contact as you enter or exit a cab.
1. Adjust the seats.

2. Fasten and adjust safety restraint belts.
3. Adjust the steering column.
4. Check mirror adjustment.
5. Operate air powered devices to circulate lubricants.

STARTING TRUCK ENGINE
Starting Engine
Starting & Operating Truck Engine
Since each vehicle is custom equipped, all engine operation instructions in this manual are
general. You will want to consult the manual for your engine to find out details about your
specific engine's needs. You may need to use a slightly different procedure from the one
outlined here.
Also check the ATA Truck Driver's Handbook in your driver's side door compartment. It will
give you tips on starting, shifting and driving a truck.
WARNIZ
Read and understand Section 2-2 "Safety Precautions and Guidelines"
drill.
and understand Section 4 "Controls" before you operate or perform any
maintenance, service or repairs on the drill.
1. Before starting the engine and beginning to drill, check inside, outside and
underneath drill for people or obstructions.
2. Check for warnings or Lockout tags on the controls. If there is a tag attached to
the switch, do not start the engine until the warning tag has been removed by
the person who installed it.
3. START the truck engine from the driver's position in the truck cab.
A CAUTION
If any controls, instruments or devices do not function correctly, refer to
the TROUBLE SHOOTING section and report any drill defects to the
proper personnel. Defects must be corrected before starting and
operating the drill.
Following are instructions for both normal temperature starting and cold weather starting.

Normal Temperature Start Procedure
When the outside temperature is about 50°F (10°C), you can use the following procedure.
1. Make sure all operator drill console controls are either in "OFF" or "NEUTRAL"
positions.
The slow feed control must be in the "CENTER" (neutral) position before
starting the engine. If accidentally bumped into an operating position, it
will cause serious damage when air is transferred back to the operator's
console.
2. Set the Parking Brake.

3. Put your main transmission in Neutral.
4. Disengage (depress) the clutch (manual transmission).
5. Turn the key switch to START (starter activation to start engine).
A WARNING
Do not depress the accelerator pedal or move the accelerator lever from
the idle position while cranking the engine. This can result in engine
overspeed and severe damage to the engine.
A CAUTION
To prevent damage to the starting motor, do not engage the starting
motor for more than thirty seconds. Wait 2 minutes between each attempt
to start.
A CAUTION
Never operate the starter motor while the engine is running. The starter
and flywheel gears could clash and jam, severely damaging them.

6. If engine does not start within 30 seconds, release the starter switch. To avoid
overtaxing the starter motor or the batteries, don't use the starter for more than
30 seconds. Let the starter motor cool and the batteries recover for two minutes
before trying again. If the engine still won't start after a couple of tries, check
the manual override shutdown valve and fuel lines for possible fuel starvation
or air leaks. Starting failure may mean fuel isn't reaching the injectors. The
absence of blue or white exhaust smoke during cranking indicates no fuel is
being delivered.
7. As soon as the engine starts, begin to watch the oil pressure gauge. Check
your engine manufacturer's manual for the right pressure for your engine. If the
oil pressure doesn't rise within a few seconds, stop the engine. Find out what
is wrong before starting the engine.
A CAUTION
The engine must have adequate oil pressure within 15 seconds after
starting. If the WARNING lamp indicating low oil pressure has not gone
out or there is no oil pressure indicated on a gauge within 15 seconds,
shut off the engine immediately to avoid engine damage.
8. Slowly engage (release) the clutch after the engine has started.
9. Idle the engine 3 to 5 minutes before operating with a load. Wait until normal
engine oil pressure registers on the gauge before idling or accelerating engine
beyond 1000 RPM.
Cold Temperature Start Procedure
In cold weather, fast engine starting helps relieve the loads on the electrical system and
cranking motor. Using the special cold starting equipment will help starting. If you follow a few
simple guidelines, you will extend the service life of your engine.
1. Keep the electrical system in top condition.

2. Use the best quality fuel of the recommended lubricating oil.
3. Use recommended engine lubricating oil.
IA WARNING
The fluid in ether starting systems is extremely flammable and
poisonous. If you swallow it, it can be harmful or fatal.
1. Do not smoke when testing, installing or servicing an ether starting unit.

Service it in a well ventilated area away from heat, open flames or sparks.

2. If swallowed, do not induce vomiting, Call a physician immediately.

3. Wear goggles to avoid getting fluid in your eyes. Avoid getting it on
your
skin and avoid breathing the fumes. If fluid does get in your eyes or fumes
irritate your eyes, flush for 15 minutes with large amounts of clean water.
Contact an eye specialist.
4. Do not move or relocate the ether cylinder or tubing from its origina
l
installation. It must be mounted to protect it from engine exhaust heat
and also from moving parts which could damage it.
5. Do not store the spare cylinder in the cab.
6. In warm weather, when you will not need the ether starting system
,
remove the ether bottle from the truck and store it safely. Also, return the
protective cap to the bottle mounting connector.
In cold weather the engine will start faster and the starter motor will work more
easily if ether
is injected into the engine cylinder while the engine is being cranked.
Automatic System
When you turn the ignition key to "START", the cranking motor and the ether system
are
engaged. When needed, starting fluid is released from a pressurized cylinder, flows
through a
valve and tubing and sprays from a nozzle in the engine's air intake system. For
more helpful
starting information, refer to the engine manual that came with your vehicle.
Engine Warm-up
The purpose of engine warm-up is to allow oil film to be established between pistons
and
liners, shafts and bearings while the engine gradually reaches operating tempera
ture. After
starting a cold engine, increase the engine speed (rpm) slowly to provide adequat
e lubrication
to the bearings and to allow the oil pressure to stabilize.
A CAUTION
Do not operate engine at low idle for long periods with engine coolant
temperature below the minimum specifications. This can result in the
following:
1. Fuel Dilution of the lubrication oil

2. Carbon build up in the cylinder
3. Cylinder head valve sticking
4. Reduced performance
DRILLING SOLUTIONS
5-23
Warm-up Procedure
1. After you've started the engine, idle it at approximately 600 PRM while you
check:
a. Oil Pressure
b. Air Pressure
c. Alternator Output
2. After a few minutes of idling at 600 RPM, increase the idle speed up to 900 or
1000 RPM. Continue your warm-up. This procedure allows oil to warm and flow
freely while pistons, liners, shafts and bearings expand slowly and evenly. In
extremely cold temperatures, you may have to increase idle speed.
NOTE: In colder climates where the temperature is often below freezing, the warm-
up for turbocharged engines is especially important. Chilled external oil lines
that lead to the turbocharger will slow the oil flow until the oil warms, reducing
oil available for the bearings. Watch the engine oil temperature or pressure
gauge for a warming trend before increasing engine idle speed (RPM).
3. Continue the engine warm-up until the coolant temperature reaches 130°F
(54°C). At this temperature, you can use partial throttle. Wait until the coolant
temperature is at least 160°F (71°C) before operating at full throttle.
Exhaust fumes from the engine contain carbon monoxide, a colorless

and odorless gas. Do not breath the engine exhaust gas. A poorly
maintained, damaged or corroded exhaust system can allow carbon
monoxide to enter the cab. Entry of carbon monoxide into the cab is also
possible from other vehicles nearby. Failure to properly maintain your
vehicle could cause carbon monoxide to enter the cab and cause serious
illness.
A WARNING
DO NOT OPERATE A DIESEL ENGINE WHERE THERE ARE OR CAN BE
COMBUSTIBLE VAPORS. The vapors can be sucked through the air
intake system and cause engine acceleration and overspeeding that can
result in a fire, an explosion and extensive property damage. Numerous
safety devices are available, such as air intake shutoff devices, to
minimize the risk of overspeeding. THE EQUIPMENT OWNER AND
OPERATOR ARE RESPONSIBLE FOR SAFE OPERATION IN A HOSTILE
ENVIRONMENT. CONSULT YOUR OEM AUTHORIZED REPAIR
LOCATION FOR FURTHER INFORMATION.

A CAUTION
Do not expose the engine to corrosive chemicals. Corrosive chemicals
can damage the engine.
A CAUTION
Never idle the vehicle for prolonged periods of time if you sense that
exhaust fumes are entering the cab. Investigate the cause of the fumes
and correct it as soon as possible. If the vehicle must be driven under
these conditions, drive only with the windows slightly open. Failure to
repair the source of the exhaust fumes may lead to personal harm.
Winterfronts and shutters can be used on a vehicle or equipment to reduce air flow through
the radiator core into the engine compartment. This can reduce the time required to warm the
engine and help maintain the engine coolant temperature.
A CAUTION
The use of a winterfront can result in excessive engine coolant, oil and
charge air (intake) temperatures, which can lead to overheating and
possible engine damage.
Use only a winterfront available from the OEM dealer that is compatible
with a 2002 EPA-compliant engine cooling system. These winterfronts
are specifically designed for use with new grill snap patterns.
NOTICE:
1. Keep the engine exhaust system and the cab ventilation system properly
maintained. It is recommended that the vehicle's exhaust system be inspected:
a. By a competent technician every 15,000 miles

b. Whenever a change is noticed in the sound of the exhaust system
c. Whenever the exhaust system, underbody or cab is damaged.
2. Do not stay in the vehicle with the engine running or idling more than 10
minutes with the vehicle's Heater and NC ventilation system in the RECIRC or
at LOW FAN SPEED. Even with the ventilation system ON, running the engine
while parked or stopped for prolonged periods of time is not recommended.

3. If other vehicles are parked next to you idling, move your vehicle or do not stay
in the vehicle for prolonged periods of time.
Operating the Engine (Normal)
If equipped, monitor the oil pressure and coolant temperature gauges frequently. Refer to
Section 6 Refill Capacities/Lubricants/Fuel for recommended specifications. Continuous
operation with engine coolant temperature above or below the engine coolant temperature
specifications can damage the engine.
If an overheating condition starts to occur, reduce the power output of the engine by releasing
the accelerator pedal or lever or shifting the transmission to a lower gear (when in driving
mode), or both, until the temperature returns to the normal operating range. If the temperature
does not return to normal, shut off the engine and refer to Trouble shooting or contact a local
Authorized Engine Repair Location.
Most failures give an early warning. Look and listen for changes in performance, sound or
engine appearance that can indicate service or engine repair is needed. Some changes to look
for are:
1. Engine misfires
2. Vibration
3. Unusual engine noises
4. Sudden changes in engine operating temperatures or pressures
5. Excessive smoke
6. Loss of power
7. An increase in oil consumption
8. An increase in fuel consumption
9. Fuel, oil or coolant leaks
Operating the Engine (Cold Weather)
It is possible to operate engines in extremely cold environments if they are properly prepared
and maintained. Satisfactory performance of an engine in low ambient temperature conditions
requires modification of the engine, surrounding equipment, operating practices and
maintenance procedures.
The correct engine coolant, lubricating oil and fuels must be used for the cold weather range
in which the engine is being operated. Below are the recommendations for these critical
engine fluids:
Ambient Temperature of 0°C to 32°C (32°F to - 25°F)
1. Use 50% ethylene glycol antifreeze and 50% water for the engine coolant
mixture.

2. Refer to Maintenance Specifications (Section 6) Oil recommendations for the

correct specifications.
3. Diesel fuel must have maximum cloud and pour points 6°C (10°F) lower than
the ambient temperature in which the engine operates.
Ambient Temperature of -32°C to 54°C (-25°F to -65°F)
1. Use 60% ethylene glycol antifreeze and 40% water for the engine coolant
mixture.
2. Refer to Maintenance Specifications (Section 6) Oil recommendations for the
correct specifications.
3. Diesel fuel must have maximum cloud and pour points 6°C (10°F) lower than
the ambient temperature in which the engine operates.
Winterfronts and shutters can be used on a vehicle or equipment to reduce air flow through
the radiator core into the engine compartment. This can reduce the time required to warm the
engine and help maintain the engine coolant temperature. Use only a winterfront available
from an OEM dealer that is compatible with a 2002 EPA compliant engine cooling system.
Refer to the engine manual for additional information on cold weather operating aids.

STARTING DECK ENGINE
Deck Engine Starting Safety

Safety is always the first step in starting the engine.
WARNING
Read and understand Section 2-2 "Safety Precautions and Guidelines"
drill.
and understand Section 4 "Controls" before you operate or perform any
maintenance, service or repairs on the drill.
1. Before starting engine, check the working area on, around and under the drill
for people or obstructions.
2. Check for Warning or Lockout tags on the controls. If there is a tag attached to
the switch, do not start the engine until the Warning tag has been removed by
the person who installed it.
3. Start the engine from the operator's station only.
4. Avoid leaving the controls with the engine running. Never leave the operator's
area while the engine is running.
Starting Procedure
ENGINE SHUT DOWN
START IGNITION
BUTTON SWITCH

1. Move all levers, switches, controls, etc. to the OFF, Neutral or minimum flow
position.
2. The Engine Shut Down Switch must be in the out or "on" position.
3. Make sure the compressor In/Out Box (if equipped) is disengaged and the
Handle Locking Pin is in place.
HANDLE LOCKING PIN

MUST BE INSTALLED COMPRESSOR IN/OUT BOX
BEFORE ENGINE WILL MUST BE DISENGAGED FOR
START ENGINE START UP
4. Turn the key operated ignition switch to the "ON" position.

5. Start the engine by pushing and holding the "Engine Start" button until the
engine starts.
NOTICE
If engine does not start after 30 seconds of cranking, stop cranking and
wait 2 minutes for the starting motor to cool and then try again. If unit has
a cold start option, heat engine until water temperature is 100°F (37.8°C),
then start engine.
6. Allow the engine to warm up at idle speed for a minimum of 5 minutes. Warm
up time should be extended when extreme low ambient conditions (cold
weather) occur or when the battery power is depleted during initial startup.
NOTICE
Allow engine to warm up to 100°F (37.8°C) before starting to drill.
7. Check engine and compressor Air Cleaner indicators.

8. Check the Hydraulic Filter Bypass indicator.
9. Increase engine speed by turning the throttle until maximum RPM is reached.

Compressor In/Out Box Operation (If Equipped)
The In/Out box, located between the engine and the compressor, allows all drill operations to
function with the compressor disengaged. The In/Out box is operated via the lever located on
the deck on the rod box side of the drill.
At initial startup, the deck engine should be started with the In/Out box disengaged. After
allowing the engine to warm up for five minutes at idle speed, shut the engine down.
Engage the In/Out box and restart the engine. Allow the compressor to warm up in the
unloaded condition at idle speed for five minutes. Increase engine speed to maximum RPM,
load the compressor at 120 psi minimum pressure before increasing discharge pressure.
Do not attempt to engage or disengage the In/Out box while the power
pack engine is running. Engine must be off to engage or disengage the
In/Out box.
NOTICE
Lubricate the lever assembly of the In/Out box at 100 hour intervals.

OPERATING
General Information
WARNINCO
drill.
Always wear correct safety gear while working on or around the drill. This includes an
Approved Hard Hat, Safety Glasses, Steel Toe Shoes, Gloves, Respirator and Ear Protection.
Do not wear loose fitting clothing that can become caught in rotating components.
and understand Section 4 - Operating Controls 8 Instruments.
1. Do not speed engine when it is cold.

3. Always perform safety checks prior to starting and using the drill.
7. Before starting engine, always check to see that the control levers and feed
controls are at stop, neutral or off position and that the parking brakes are
applied.
personnel and allow sufficient time before putting the drill in motion.

Operation
1. Before the drill startup, a pre-operational general inspection of the T3W
Waterwell drill should be performed in accordance with those instructions
previously mentioned and in the instructions found in the Maintenance Section
(Section 6).
2. Lower the driller platforms from road (driving) position to drilling position. Unbolt
the bottom bolt and push the platforms down to a horizontal position as shown
below.
OPERATOR'S
SIDE
DRILLER
PLATFORM
3. Make sure all operator console controls are either "OFF" or in the "NEUTRAL"
position and all control console gauges read zero.

4. Make sure the Emergency Stop button is in the pulled out position (reset).
5. Start the deck engine from the operator's platform only. Turn the ignition switch
to the "ON" position. Press the start button. When the engine starts, release the
start button.
NOTICE: As a general rule, DO NOT operate the starter motor more than 30
seconds at a time without pausing to allow the starter motor to cool for at least
2 minutes. Overheating, caused by excessive cranking, will seriously damage
the starter motor.
6. Allow the engine to warm up at idle speed (1200 RPM) for a minimum of 5
minutes. Warm up time should be extended when extremely low ambient
conditions (cold weather) occur or when battery power is depleted during initial
start up.
7. Check the Engine and Compressor Air Cleaner indicators to determine if those
elements require servicing.
8. Check the "Filter Bypass" indicator on the operator's console to determine if
those elements require servicing.
9. Check the panel gauges to insure all readings (pressures and temperatures)
are within specifications:
a. Tachometer: Idle Speed = 1200RPM

b. Engine Water Temperature Gauge: 125°F to 165°F (51°C to 74°C)
10. Transfer the air pressure from the deck engine compressor to the operator's
console by turning the air transfer valve to a horizontal position.
AIR
TRANSFER
VALVE

Leveling the Drill
IL A WARNING'S
Be sure the ground is level and solid before lowering the jacks. Never
stop the drill against a high wall that is liable to collapse or cause a
crushing risk.
Remember, in the level position, the jacks alone must carry the entire
weight of the drill. In deephole drilling (more than 300 feet)), it is
imperative that adequate cribbing be used. THE LIABILITY FOR TIPPING
A DRILL OVER LIES SOLELY WITH THE DRILLER.
1. Check ground conditions under the drill. Make sure it will support the weight of
the drill.
2. Install suitable Cribbing (Blocking) under all jacks as required for ground
conditions. The purpose of cribbing is to increase the area of jack pad.
•e
3. Increase engine speed to 1800 RPM maximum with throttle control lever.
0 _0
• 0
-
THROTTLE
4. Raise the leveling jacks valve levers to extend the jacks and raise the drill.
Methods may vary, but one way would be to extend the two rear jacks at the
same time and then the two front (mid) jacks. Raise the drill evenly (front to rear
and side to side) until the desired level is reached.
0 0
BUBBLE
LEVEL
- „r-
e 0 0
LEVELING JACKS

WARNING
Raise the drill evenly to avoid inducing a twist into the truck frame.
5. Keep the drill as low to ground as possible to lower the risk of

rollover if ground
gives away under one jack.
6. Level the drill to the drill level bubble.
NOTICE: The derrick is plumb when the drill level bubble is centered.
Raising the Derrick
A DANGER
Before raising the derrick, make sure there are no overhead electri
cal
power lines in the immediate vicinity.
A DANGER 0
BUBBLE
LEVEL
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DERRICK RAISING
WARNING
Check all hoses and cables to be sure they are free and clear. Check
the
derrick for any tools or loose objects before raising the derrick.
1. Ensure the drill is level. The drill should be on its jacks and level at its lowest
possible position.
NOTICE: Check the blocking and cribbing before raising the derrick.
2. Increase engine speed to full RPM by turning the throttle clockwise.
3. Add slack to the main hoist cable if the cable is tied off. Check all hoses
and
cables to make sure they are clear and free and remain so during raising.
DRILLING SOLUTIONS
5-35
on the main
4. Remove the derrick anchor bolts from the derrick foot rests located
frame and store them in the table as shown below.
DERRICK DERRICK ANCHOR DERRICK
FOOT REST BOLT STORAGE FOOT REST
the control
5. Locate the derrick raising control lever. (Raise the derrick by pulling
lever up. Lower the derrick by pushing the control lever down.)
snag or bind
NOTICE: Recheck hoses and cables making sure they do not
during raising.
approaches
6. Raise the derrick until it is in the vertical position. Before the derrick
n (or "feather"
the vertical position, slowly move the control to its center positio
slam derrick
the control) to allow the derrick to position without impact. Do not
against stops.
with the bolts
7. When the derrick is raised, bolt it down to the derrick foot rests
re will warp the
removed in step 4. If not bolted down, any stress or pressu
anchor bolts
derrick and cause severe damage. CAUTION! Never drill with
unfastened.
8. Recheck to make sure the drill is still level.
9. Check the Overpressure Controls before drilling.
Rotary Head Retract

the drill
1. The rotary head should be in the retract (inner track) position. Move
up and out of the retract
feed control to UP position until the rotary head moves
when going out of
position. The retract gates will open and close automatically
retract.
the rotary
2. Move the rotary head fast feed control to DOWN position and bring
head to the bottom of the derrick.
DRILLING SOLUTIONS
5-36
3. Grease the rotary head spindle sub threads.

4. Move the rotary head fast feed control to UP position and raise the rotary head
above the retract gates.
5. Follow these steps to bring the rotary head into retract position:
A.
OPERATORS
FOLDING
PLATFORM
UPPER
BREAKOUT
WRENCH
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a. Step on the powerhead retract foot pedal to open the retract gates on the
guide channel.
b. While holding the powerhead retract foot pedal down, move the drill feed
control to DOWN position to start the rotary head moving into retract.
c. Once the rotary head starts moving into retract position, release the
powerhead retract foot pedal or damage to the main air hose and rotary
head hoses will occur.
d. Move the drill feed control to "CENTER" (neutral/stop) position when the
rotary head is fully into retract.
Over Pressure Control Check
The T3W feed system provides more than enough feed capability to "lift" the drill by over
feeding the bit. To reduce the possibility of tipping the drill over due to operator error in over
feeding, the "Over Pressure Control" has been added to the feed circuits.
A WARNING
The Over Pressure Control does not relieve the operator from the
responsibility of having control of the drill at all times. While the Over
Pressure Control reduces the chances of a tipover, the operator must see
that he does not overfeed the drill to this extent.

NOTICE: The operator must ensure the jacks are located on firm ground. Nothing can prevent
the drill from upsetting if the ground or shoring under the jacks gives way.
NOTICE
LIABILITY FOR TIPPING A DRILL OVER LIES SOLELY WITH THE
DRILLER.
To ensure the over pressure control is operational and working properly, the following
procedure should be performed daily or before each drilling shift:
PISTON IN
THE OVER
PRESSURE
VALVE
1. Locate the drill on a level, graded surface. Raise and level the drill just high
enough so that the pistons in the over pressure valves on the drilling end jacks
are no longer depressed. The tires should be just off the ground.
2. Raise and lock the derrick.
3. Remove all drill rod, stabilizers, hammers, etc. from the rotary head.
4. Lower and stall the empty rotary head at the bottom of the derrick using slow
feed.
5. Raise the leveling jack on the drilling end rod box side enough to depress the
over pressure piston.
6. Read the feed pressure gauge and verify the feed pressure drops below 600
psi.
NOTICE: If the feed pressure does not drop below 600 psi, troubleshoot and
repair the circuit.
7. Repeat the above for the drilling end console side leveling jack.
8. Repeat the above process using the fast feed control.
If all checks are met, the over pressure control is functional and drilling can proceed.

Rotary Head Swivel

After the Over Pressure Control check and with the rotary head still at the bottom of the derrick,
lubricate the packing and bearings before rotating the swivel, especially if the drill has not been
operated over a period of time. Slowly rotate the spindle/swivel to unstick the packing from the
washtube.
`-',.13RICATE FACKNG EVERY

3-4 I-oun OF OPERATION
OR 1A, IEN PACKING BEGINS
TO LEAK
LJER;CA7E BEARING. AS
SPINDLE S RCTATING.
AF-ER TI-E I-01, P
CF CFEPATICN
ROTARY HEAD vivive',_
NOTICE: Lubricate the bearings, with the spindle rotating, after the first hour of operation.
•
Lubricate the packing every 3 - 4 hours of operation or when it begins to leak.
Compressors
Air to operate drilling functions (sliding breakout wrench, upper holding wrench, retract
cylinders) originates from the deck engine compressor and is transferred to the drill console
through the air transfer valve.
Compressed air for down hole air and DHD air originates from a high pressure two stage, over/
under, oil flooded asymmetrical rotary screw compressor driven by the deck engine.
Once the drill is level, the derrick raised and the overpressure control is checked, the
compressor must be engaged.
Electronic Air Regulation
At start up the electronic M2C controller will activate the butterfly valve to the closed position,
preventing air entry into the compressor, and will open the vent valve to vent any trapped air
in the system and the receiver to atmosphere. This allows the engine to start with the least
possible load. After engine speed reaches the minimum RPM (low idle), there is a factory set
delay time to allow the engine to stabilize after which the M2C controller regulates the
compressor to which ever input is applicable (On/Off, Flow or Pressure command).
1. Turn the compressor On/Off Switch "On" to energize the flow and pressure
control commands. When the switch is in the on position, the Flow and
•
Pressure control knobs are active and their combined inputs to the MC2
controller regulate the desired compressor output. When the switch is in the off
position, the Flow is set to the minimum flow required to prevent damage to
the compressor and the Maximum pressure is set to the minimum holding tank
pressure.

2. When the compressor on/off switch is in the on position, the Flow Control
knob regulates the flow into the compressor between the minimum flow
(required to prevent damage to the compressor) and maximum flow (full open
position on the butterfly valve).
3. When the compressor on/off switch is in the on position, the Pressure Control
knob regulates the maximum pressure in the receiver tank between the
minimum holding tank pressure and the maximum working pressure of the
compressor system.
Compressor (Without In/Out Box)
Before starting a drill that is not equipped with an In/Out Box, make sure the Flow Control knob
and the Maximum Pressure Control knob on the upper operator's control panel are turned to
the left (turned off). When starting the drill, the compressor flow and pressure controls should
not be active, but the compressor will still build air to the minimum pressure and will register
the minimum pressure on the Receiver Pressure Gauge.
RECEIVER INTERSTAGE PRESSURE
PRESSURE
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PRESSURE 0 INTERSTAGE
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THROTTLE
THROTTLE ENGINE ON-LOCK

START KEY SWITCH
1. Increase engine speed to 1800 RPM (maximum RPM).

2. Turn the compressor on/off switch to the "ON" position.
NOTICE
Do not switch compressor to "ON" position at less than full engine speed.
3. Adjust Maximum Pressure Control and Flow Control to desired settings.

Maximum Pressure reading can be seen on the Receiver Gauge.
4. Interstage Pressure will register indicating the compressor is building air.

5. Oil level must be between the middle and the top of the sight glass when drill is
running and compressor is on.
OIL LEVEL
FILL PLUG
OIL LEVEL
SIGHT
GLASS
Compressor (Equipped With In/Out Box)
Before starting a drill that is equipped with an In/Out Box, make sure the Flow Control knob
and the Maximum Pressure Control knob on the upper operator's control panel are turned
to
the left (turned off). When starting the drill, the compressor flow and pressure controls should
not be active, but the compressor will still build air to the minimum pressure and will register
the minimum pressure on the Receiver Pressure Gauge.
RECEIVER INTERSTAGE PRESSURE

PRESSURE
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MAXIMUM
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THROTTLE ENGINE ON-LOCK

START KEY SWITCH
1. Decrease the engine speed to idle by turning the engine throttle to the left
(counter clockwise).
2. Turn the engine off with the On/Lock Key Switch.

3. Remove the handle locking pin, move the compressor In/Out Box to the
engaged position, then reinstall the pin (the pin must be installed before the
engine will start).
HANDLE LOCKING PIN

COMPRESSOR IN/OUT BOX
MUST BE INSTALLED MUST BE DISENGAGED FOR
BEFORE ENGINE WILL ENGINE START UP
START
4. Turn the ON-LOCK Key Switch "ON".

5. Start the engine by pushing the "Engine Start" button.
NOTICE
If engine does not start after 30 seconds of cranking, stop cranking and
wait 2 minutes for the starting motor to cool and then try again. If drill has
a cold start option, heat engine until water temperature is 100°F, then
start engine.
6. Allow the engine to warm up at idle speed for a minimum of 5 minutes. Extend
the warmup time should extreme low ambient conditions (cold weather) occur
or when the battery power is depleted during initial startup.
7. When the engine is started, the compressor flow control and maximum
pressure control will not be active but the compressor will still build air to the
minimum pressure and will register the minimum pressure on the Receiver
Pressure Gauge.
8. Increase the engine speed to 1800 RPM (maximum RPM).
9. Turn the compressor on/off switch to the "ON" position.
NOTICE
Do not switch compressor to "ON" position at less than full engine speed.
10. Adjust Maximum Pressure Control and Flow Control to desired settings.
Maximum Pressure reading can be seen on the Receiver Gauge.

• Section 5 - Operating Instructions T3W Instruction Manual
11. Interstage Pressure will register indicating the compressor is building air.
12. Oil level must be between the middle and the top of the sight glass when drill is
running and the compressor is on.
OIL LEVEL
FILL PLUG
OIL LEVEL
SIGHT
GLASS
•
Rotary Drill
Rotary Drill String
Rotary drilling methods use the combination of raw weight and rotation to chip and carve rock
from a hole. The rotary method works fine in soft formations where adequate weight and stress
can be applied to the rock to initiate fracture and chipping.
Rotary drilling is done by rotating a tricone bit against the rock while applying sufficient down
pressure onto the bit to crush the rock. A stabilizer is normally used to keep the hole straight
and to prevent the bit from becoming stuck.
After the drill has been set up for drilling, there are a number of operations which involve
handling heavy drill rods, drill bits and other components used for various drill rod and drill bit
changing procedures.
go
A WARNING .
Heavy components must be handled with care using appropriate lifting

aids provided to facilitate heavy component lifting operations.
WARNING
• Read and understand Section 2 - Safety Precautions and Guidelines

drill.

WARNING
and understand Section 4 - Operating Controls 8 Instruments.
Rotary Drill String Assembly
Illustrated below are the drill string and the accessories and tools needed to install and change
drill pipe, bits and spindles
ROTARY reAD
USi
SPSIN
DRILL
PIPE
CROSS OVER sue

fusee WITH STNIVUZeR)
STABLZER ANO COLLAR

BUSKING (V REQUIRED) DRILL COLLAR
OR TABLE CENTRALIZER USED wrrri
BUSHING (W REMISED) STABILIZER
(OPTIONAL)
Sr" SUB IS JSED V,MEN

TpICCP.E err
STABILIZER AND DRILL
COLLAR ARE NOT
USED
DRILL STRING

Rotary Drill String Assembly (Continued)
AUXILIARY
MOIST CABLE
CMAN WRENCI"
NOTE: CARRY EXTRA LINKS TO

EACH JOB SITE
1 LINK • 1 INCH. MMUS
SLIC:N3 FC:K
DRILL. STRING
ACCESSORIES
The process for building the Rotary Drill String assembly starts with
loading the stabilizer and
the spindle sub and crossover sub, if required. Next the tricone bit
is mounted, then the drill
pipe is added. In some cases, a stabilizer is not needed and the tricone
bit is mounted onto a
bit sub installed in place of the stabilizer assembly.
Loading Stabilizer, Tricone Bit and Stabilizer Bushings
The T3W is designed to drill a variety of holes. Some holes will require
a stabilizer at the
bottom of the drill string. Follow the process below to mount the stabiliz
•
er, bit and bushings.
1. Select the stabilizer and manually screw on the crossover sub,
if needed.
2. Install hoist (lifting) plug onto sub/stabilizer and connect main hoist
cable.
DRILLING SOLUTIONS
5-45
WARNING
between
Be sure a good joint has been made by looking at the connection
moving the
the lifting bail and the stabilizer pin end threads before
stabilizer.
Retract Rear
- Table Section
Centralizer Tabk Control

(Pull Control Up To Retract Table)
Remove Pin To Open Open Front Pull Control Up

Front Table Section Table Section to Retract Table
stabilizer through
3. Retract the table. Then open front table section and lower the
opening.
can be raised
4. Raise hoist until stabilizer is above centralizer table. The hoist
on the operat or's consol e and the other
from one of two controls. One is located
l away from the operat or to raise the
is at the helper's controls. Push the contro
hoist.
A WARNING
Do not let the centralizer bushing drop into the drilled hole.
table, so the
5. Put a block of wood or metal on the ground, underneath the drill
ctions. For
stabilizer or starter pipe can rest on the ground while making conne
a fork chuck
short stabilizers, secure the upper section on the drill table with
wrench so rotary head can be threaded to it.
DRILLING SOLUTIONS
5-46
CENTRALIZER
BUSHING
6. Install the centralizer bushing.

7. Lower stabilizer or starter pipe through table and onto the block of wood or
metal plate on the ground. Close the front table section, then close the back
table section.
•
8. Remove hoist plug and move hoist cable out of the way.
9. Lubricate threads of sub/stabilizer with tool joint compound.
ROTATION SLOW FAST
CONTROL FEED FEED
UPPER
BREAKOUT
WRENCH
•
POWERHEAD r a ;,r;,;(;1;:t; r; r;111. t
i
RETRACT /0 4A, ef 4100 le l.r.;* I Vi `— '47.
ii4t4 4140 iti•i•It feo V. •
10. Bring rotary head out of retract and feed it down the derrick until it is just above
stabilizer. To feed the rotary head down the derrick, pull the slow feed control
toward the operator.
11. Align tool joints and feed the rotary head down while using slow forward rotation
to make a connection. Forward rotation is achieved by pushing the rotation
control away from the operator.
12. Once the connection is made, feed the rotary head up until stabilizer is above
the table.
13. Remove the stabilizer bushings.
• 14. Use this same process to add the drill collar that will be used with the stabilizer.
Raise this assembly above the table.
15. Install the rotary (or tricone) bit basket and the appropriate bit basket insert into
the drill table.
DRILLING SOLUTIONS
5-47
16. Place the tricone bit into the bit basket.

17. Lubricate the threads on the bit.
18. Feed the rotary head and the stabilizer (or drill rod) down and engage the
threads on the tricone bit. Tighten securely by using slow forward rotation.
19. Use slow forward rotation to tighten the bit onto the stabilizer. Tighten securely.
20. Raise the stabilizer assembly above the table.
21. Remove the bit basket and bit basket insert.
22. Lower the stabilizer until the bit is below the table.
23. Install stabilizer bushings in table.
Pipe Handling Procedures
Prepare to Add Drill Pipe to Drill String
Once the string is drilled down to the flats level with the table and the stabilizer, bit and
bushings are in place, it is time to add the drill pipe. The drill string must be separated below
the spindle sub. The general procedure for adding drill pipe uses the following steps,
regardless of location.
A WARNING!!
aids provided to facilitate component lifting operations.
FA WARNING
drill.
Unexpected drill motion or moving parts can cut or crush. If you are not
experienced with the drill's controls and instruments, read and
understand Section 4 - Operating Controls & Instruments.
5-48
DRILLING SOLUTIONS
1. Drill down until the box end of the pipe flats or crossover sub flats pass below
the drill table.
2. Stop rotation and feed.
3. Turn off the drill string air by pulling the drill throttle control out.
DRILL STRING
AIR ON/OFF ROTATION SLOW FAST
CONTROL - CONTROL FEED FEED
4. Open the table and remove the stabilizer or DHD bushing, then mount drill pipe
•
centralizer bushing and close table.
5. Reverse feed and raise the pipe flats or crossover sub flats above the table.
Rotate the drill string slowly until the sliding fork wrench (table wrench) aligns
with the flats.
ALIGN FLATS WITH SLIDING
TABLE WRENCH (FORK WRENCH)
6. Extend the table wrench onto the flats. Extend the table wrench by pulling the
table wrench control towards the operator.
PULL TABLE WRENCH CONTROL TOWARD

OPERATOR TO EXTEND SLIDING FORK WRENCH
5-49
DRILLING SOLUTIONS
7. Turn off the water injection, if equipped. Deactivate water injection pump by
turning the control knob counter clockwise.
WATER INJECTION
CONTROL
OHO
LUBRICATOR WATER INJECTION
FLOW CONTROL
8. Turn off the DHD lubricator, if equipped.

9. Open the drill string vent (exhaust). Allow all air pressure to escape the drill
string. Close the drill string vent.
ROTATION SLOW FAST
CONTROL FEED FEED
DRILL STRING VENT
10. Loosen the threaded joint by pulling the rotation control toward the operator.
11. As soon as the threads loosen, gently push the slow feed control away from the
operator to feed the rotary tophead up until the joint has separated, then return
the slow feed control to the center position.
12. Once the joint is separated, push the fast feed control away from the operator
to feed the rotary head to the top of the derrick.
Adding Drill Pipe to the Drill String
Drill pipe is stored in the carousel. the pipe rack or on a separate service vehicle and is
hoisted
into position to connect to the rotary tophead. When a hole is started, pipe is added to
the drill
string from the carousel first. When all of the pipe is removed from the carousel, pipe
is then
taken from the pipe rack on the side of the drill. If more pipe is needed to complete the
hole, it
must be taken from the ground or another vehicle.
5-50
DRILLING SOLUTIONS
• /A WARN IN
aids provided to facilitate component lifting operations.
Adding Drill Pipe from the Carousel
1. To add drill pipe from the carousel, open the retract gates using the rotary head
retract foot pedal. Hold the retract gates open and move the rotary head down
slowly. The moment the upper rollers are in the retract gate channels, close the
retract gate by releasing the rotary head retract foot pedal.
• UPPER
BREAKOUT
WRENCH
POWERHEAD 7, , • ,
RETRACT 'Or 000 etrnIl e, a.m., 1111130 tolmr•1•4iiliVICAVS.N‘
","4.41,0444,71,4k
.1.4,44"0410fit.J*;ts)41a61,10%),,
.
4fittf.ttStit 4•10100 V. • • • ilN:•*.•i •S

,41, 466 CAROUSEL INDEX
2. Rotate the carousel with the carousel index control until the drill pipe is directly
under the rotary head spindle.
3. Start slow forward rotation and with the slow feed control continue to lower the
rotary head until the spindle sub makes contact with the drill pipe in the
carousel.
4. Increase forward rotation at a medium speed as the drill pipe rises onto the
threads.
5. Tighten the joint until the pipe rotates in the carousel cup. Look up at the joint
and ensure the joint is made.
6. Stop rotation.
7. Raise the drill pipe out of the carousel. Continue to raise the rotary head out of
•
the retract track and onto the main track. The retract gates will open and close
again without operator assistance when the rotary head is moved up out of
retract.

8. Listen for both retract gates to close, then lower the drill pipe to a position
immediately above the drill string assembly held by the sliding fork wrench.
Lubricate the threads.
9. Lower the drill pipe until the pin makes contact with the drill string assembly in
the table.
10. Start forward rotation and feed down slightly until the joint is made. Make sure
the joint is tight.
11. Stop feed and rotation. Release torque on the sliding fork wrench by reversing
the rotation by 1/4 inch (6.35 mm).
12. Raise the drill string slightly until the sliding fork wrench can be retracted away
from the drill pipe.
13. Begin drilling.
Adding Drill Pipe from the Pipe Rack
In order to add drill pipe to the drill string from the pipe rack, one joint of pipe must be placed
in the carousel. Therefore, when drilling a deep hole, one section of the carousel must be left
open to receive the extra joint of pipe. The technique is similar to a table drive operation in that
the extra joint must be drilled in and then removed in order to add a section of pipe from the
pipe rack.
1. Raise the rotary head and one drill pipe out of the hole.
2. Extend the sliding fork wrench (table wrench) onto the flats of the lower drill
pipe.
3. Break the joint at the table. If the upper pipe comes loose first, go to the next
step. If not, raise the rotary head and pipe to the top of the derrick and into the
retract channels. Open the retract gates using the rotary head retract foot
pedal. Hold the retract gates open and move the rotary head down slowly. The
moment the upper rollers are in the retract channels, close the retract gates by
releasing the rotary head retract foot pedal.
0 0
..'"••••••(-
0
/0 0
BREAKOUT
WRENCH ROD SPINNER
4. If the upper pipe does not come loose first, then, using the hydraulic breakout
wrench, break the joint at the table and place the pipe into the carousel. Make
sure the pipe is secure to the rotary head.

5. Attach the hoist plug to the box end of the pipe in the pipe rack. Extend the jib
arm and swing the jib over the pipe rack.
6. Connect the hoist jib line to the hoist plug.
7. Carefully lift the drill pipe until it hangs vertical.
8. Swing the jib back to the center of the derrick and retract the jib into position
over the drill string.
9. Lubricate the pin end tool joint and lower the pipe until it engages the pipe in
the table.
10. Screw the pipe hanging on the hoist into the pipe in the table with the rod
spinner option, by hand or use a small chain wrench.
11. Raise the hoist slightly, lifting the entire drill string and retract sliding fork
wrench.
12. Lower the drill string into the hole until the sliding fork wrench can be engaged
at the box end of the added drill pipe.
13. Align flats and engage the sliding fork wrench to secure the string to the table.
•
14. Remove the hoist plug.
15. Bring the rotary head and the drill pipe still attached up and out of the retract
channels, then lower to connect to the pipe in the table. Lubricate threads
before connecting.
16. Resume drilling.
Adding Drill Pipe from Single Pipe Loader
The single pipe loader is used to load drill pipe when the carousel is not used. Pipe must be
loaded into the single pipe loader from the pipe rack or from a service vehicle.
REMOTE WINCH MAIN WINCH JIB CONTROL

CONTROL CONTROL
•
REMOTE
JIB CONTROL
1. Attach the pipe handling tool (sling) to the hook on the jib hoist.
2. Lower the pipe handling tool until it can be installed onto a joint of pipe.
5-53
DRILLING SOLUTIONS
3. Connect the pipe handling tool (sling) to a joint of pipe. The top (spring loaded
end) of the pipe handling tool is first inserted into the box end of the drill pipe.
Then, by compressing the spring, the bottom hook can be inserted into the pin
end of the pipe.
A WARNING
Drill pipe must be kept under control at all times. Serious injury or death
can result if pipe falls or rolls. The pipe must be prevented from sliding
off of the trailer or rack and hitting the hoist operator.
4. Raise the pipe until it is hanging beside the single pipe loader.
5. Use the jib swing control to move the pipe in line with the loader.
6. Lift the drill pipe up and carefully position the lower end of the drill pipe into the
single pipe loader boot. Then lower it all the way to the bottom of the boot.
ROD LOADER BOOT
7. Apply slack to the hoist line slightly.

8. Pull the hook down and out of the pin end of the pipe.
9. Raise the hoist and remove the pipe handling tool from the drill pipe.
10. Swing the pipe handling tool out of the way.
11. Swing the single pipe loader under the rotary head.
12. Feed rotary head down and start forward rotation until the spindle adapter
makes contact with the box end of the pipe standing in the single pipe loader.
13. Tighten the joint until the pipe rotates in the bottom of the loader boot.
14. Stop feed and rotation.
5-54
DRILLING SOLUTIONS
15. Raise the drill pipe out of the loader.

16. Lubricate the pipe threads.
17. Start a slow forward rotation and feed down to connect the joint. Continue until
the joint is tight.
18. Stop the feed and rotation. Release the torque on the sliding fork wrench by
reversing the rotation by 1/4 inch.
19. Raise the drill string slightly until the sliding fork wrench can be retracted away
from the pipe.
Changing the DHD Bit
1. Remove all drill pipe from the drill string and store them out of the way. Connect
the rotary head to the DHD (Down Hole Drill).
2. Feed the rotary head up until the DHD is just below the table.
3. Remove the drill pipe bushings.
•
4. Feed the DHD up until it is above the table.
5. Install the bit basket and the appropriate insert.
6. Lower the bit into the basket.
WARNING
Do not force chuck into the bit.
7. Mount the Chain Wrench onto the hydraulic breakout cylinder.

8. Retract the breakout wrench cylinder and position the wrench onto the chuck.
BREAKOUT (PIPE/CHAIN) WRENCH SLIDING (TABLE)

WRENCH CONTROL
• SLIDING FORK
(TABLE)
WRENCH
DRILL PIPE
BUSHINGS
9. Extend the breakout cylinder to loosen the chuck.
DRILLING SOLUTIONS
BREAKOUT (PIPE/CHAIN)
WRENCH CONTROL
5-55
10. When the chuck is loose, remove the breakout chain wrench and store it.
11. Use reverse rotation and slowly feed up to unscrew the chuck from the wear
sleeve.
12. Feed the DHD up until the retaining rings and the chuck can be removed from
the bit.
13. Replace the bit with a new bit.
14. Install the chuck and retaining rings on the new bit.
15. Lubricate the threads with tool joint compound.
16. Slowly feed wear sleeve over bit while holding chuck up.
17. Use slow forward rotation to connect the chuck to the wear sleeve. Tighten
securely to the proper torque.
18. Feed the DHD assembly up and remove the bit basket and the bit insert.
Changing Rotary Bit
1. Remove all drill pipe from the drill string and store. Do not remove the stabilizer.
2. Feed the stabilizer up until it is just below the table.
3. Remove the drill pipe bushings.
4. Feed the stabilizer up until the bit is above the table.
5. Mount the bit basket and the appropriate insert into the table.
6. Lower the bit into the basket.
A WARNING
Do not force the bit into the basket.
7. Mount the chain wrench onto the hydraulic breakout cylinder.

8. Retract the pipe/chain wrench cylinder and position the wrench onto the bit.
9. Extend the pipe/chain wrench cylinder to loosen the bit.
10. When the bit is loose, remove the pipe/chain wrench.
11. Use reverse rotation and slowly feed up to unscrew the button bit from the
stabilizer.
12. Remove the old bit and place the new bit into the insert in the bit basket.
13. Lubricate the threads on the new bit.
14. Using the rotary head, feed the stabilizer down onto the threads of the bit and
tighten using forward rotation.

15. Raise the rotary head and remove the bit basket.
Removing Drill Pipe and Drilling Tools

When the hole is finished and the drill pipe and drilling tools must be put up, it is important to
remember to load the drill pipe into the carousel before reloading the pipe rack and any service
vehicle.
Reloading Pipe Into Carousel
1. Raise the rotary head and one drill pipe out of the hole.
2. Bring the joint between the top drill pipe and the next drill pipe above the table
and extend the sliding fork wrench on the flats of the lower pipe.
3. Reverse the rotation of the rotary head at full pump volume and break the joint
at the table. If the upper joint breaks first, stop rotation. Break the joint by using
the breakout wrench and hydraulic breakout cylinder.
• A CAUTION
Watch the upper tool joint when breaking out.
If the upper joint comes loose before the lower joint, stop rotation
immediately.
4. Work the breakout wrench back and forth until the shoulders are loose.
5. Once the lower shoulder is loose, remove the breakout pipe/chain wrench and
the breakout hydraulic cylinder connection.
6. Use reverse rotation to finish unscrewing the lower section.
7. Once the joint is apart, raise the rotary head with drill pipe to the top of the
derrick and lower into the retract channels.
8. Lower the drill pipe into the tube in the carousel. Lower the drill pipe (pulldown
low speed) until the bottom drill rod shoulder touches the top of the carousel
spring. This places the drill pipe flats in the correct position to engage the upper
•
breakout wrench.

UPPER
BREAKOUT
.............. ............
WRENCH
CAROUSEL
BOOT
SPRING POWERHEAD
RETRACT 7, I, 7.0,1tro N• *VW's, i•Vsks
4;4*(..14."#Z,:ot,101.)17§00 Os' • ss•••;•Skt.c
i,eet 4.4It444(4(i89 tt s •
9. Engage the upper breakout wrench and use reverse rotation to break the tool
joint.
10. Once the joint is broken, stop rotation and disengage the upper breakout
wrench.
11. Lower the drill pipe to the bottom of the carousel cup and then continue reverse
rotation to complete breaking the joint.
12. Raise the rotary head and rotate the carousel to ready it for the next drill pipe.
13. Bring the rotary head out of the retract channels.
14. Fast feed the rotary head to the bottom of the derrick to pick up another joint.
15. Repeat this process until all but one of the carousel cups are full. Always leave
one cup open in case of trouble.
Reloading Pipe Into Pipe Rack
1. Lower the rotary head and drill string to the table.

2. Engage the sliding fork wrench onto the flats of the drill pipe.
3. Reverse the rotary head rotation and break the joint at the table.
4. Once the joint is broken, raise the rotary head to the top of the derrick and move
it into the retract channels.
5. Thread the hoist plug into the box end of the drill pipe in the table.
6. Connect the jib hoist hook to the hoist plug.
7. Raise the drill string with the jib hoist until the next pipe joint can be engaged
with the sliding fork wrench.
8. Use the breakout wrench to loosen the pipe joint at the table. Complete
unscrewing the joint with the rod spinner (option) or by hand.
9. Use the jib hoist to raise the drill pipe and move it into the side of the pipe rack.
Then lower it into the pipe rack.
10. Remove the hoist plug and attach it to the next pipe in the table.
11. Repeat this process until the pipe rack is full.

Reloading Pipe to Service Vehicle
1. Bring the rotary head out of the retract channels.

2. Fast feed the rotary head down to the table and connect to the drill pipe at the
table. Do not torque the connection.
3. Raise the rotary head and drill string until the next pipe joint is at the table.
Break the joint.
4. Raise the rotary head and the one drill pipe to the top of the derrick.
5. Move the single pipe loader under the drill pipe.
6. Lower the rotary head and drill pipe to the bottom of the cup of the single pipe
loader.
7. Use reverse rotation to finish disconnecting the rotary tophead from the drill
pipe. Raise the rotary head up and out of the way.
8. Mount the pipe handling tool (sling) onto the jib hoist hook. Raise the pipe
handling tool and install the top of the tool into the pipe in the pipe loader.
9. Mount the bottom of the tool to the bottom of the pipe.
10. Mount a "tag" line to the drill pipe.
11. Raise the jib hoist until the pipe is just above the cup of the single pipe loader.
12. Swing the jib hoist to the service vehicle (or laydown area) and align the pipe
to be laid down.
13. Slowly lower the jib hoist and pull the box end of the pipe away from the drill as
it is being lowered.
14. When the pipe is safely down and is prevented from rolling, remove the pipe
handling tool.
15. Continue this process until all the drill pipe has been relocated.
Loading Drill Pipe Storage Rack
1. The drill pipe storage rack has a capacity for nine 3-1/2 inch x 20 foot (89 mm
x 6.1 m) or seven 4-1/2 inch x 20 foot (114 mm x 6.1 m) drill pipe.
2. To load the rack, thread the hoist plug into the box end of the drill pipe.
3. Raise the pipe to the height required to clear the end of the rack.
4. Lower the pipe with the hoist while guiding the pipe in the rack.
5. Remove the hoist plug.
6. Repeat the procedure until the rack is full as described in step 1 above.

Down Hole Drill
DHD Drill String
DHD's achieve high productivity in hard rock applications by adding percussion to the drilling
process. In harder rock, the rotary method cannot supply sufficient load on the bit inserts to
crack the rock and produce a chip.
Percussion drills overcome the rotary bit load limitation by producing a very high load during
impact on the hammer. This load is sufficient to drive the cutting inserts into the rock to
produce chips.
DHD's operate by using the position of a piston to direct supply and exhaust air to and from
drive and return volumes. The drive volume "drives" the piston toward impact and the return
volume "returns" the piston in preparation for another impact stroke.
handling heavy drill pipe, downhole hammers, drill bits and other components used for various
drill pipe and drill bit changing procedures.
WARNIN
and understand Section 4 - Operating Controls & Instruments.

drill.

• DHD Drill String Assembly
Illustrated below are the drill string and the accessories and tools needed to install and change
drill pipe, bits and spindles.
ROTARY I-15.AD
SPINDLE
Sue
DRILL
PIPE
• SOX END
PIN END
STAB:LIZ ER
(OPTIONAL)
CP.OSS OVER
Sue
•
• t•la
Dip 1-Ar.qmeR
DRILL ASSEYS2(
EUT-ON BIT

DHD Drill String Assembly (continued)
AUXILIARY
HOIST CAZILE
0110 SPLIT
LIFTING BUSHING
DAIL J-WRENCH
CHAIN WRENCH
NOTE CARRY EXTRA LINKS TO

EACH J06 SITE
1 MC a 1 NIGH DIAMETER
SWING PORK
0110
WAWA
DRILL BIT

• The DHD (Down Hole Drill) can be used to drill overburden and rock. Casing bits and reamers
are used to drill the initial holes to install casing and to provide an annulus for grouting. The
following instructions are for a stabilizer to be used. If a stabilizer is not required, use a drill
pipe from the carousel in its place.
1. Select the stabilizer and manually screw on the crossover sub, if needed.
2. Install hoist (lifting) plug onto stabilizer/sub and connect main hoist cable.
A WARNIN
Be sure a good joint has been made by looking at the connection between
the lifting bail and the stabilizer pin end threads before moving the
stabilizer.
REMOTE WINCH MAIN WINCH JIB CONTROL

CONTROL CONTROL
• TIM • V it, ‘1
AGG
,0
REMOTE
JIB CONTROL
3. Raise hoist until stabilizer is above centralizer table. The hoist can be raised
from one of two controls. One is located on the operator's console and the other
is at the helper's controls. Push the control away from the operator to raise the
hoist.
4. Retract the table. Open the front table section and lower the stabilizer through
opening.
WA1NING'
Do not let centralizer bushing drop into drilled hole.
•
5. Place a block of wood or metal on the ground underneath the drill table so the
stabilizer or starter pipe can rest on the ground while making connections. For
short stabilizers, secure the upper section on the drill table with a fork chuck
wrench so rotary head can be threaded to it.

6. Install the centralizer bushing.
CENTRALIZER BUSHING
7. Lower stabilizer or starter pipe through table and onto the block of wood or
metal plate on the ground. Close the front table section and then close the back
table section.
8. Remove the hoist plug and move hoist cable out of the way.
9. Lubricate threads of sub/stabilizer with tool joint compound.
ROTATION SLOW FAST

CONTROL FEED FEED
UPPER
BREAKOUT
WRENCH
1.
POWERHEAO I 140 ft it t9J Y, 7., ;444•01,4`170;1 ‘;*;Ii;:ai:c
RETRACT 41*/*.i* eir N.J.:* /*Jr Zs * VI 0 **0.0% •
die. 1.4 414 it., itillattt0
10. Bring rotary head out of retract and feed down the derrick until it is just above
stabilizer. To feed the rotary head down the derrick, pull the drill feed control
toward the operator.
11. Manually align tool joints and feed rotary head down while using slow forward
rotation to make connection. Forward rotation is achieved by pushing the
rotation control away from the operator.
12. Once connection is made, feed the rotary head up until stabilizer is above the
table.
13. Remove the stabilizer bushings.
14. Mount the lifting bail to the backhead of the DHD.

°A WARNING'
Be sure a good joint has been made by looking at the connection between
the lifting bail and the DHD backhead pin threads before moving the DHD.
15. Connect the hoist cable to the lifting bail and raise DHD until it hangs over
centralizer table. The hoist can be raised from one of two controls. One is
located on the operator's console and the other is at the helper's controls. Push
the control away from the operator to raise the hoist.
16. Install the DHD table bushings and lower the DHD into the hole in the table.
17. Mount the J-Wrench onto the flats at the backhead with the handle against the
derrick.
Hoist
Cabla
•
Lifting
Bail
DI-ID Split
Contralizar
Bushings
DHD
J — Wrench
18. Lower the DHD until it hangs on the J-Wrench.

19. Remove the lifting bail and secure the hoist cable out of the way.
NOTICE: When using the DHD for the first time, pour one cup (8 oz./230m1) of
Rock Drill Oil into the drill backhead to lubricate it before starting the DHD.
Follow actual manufacturer's lubrication instructions when using DHD
hammers.
ROTATION SLOW FAST
CONTROL FEED FEED
• 20. Use the fast feed drill control to lower the rotary head until the stabilizer is just
above the DHD backhead and stop.

21. Lubricate the threads with tool joint compound.

22. Slowly feed the stabilizer and crossover sub assembly onto the DHD backhead
and slowly rotate until the J-Wrench starts to rotate.
A CAUTION
Keep away from the J-Wrench while tightening the connection.
23. Stop rotation and feed. Release the torque on the J-Wrench by reversing the
rotation by 1/4 inch (6.35mm).
24. Cover the drilled hole so that parts and components used do not fall into the
hole.
25. Remove the J-Wrench and the DHD table bushings.
26. Break the DHD chuck loose.
27. Feed the rotary head up until the DHD chuck is about two feet above the table.
28. Manually unscrew the chuck and remove the bit retaining rings.
29. Install the bit basket into the table and secure it.
30. Install the appropriate sized insert into the basket.
31. Manually install the button bit into the insert. Be careful not to damage the
carbide buttons.
32. Install the DHD chuck over the splines of the bit. Install the bit retaining rings
onto the bit.
33. Lubricate the threads of the chuck with tool joint compound.
34. Slowly feed the wear sleeve over the bit while holding the chuck up.
35. Use slow forward rotation to connect the chuck to the wear sleeve. Tighten
securely using proper torque.
36. Feed the DHD assembly up and remove the bit basket and insert.
37. Feed the bit below the table and install the DHD table bushings.
BIT
RETAINER
-- 0-RING
----SPACER
CHUCK
DRILL BIT

Drilling With Air

Drilling operations are similar whether drilling with straight air rotary, down-hole hammer,
straight mud or mud/air etc.
This text explains the operation procedure for straight air rotary drilling. The procedure
differences for water injection drilling, DHD hammer drilling and mud drilling are explained
after the straight air rotary drilling procedure.
ROTATION TORQUE SLOW FAST FEED
CONTROL LIMIT FEED FEED PRESSURE
SLIDING
WRENCH
•
1. Make sure the feed pressure control is turned out, but not completely.
2. Lower the drill pipe, with slow feed low speed, until the rotary bit is
approximately 4 to 6 inches (101.6 to 152.4 mm) above ground.
3. Start spindle rotation by moving the rotation control lever to full "DRILL" position
and start drilling. Always drill with pulldown low speed.
4. A driller can tell what is happening down hole by watching three key gauges
and the cuttings that are coming out of the hole. The further down the hole, the
more important these gauges become because depth increases the pressure
readings.
RECEIVER PRESSURE
ROTATION PRESSURE FEED PRESSURE
•
a. Rotation Pressure Gauge - Measures the amount of torque being
demanded from the rotary head (or amount of hydraulic pressure being
demanded by the rotary head motors). Depending on ground conditions,
pulldown pressure might be increased by using the feed pressure regulator.
This affects the reading on the rotation pressure gauge.

A WARNING
Do not drill if the indicator moves into the red area. This indicates the
hydraulic system is overloaded, which causes overheating and serious
damage. When the indicator moves into the red area, reduce the
(pulldown) feed pressure setting. This will move the indicator back to the
green (safe) area. If the rotary head stalls; raise the drill rod, reset the feed
pressure regulator and resume drilling.
b. Feed Pressure Gauge - Measures the amount of hydraulic pulldown

pressure in the hydraulic pulldown (feed) cylinder(s). Increase or decrease
feed pressure with the feed pressure regulator. Note: Adjustments with the
feed pressure regulator have a direct affect on the readings of both the feed
pressure gauge and rotation pressure gauge.
A WARNING
Do not exceed 1500 psi (103 bar) on the feed pressure gauge. There is
sufficient overpressure capability to raise the drill off the jacks. STAY
ALERT!
c. Receiver Pressure Gauge - Measures how much air pressure is in the

receiver tank. The gauge should register between 75 psi (when not in use)
and 250 psi. It will fluctuate when drilling. A sudden high pressure reading,
when drilling, indicates the drill bit is plugged. Stop the slow feed and raise
the bit 4-6 inches (101.6-152.4 mm) off the bottom of the hole, allowing air
pressure to build up and blow out the dirt/cuttings. Do not stop spindle
rotation when moving a drill rod up/down the hole. Resume drilling when the
pressure drops back to normal on the gauge.
5. Drill down until the rotary head hits the stop on the derrick and move the slow
feed control to neutral "CENTER" position.
6. Raise the drill pipe with the slow feed control until the drill pipe flats are in
position to be held with the sliding fork (table) wrench.
7. Turn off spindle rotation when the drill pipe flats line up with the bottom holding
wrench.
8. Bring the sliding fork (table) wrench out onto the drill pipe flats
9. Shut off the rotary screw compressor ON/OFF switch.

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10. Slow engine speed down to 1200 rpm.

11. Open the drill string vent to relieve any down hole air pressure. When the
standpipe air pressure gauge reaches 0 psi, all air pressure is relieved (except
minimum pressure in the receiver tank).
12. Move the hydraulic breakout wrench lever to "OUT" position. Manually put it on
the rotary head spindle sub and tighten.
A CAUTION
Be sure the hydraulic breakout wrench is ONLY attached to the rotary
head spindle sub.
13. Move the hydraulic breakout wrench lever to the "IN" position to break the joint.
Manually remove the hydraulic breakout wrench.
14. Move the rotary head rotation control lever to a slow speed "BREAKOUT"
position while moving the slow feed control to "UP" position. This dual action
will unthread the joint.
15. When the joint is unthreaded, stop slow feed and rotary head spindle rotation.
16. Grease the rotary head spindle sub threads.
17. Raise the rotary head and put it into retract.
18. Load the next drill pipe from the carousel, make the joint with the lower drill
pipe, increase engine rpm, turn on the compressor air and continue drilling,

Carousel Reloading
1. Turn off the air compressor ON/OFF switch and relieve the air pressure with the
drill string vent switch.
2. With the rotary head spindle rotation in "DRILL" position, raise the drill string
one complete pipe length with fast feed until the bottom pipe flats are level with
the bottom holding wrench (sliding table fork wrench).
ROTATION SLOW FAST
CONTROL FEED FEED
3. Turn off the spindle rotation when the bottom drill pipe flats line up with the table
wrench.
4. Bring the sliding fork wrench out onto the bottom drill pipe flats.
5. Move the hydraulic pipe/chain wrench lever to the "OUT" position. Manually put
it on the upper drill pipe and tighten.
A CAUTION
The hydraulic breakout wrench MUST be attached to the upper drill pipe
ONLY.
6. Move the hydraulic breakout pipe/chain wrench lever to the "IN" position to
break the joint. Manually disconnect the hydraulic pipe/chain wrench and push
it back out of the way.
7. At the same time, put the rotation control in slow speed "BREAKOUT" position
and move the slow feed control to "UP" position to unthread the pipe joint.
NOTICE: Make sure that the drill pipe does not unthread from the rotary head
sub.
8. When the joint is unthreaded, stop the rotary head breakout spindle rotation.
Raise the drill pipe until the rotary head is above the retract gates.
9. Put the rotary head (and drill pipe) into retract.
10. Using slow feed, lower the drill pipe into the carousel until the bottom shoulder
is in the center of the hole in the middle of the carousel.

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11. Step on the upper holding (breakout) wrench foot pedal to move the air
operated upper breakout wrench out to the drill pipe. Keep the upper breakout
wrench pedal down. Move the rotary head rotation control lever slowly to
"BREAKOUT" position. This will turn the drill pipe and enable the upper
breakout wrench to engage with the pipe upper flats.
12. Use the rotary head spindle rotation in "BREAKOUT" position to break the joint
between the rotary head spindle sub and drill rod. Do not completely unthread
•
the joint. When the joint is loosened, return the rotation control lever to
"NEUTRAL" position
13. Release the upper breakout wrench foot pedal.
14. Lower the drill pipe (slow feed) until the bottom drill pipe shoulder touches the
top of the carousel spring.
15. Move the rotary head spindle rotation lever to the "BREAKOUT" position and
unthread the joint. The drill pipe will drop to the bottom of the carousel when
unthreaded.
16. Raise the rotary head out of retract position. Go back down for the next drill
pipe. Repeat the process until the carousel is loaded.
Water Injection
1. The water injection pump injects water into the air stream. This serves a
number of purposes.
a. A small amount of water subdues the drilling dust, reduces wear on the
equipment and prolongs truck, engine and compressor filter life.
b. When small quantities of water are encountered in rock, dust will stick to the
walls of the hole and drill pipe making a mud collar which prevents the
pulling of the drill pipe and bit. The water pump supplies adequate water to
• flush the hole clean.

c. When drilling with a DHD, the water pump serves the same purpose as
above, plus the water cools the air which improves the lubrication of the
hammer and prolongs its life. Water also serves as a seal between hammer
piston and cylinder walls, giving better compression on worn hammers.
d. The water injection system affords an excellent method of injecting drilling
chemicals down the hole. There has been much progress in drilling
chemicals and, when used, these chemicals are added through the water
injection pump or the pulse pump.
e. The water injection system can be used as a wash down system for the
drilling rig and other equipment by using the blowdown line as a spray hose.
2. Connect the water suction line to the quick disconnect on the water injection
pump suction and place the line in a clean water source.
NOTE: Be sure that the blowdown valve on the water injection pump is
closed and that the discharge valve has been opened.
3. The air compressor must be running before the water injection system is turned
on.
1A WARIA
Water entering the air line when the bit is plugged can cause severe
damage to the compressor.
4. The water injection control is used to activate and deactivate the water injection
pump. Activate the water injection pump by lifting the control lever. Deactivate
the water injection pump by lowering the control lever to the neutral position.
NOTE: The Cat pump rod lubricator valves should be adjusted before
starting the pump.
WATER INJECTION
(OFF/ON) CONTROL
FOAM CONTROL WATER INJECTION

FLOW CONTROL

5. The Water Injection Flow Control adjusts the flow rate of water into the air
stream to keep down dust and prevent collaring in the hole when the water
injection pump is running. Rotate the switch clockwise to increase or
counterclockwise to decrease the water flow rate.
6. Move the water injection (Off/On) control to off position when adding drill pipe
or unloading drill pipe.
7. The Cat pump lubricators should be checked periodically during operation for
proper drip rate. Note: The drip valves should be closed when the pump is not
in use.
Foam Injection Operation

The foam control is used to adjust The amount of drill foam added to the water injection flow.
Foam volume is increased by turning the foam volume control to the right. Foam volume is
decreased by turning the foam volume control to the left.
1. Follow the above water injection procedures #2 through #5.

2. Connect the pulse pump suction hose to the chemical tank.
3. After water flow has been established, open the pump needle valve about one
(1) turn. This will purge air from the pulse pump and at the same time prime it.
A CAUTION
Do not operate the pulse pump dry. This could damage the diaphragm.
Make sure that the metering valve is tightened after all the air has been
purged.
4. Then set the water injection system for the proper discharge rate and adjust the
foam system metering valve to obtain the desired water/chemical ratio.
NOTE: Check chemical output by measuring the chemical tank.
NOTICE: Before shutting the pump down, flush out the pulse pump's system with
water by placing the suction line in a clean water source. Failure to clean
system could cause loss of drill time.
DHD Hammer Drilling

Hammer drilling uses a percussion type bit, a DHD lubricator and DHD air pressure regulator.
The DHD lubricator control controls the pump that forces DHD oil down the drill string to the
DHD for lubricating purposes. When the toggle switch is turned ON, a pump under the
lubricating tank starts pumping. The flow indicator light blinks every time oil is injected into the
air stream. Instructions for flow settings are located on the face of the DHD lubricator tank.

Note that flow settings are set for air compressor size.
ROTATION SLOW FAST

FEED FEED
CONTROL FEED PRESSURE
DHD
LUBRICATOR
TANK
DHD LUBRICATOR
When using the DHD for the first time, pour one cup (8 oz./230m1.) of Rock Drill Oil into the
drill backhead to lubricate it before starting the DHD.
NOTICE: Follow Actual Manufacturer's Lubrication Instructions when using DHD hammers.
1. The DHD should be connected to the starter pipe to drill the hole.
2. The engine speed should be 1800 RPM.
3. Turn on the compressor. Adjust air volume (flow control) to the desired setting.
RECEIVER FLOW INDICATOR
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4. Turn on the DHD lubricator switch on the console.

5. The DHD lubricator indicator light will light up to confirm the lubrication system
is in service.
6. Regulate the flow if necessary. Read the instructions on the side of the
lubricator to regulate to the compressor size of the drill.
7. Start slow forward (clockwise) rotation using the rotation control. Rotation
speed can be adjusted with the rotation control.
8. Make sure the dust aprons are in place.

9. Open the drill air throttle valve slowly and allow air flow to operate the DHD.
DRILL STRING
AIR ON/OFF
CONTROL
• •
10. Move the slow feed controller to the DOWN position while starting a hole and
adjust the drill feed pressure valve to set the speed for the drilling conditions.
11. The first several feet or meters of drilling is called "overburden". It usually
consists of soft soil, broken rock, gravel or clay. When drilling through this
mixture, care must be taken to prevent excessive cuttings from being blown out
of the hole and causing a washout.
12. When the DHD has drilled below the drill table, it should be withdrawn from the
hole. Move slow feed controller to UP position and raise the DHD up out of the
table until the split DHD bushings can be removed.
13. Stop rotation. Shut off drill air throttle. Turn off DHD lubricator.
14. Slowly lower the drill string down until the drill rod centralizer bushing can be
inserted into the drill table. This bushing should be sitting on the DHD backhead
around the drill rod. Drilling can now be resumed.
15. Start forward (clockwise) rotation using the rotation control valve.
16. Move the slow feed control to the DOWN position while starting a hole. Adjust
the drill feed pressure valve to set the speed for the drilling conditions.
17. Turn on the compressor. Adjust pressure regulator to the desired setting.
18. Open the drill air throttle valve slowly and allow air flow to operate the DHD.
19. Adjust the rotation and feed speed (down pressure) by checking the rotation
and pulldown gauges. The pulldown pressure can be turned to holdback
pressure when there is enough weight on the drill string to pull the drill string
downward.
20. Watch the cuttings coming from the hole to determine what type formation you
are drilling through. Continue drilling.
•
21. A driller will listen for different "sounds" when hammer drilling.
a. A rapid "high pitch" sound means that air pressure is keeping the hammer
too far off the bottom of the hole to drill. Increase the feed pressure with the
feed pressure regulator.

b. A rhythmic "medium-low pitch" sound indicates the hammer is drilling

correctly. Look for cuttings coming out of the hole.
c. A very erratic "low-deep pitch" sound means there is too much down
pressure on the hammer. The drill rod will "jerk" instead of rotating evenly.
When the spindle rotation pressure gauge needle jumps erratically from
high-to-low, it also indicates too much down pressure. When there is too
much down pressure, cut back on the feed regulator.
22. After reaching a certain depth, the weight of the drill string steel will force the
hammer to the bottom of the hole. Use the air pressure regulator to overcome
the steel weight and keep the hammer up off the bottom of the hole.
23. Maintain the receiver pressure gauge reading between 300-600 psi, by using
the slow feed control and air pressure regulator, for better efficiency when
hammer drilling.
General Drilling Hints
1. The DHD lubricator must always be used whenever a DHD is being operated.
Use the correct oil for the DHD and the season. The amount of oil varies with
the air compressor size, not the DHD. Select the compressor size on the three
position lubricator air flow selector.
NOTICE: Follow Actual Manufacturer's Lubrication Instructions when using
DHD hammers.
2. Water injection should be used to contain dust and whenever water is
encountered in the hole to prevent collaring.
3. Do not operate the water pump if no circulation is being observed (i.e., the bit
is stuck in the hole). Water will fill up the air supply lines and flow back into the
receiver separator tank of the compressor.
4. Do not open the drill air throttle flow control suddenly. It may cause a collapse
of the separator element over a period of time.
Mud Drilling
Description
When drilling in unstable formations, a mud "mix" is necessary to stabilize the hole wall and
prevent cave ins. A mud pump forces mud mix down the hole through a circulating mud system
and applies the mud mix directly to the hole wall, thereby reinforcing and stabilizing it.
While drilling, make sure the mud mix circulates. Samples of mud circulation cuttings will
indicate what type of soil conditions exist.
handling heavy drill pipe, drill bits and other components used for various drill pipe and drill bit
changing procedures.

• ARNING41
Do not wear loose fitting clothing that can become caught in rotation components.
Mud/Rotary Drill String Tools & Accessories
The following illustration shows a typical drill string suited for mud/rotary drilling.
•
UPPER
SUB
DRILL COLLAR
USED WITH
STABILIZER
(OPTIONAL)
DRILL
PIPE
STABILIZER
(OPTIONAL)
CROSSOVER
D -
SUB (PIPE
TO COLLAR)
r
STABILIZER AND COLLAR
BUSHING (IF REQUIRED)
ON TABLE CENTRALIZER
BUSHING (IF REQUIRED)
TRICONE
•
BIT

Mud Drilling Procedures
Preparation of the drilling site includes preparing the mud source, checking the mud pump
before starting and mixing the mud according to the specifications of the manufacturer and
requirement of the hole.
MUD
PRESSURE
GAUGE
a
MUD PUMP
BALL VALVE
CONTROL
AIR
STANDPIPE
MUD
STANDPIPE
1. Change the main derrick air hose from the air standpipe over to the mud
standpipe.
Shut down the air compressor and relieve all air pressure before
disconnecting the air hose from the air standpipe.
2. Attach a bypass hose to the bypass valve outlet on the mud standpipe and
position the remaining end of bypass hose in mixing area of the mud source.
3. Connect the mud pump suction hose to the mud pump inlet and place the free
end into the suction side of the mud source.
Fill the mud source with water.
A CAUTION
The mud pump suction inlet must always be completely under water. DO
NOT allow pump to draw air. Severe pump damage may result.
5. Open mud injection bypass valve (located on mud standpipe).

6. Close the mud pump ball valve lever (located on top of console).
7. Set the engine speed at high speed.
8. Turn the mud pump volume control on the console to start water flow through
the bypass hose.
ROTATION SLOW FEED FAST FEED
MUD PUMP CONTROL
9. Mix desired type of mud at end of mud source farthest away from pump suction
inlet.
10. Arrange a return line from drill hole to mud source. The return line must enter
the mud source area furthest from pump suction inlet area.
11. Open mud pump ball valve lever (top of console) and then close bypass valve
(under mud manifold) to start mud injection.
WARNINCII
DO NOT EXCEED 400 PSI (27.57 bar) mud injection pressure!
12. Mud flow is controlled by adjusting the speed of the mud pump. Turn the mud
pump control on the console to increase pump speed.
A CAUTION
In freezing weather, the mud pump gear end oil must be warmed before
starting the pump. It is recommended that a cold pump be brought up to
speed gradually.
13. Use the bypass valve as a relief to regulate mud injection pressure so as not to
exceed 400 psi (27.57 bar).
14. Turn on forward rotation and adjust speed with the rotation control.
15. Use slow feed in the down position to start drilling.

16. Monitor the mud pump pressure gauge. By watching the pressure gauge,
located on the mud pump standpipe, an operator can decide what flow of mud
mix is needed to meet the drilling requirements and adjust the mud pump speed
controller speed accordingly.
NOTE: Adjust the mud pump speed control to select a flow that will not
allow the bit to plug or the pump to lose prime. This is directly affected by
the formation in which you are drilling.
17. While drilling, make sure the mud mix circulates. Samples of circulation
cuttings will indicate what type of soil conditions exist.
18. When adding drill pipe to the drill string: Move the mud pump speed
controller to the "OFF" position. Close the mud pump ball valve on the drain
line. Then open the mud pump valve lever (on top of the console) and relieve
the down hole pressure.
19. Add drill pipe per previous instructions.
20. Open the ball valve on the drain line, turn on the ON/OFF valve and continue
drilling.
21. Drill down to desired depth.
NOTE: When mud drilling, there are three additional steps that must be
followed when coming out of the hole. (Be sure to add the mud wiper
before starting out of the hole).
a. After each joint is separated, raise the drill pipe about one foot from the
separated joint.
b. Place the mud suction hose into a clean water source.
c. Using the mud pump, flush the drill pipe (this serves to flush the mud pump
also).
NOTE: Flush, wash and clean the mud mix from all drill pipe prior to
loading them into the rod box or transport vehicle. The bit should also be
free of any mud mix residue.
22. When drilling is completed, flush and clean the mud mix from the mud pump.
23. Open bypass valve completely and close the mud pump ball valve lever (top of
console).
24. Slow mud pump down to a stop.
25. Disconnect the main air hose from the mud standpipe and connect it to the air
standpipe.
26. Wash and clean the mud mix from the drill pipe before loading in the carousel
and/or storing the drill pipe.
27. Drain the mud pump and mud pump standpipe if the temperature is below
freezing.

Pr
A WARNING
This procedure must be followed or severe damage will occur to both the
mud pump and all associated piping. This could lead to an extended
down time maintenance requirement.
Casing
The following information is related to setting casing and flushing the hole wall.
Setting Casing
1. Raise the rotary head to the top of the derrick and put the rotary head into the
retract position.
2. Un-pin and swing out the clamping bar. Then retract the table.
3. Remove the split centralizer bushings in the table and clamping bar. Replace
them with the required size casing clamps.
4. Connect a choker sling onto the first piece of casing.
5. Attach the hoist cable to the choker sling and raise the casing above the hole.
Lower the casing down into the hole until the casing is about one foot above
table level. WARNING: Do not use free fall for lowering casing down the
hole.
6. Move the table out to drilling position. Close the clamping bar and pin it shut.
7. Remove the choker sling and attach it to the next piece of casing.
NOTE: A choker sling cannot be used on a plain end pipe.
8. Lift the casing, with the hoist, above the first casing.
a. If "plastic casing" is used: put on the casing collar and cement the joint.
b. If "weld type casing" is used: join the casing shoulders and weld.
c. If ''threaded casing" is used: clean and grease the threads of each piece of
casing before making the joint. Use a manual casing chain wrench or the
breakout wrench to tighten the joints.
9. Using this procedure, set the screen and remainder of the casing.
10. When the casing and the screen are set, unpin and swing out the ctamptng bar
(centralizer half of the driller's table). Retract the table to make working room
above the hole.
11. Add the required grouting around the casing.

Flushing the Hole Wall
After mud drilling, mud mix is usually blocking the watershed around the screen. Use the
following procedure to flush the mud mix from the hole wall and to open well to water flow.
1. Attach a spray nozzle on the end of a drill pipe and run the drill string back down
the hole inside the casing.
2. Use the mud pump and a clean water source to flush the casing and the screen.
3. With the pulldown in slow feed and the rotary head spindle in drill rotation,
stroke the drill string up and down in the area of the screen several times to
remove the mud mix wall.
4. When the watershed is flowing, raise the drill string and disassemble the drill
string.
5. Set the water pump in the well.

SHUT DOWN & DRIVE AWAY
Shutdown Procedures
NOTE: See section 4 "Operating Controls" for a more complete

description of all the operating controls, instruments and indicators that
are used when operating the drill.
The following procedures are related to the drill functions. Do not confuse them with the truck
(carrier) functions, which are moving, transporting and parking the drill.
Normal shutdown describes how the drill is to be shutdown following a drilling operation or
work shift.
1. Raise the drill string out of the hole to clear the cuttings. Keep the drill string
rotating and be sure air is flowing while withdrawing the bit.
2. Stop feed and rotation when the bit enters the table dust seal.
3. Switch off lubricator if it is being used. Turn off water injection pump if it is being
used. Turn off drill air with the drill air throttle. (The drill air throttle should be
opened slowly in order to prevent premature failure of the receiver separator
element. To open, pull the lever out). To close, push the lever in.
4. Exhaust the air from drill string by opening the drill string vent valve (located on
the console). Close the valve when all pressure is exhausted.
5. Turn off the compressor and allow the receiver to blow down to minimum
pressure.
6. If the hole is completed, remove all drill pipe from the derrick. Remove all loose
tools, material and accessories from the drill and stow in their proper place.
7. Remove the centralizer half (clamping bar) of the driller's table and store it
securely.
8. Prior to lowering the derrick, inspect for proper overhead clearance and for any
obstruction or tool left on the drill or derrick.
9. Lower the Derrick.
10. Raise the leveling jacks until they are fully retracted.
NOTE: Any material used for cribbing or blocking the drill should be
removed and stored in the support vehicle.
11. Lower the hoist and position the arm for proper storage or shipment. Anchor the
hoist cable.
12. Make sure all controls are in "OFF" or "NEUTRAL" positions and all water lines
and other connections are removed and stored. BE SURE THE FEED
CONTROLS ARE IN THE "CENTER" POSITION.

13. Disconnect the mud pump suction hose (if used) and store it out of the way.
14. Be sure that the mud pump ball valve lever has been pushed in to the closed
position and the mud pump volume control is turned off.
15. Turn off the air transfer valve behind the truck cab.
NOTE: This valve must be shut off when moving over public roads to
comply with federal laws.
16. Install the console cover. Lock all lockable compartments.

17. Clean off all transport lights so they can be seen from behind.
18. Shift from PTO to Driving position.
Moving the Drill
The following procedures are related to the truck (carrier) moving functions. Do not confuse
them with the truck (carrier) parking or transporting the drill procedures.
1. Make sure all drill pipe is out of the hole before moving.
2. Do not get on or off the drill when it is moving.
3. Lower the derrick before moving the drill.
4. Secure all drill pipe and tools before moving the drill.
5. Know the drill's height, width, weight and length before moving.
6. Check the brakes on the truck before leaving the job site.
7. Be careful cornering to allow for derrick overhang.
8. Know where your helpers are at all times. Do not move the drill if they are not
in view.
9. Know and use proper signals when moving the drill.
Parking the Drill
1. Always use the steps and hand holds when mounting and dismounting by using
a three point stance.
2. Release the parking brake, located on the truck dashboard, before moving the
drill. To release parking brake, push knob in. The parking brake is to be used
for parking the vehicle only. See actual manufacturer's parts and service
manuals for more complete carrier information.
3. Move the drill away from the highwall or face before shutting the drill down for
the day.
4. Don't park the drill under an overhang or where a bank can cave in.

5. ALWAYS park the drill on solid, level ground. If this is not possible, always park
the drill at a right angle to the slope and chock the wheels.
6. If the drill is left over a hole, lower the jacks so the wheels touch the ground.
7. To park the drill, move it to firm, level ground and bring the drill to a complete
stop as mentioned above.
8. USE proper flags, barriers and warning devices, especially when parking in
areas of heavy traffic.
9. Apply the parking brake as mentioned above.
10. Shut off carrier engine per carrier instructions.
11. Lock the ignition and remove the key before leaving the carrier cab.
12. Lock the carrier cab if the drill is to be left unattended.
Daily Precautions After Work
Perform the following precautions each day after work in addition to the daily routine
maintenance on the lubrication chart.
1. Fill the fuel tanks to prevent condensation problems.

2. Clean the drill of accumulated material.
3. Lock all vandal protection devices on the drill.
Equipment and Attachments
NOTE: All optional equipment mounting and dismounting on the drill

must be performed by authorized, trained personnel only.

TRANSPORTING THE DRILL
Transportation Procedures
Safety Precautions
Before moving the drill on public roads, check for instructions and information in respect to
traffic regulations regarding construction machinery.
WARNING
Driving the drill and moving equipment between work sites is potentially
hazardous.
Drill rig cannot be transported with drill pipe in the carousel.
The drill must be driven and transported only in accordance with the operating instructions.
1. When driving the drill, observe the prescribed transport position, admissible
speed and itinerary.
2. Do not attempt to drive unless knowledgeable and experienced.
3. Keep the carrier cab and carrier entry steps clean of clay, oil, mud, ice, frost
and other material that can become slippery.
4. Always know the overall height, weight, width and length of the drill. MAKE
SURE there is sufficient clearance when crossing underpasses, bridges and
tunnels or when passing under overhead lines.
5. When moving the drill on public access roads, obey all traffic regulations and
be sure that proper clearance flags, lights and warning signs, including the
"Slow Moving Vehicle" emblem, are properly displayed. Know your
approximate stopping distance at any given speed. Never turn corners at
excessive speeds. Look in all directions before reversing your direction of
travel.
Drill Preparation
1. Remove all loose tools, materials and accessories from the drill and store in the
tool compartment or other proper place.
2. Raise the rotary head to the top of the derrick and place in retract position.

3. Swing the pipe holder option (if used) into the closed position.
4. Remove the derrick and table locking pins and store them.
5. Remove the drillers platform bracket bolt from table support post.
6. Check again for overhead clearance. Lower the derrick onto the derrick rest.
Feather the derrick raise/lower control lever as the derrick approaches the
derrick rest so it doesn't hit with excessive force. Never slam the derrick into the
horizontal position.
7. Retract the jacks, starting with the mid jacks on the non-drilling end of the truck.
Retract the other jacks. Store any cribbing that was used.
8. Anchor the Hoist cable.
9. Make sure all controls are in neutral or off positions and all water lines and other
connections are removed and stored.
10. Raise the driller's platform and bolt them in the upright (road) position.
11. Install the console cover. Lock all lockable compartments.
12. Clean off all transport lights so they can be seen from behind.
• Driver Checklist
1. Be sure you know your vehicle and its equipment and how to use it safely.
2. See that windows, mirrors, lights and the truck cab are clean and unobstructed.
3. Check tires for proper pressure and inspect for damage.
4. Check to be sure that all lug (wheel) nuts are in place.
5. Check for fluid leaks.
6. Listen for air leaks.
7. Drain moisture from air tanks daily.
8. Check lights and reflectors.
9. Check oil and coolant levels.
Start Up
1. Before starting the engine, check inside, outside and underneath the drill for
people or obstructions.
2. ALWAYS sound the horn before starting the truck to alert everyone in the area.
3. Check to be sure that the warning lights work as the key is turned on.
• 4. Check all gauges (including fuel).

5. Start engine.
6. Check for excessive noise or vibration.

Final Walk Around Check
1. Look for leaks, now that the engine is running.

2. Check to see that all the lights work.
3. Check to see that doors, covers and emergency equipment (and contents) are
in place.
4. Be sure everything is properly stowed.
5. Before beginning to move, check inside, outside and underneath the drill for
people or obstructions.
6. Check area behind the drill before backing up.
Before Driving
1. Fasten seat belts.

2. Adjust each mirror so you can just see the side of the vehicle in the side of the
mirror closest to the vehicle. This helps you determine the relation to objects
seen in the mirror.
3. Release the parking brake.
NOTE: Air pressure must be high enough to release the spring loaded
parking brakes before moving the drill (75 psi).

TOWING THE DRILL
Towing Information
Be Safety Conscious
Proper equipment must be used to prevent damage to the vehicle and the drill during any tow.
State and local laws which apply to vehicles in tow must be followed.
If the vehicle is to be towed by a wrecker, use only equipment designed for this purpose,
following the instructions of the wrecker manufacturer. A safety chain system must be used.
WARNING"'
Personal injury or death could result when towing a disabled drill
incorrectly.
•
Block the wheels of the drill to prevent movement before releasing the
emergency brake system or disconnecting the propeller shaft at axle
pinion or removing axle shafts. The drill can roll free if it is not blocked.
Use the following recommendations to properly perform the towing

procedure.
Be sure to block the wheels of the drill and reapply the emergency brake
system before disconnecting from the towing vehicle.
A CAUTION
Maximum towing speed = 35 mph (60 km/h)
A WARNING"
Drill rig cannot be transported with drill pipe in the rod box.
1. All state and local laws regarding such items as warning signals, night lighting,
•
speed, etc. must be followed.
2. No vehicle should ever be towed over 35 mph (56.33 km/hr).
3. Loose or protruding parts of the drill should be secured prior to moving.

4. A safety chain system that is completely independent of the primary lifting and
towing attachment must be used.
5. Operators should refrain from going under a vehicle which is being lifted by the
towing equipment unless the vehicle is adequately supported by safety stands.
6. No towing operation which for any reason jeopardizes the safety of the wrecker
or any bystanders or other motorists should be attempted.
7. Do not allow the operator, or any other personnel, on the drill when it is being
towed.
8. The driver of the towing vehicle must be aware of the total weight load on the
axles and the overall dimensions of the drill. For further information, refer to
Weights and Dimensions in the Technical Specifications section of this manual.
9. Sudden machine movement could cause premature breakage. Gradual and
smooth acceleration will minimize breakages of towing components.
10. Normally, the towing vehicle should be as large as the disabled drill and have
sufficient braking capacity, weight and power to control both the towing vehicle
and the disabled drill for the grade and distance involved.
11. To provide sufficient control and braking when moving the disabled drill
downhill, a larger towing vehicle or additional tandem connected vehicle could
be required. This will prevent a runaway or uncontrolled towing operation.
12. All the different situation requirements cannot be given here. Capacities range
from minimal towing vehicle capacity required on smooth, level surfaces and
increases to maximum capacity required on inclines and on poor surface
conditions.
Towing Procedures
Proper equipment must be used to prevent damage to the towing vehicle and the drill during
any tow. State and local laws which apply to vehicles in tow must be followed.
If the vehicle is to be towed by a wrecker, use only equipment designed for this purpose,
following the instructions of the wrecker manufacturer. A safety chain system must be used.
The procedures below must be followed when towing for extended distances to prevent
possible damage to the transmission.

SPECIAL CONDITIONS OF USE
Special Conditions
Cold Weather Conditions
1. Refer to Section 6 - Refill Capacities / Lubricants / Fuel in the maintenance

section for information regarding cold weather lubricants, hydraulic fluids,
coolants. fuel etc.
2. Use winter grade diesel fuel for operation at subzero temperatures.
3. Be extremely careful when using cold weather starting aids. Starting aids are
very flammable and should only be used if needed.
4. Remove batteries and store in a warm area to about 68°F (20°C).
Hot Weather Conditions
1. Monitor temperature gauges.

2. Keep cooling fins on radiator and oil cooler clean and free of accumulated dirt.
Water and Muddy Conditions
1. Clean the drill of accumulated material and thoroughly grease all lubrication
points. Refer to Section 6 - Refill Capacities / Lubricants / Fuel in the
maintenance section for information regarding lubricants, hydraulic fluids,
coolants, fuel, etc.
Dusty Conditions
1. Keep air cleaner elements clean and free of accumulation of dirt.

2. Wear a protective mask.
High Altitude Conditions
1. Be aware that engine power will be reduced.

2. Keep cooling fins on radiator and oil cooler clean and free of accumulated dirt.
Preservation & Storage
Observe the following when storing the drill for short periods of time:
1. Replace and secure all weatherproof covers.

2. Change all lubricants and fluids that may have deteriorated with use. Refer to
Section 6 - Refill Capacities / Lubricants / Fuel in the maintenance section for
information regarding lubricants, hydraulic fluids, coolants, fuel, etc.
3. Check that the storage site is not subject to flooding or other natural hazards.
4. Wherever practical, run the engine and operate all the drill functions at regular
intervals.

•
Section 6 - Maintenance
DRILLING SOLUTIONS
6-1
T3W Instruction Manual Section 6- Maintenance
6-1 MAINTENANCE SAFETY
Maintenance Safety and Health

physical dangers that are present in all phases of operation and maintenance of this drill.
Improper maintenance can cause severe injury or death. Read and

understand the SAFETY PRECAUTIONS AND GUIDELINES section of this
manual before you operate or perform any maintenance, service or
repairs.
Anyone working around this drill must read and thoroughly understand the precautions
outlined in this manual before attempting to operate or perform work on the drill. In addition,
"SAFETY ALWAYS" must always be the primary consideration of all personnel when working
around this drill under normal or unusual conditions.
WEAR PROTECTIVE CLOTHING

Anyone working around the drill must wear
APPROVED safety equipment (safety shoes or
protective footwear, safety glasses, hearing
protection, hard hat, gloves, respirator, etc.) when Safety Glasses Hard Hat Ear Protection
operating or maintaining the machine.
Wear close fitting clothing and confine long hair.
Operating equipment requires the full attention of

the operator. Do not wear radio or music 0LN
headphones while operating the machine. Electrically Respirator Electrically
Insulated Boots
Insulated Gloves
exercise good judgement and common sense when operating, servicing or working near this
drill.
and understand the OPERATING CONTROLS & INSTRUMENTS section of
this manual.

• Section 6 - Maintenance
If there is any doubt about the safe operating procedure of the drill,
Solutions representative for assistance.

Make sure all new employees read and understand the decals in the
mounted on the drill. Never remove the Decal Safety Manual. Replac
Stop! Review the

information supplied with the drill, ask your supervisor or contact your
nearest Drilling
Decal Safety Manual

e the manual if it
becomes lost or illegible.
the
Most accidents involving product operation, maintenance and repair are

caused by failure to
observe basic safety rules or precautions. An accident can often be avoide
d by recognizing
potentially dangerous situations before trouble occurs. Some of the potenti
al problems and
ways to prevent them are shown below.
•
Fluid Penetration
1. Always use a wooden board or cardboard when checking for leaks.

2. Leaking fluid under pressure can cause serious injury or death.
3. If fluid is injected into the skin, see a physician immediately.
Lines, Tubes and Hoses
1. Repair any loose or damaged fuel and oil lines, tubes and hoses. Leaks
can
cause fires.
2. Inspect all lines, tubes and hoses carefully. Do not use your bare
hands to
check for leaks.
3. Tighten all connections to the recommended torque.
4. Make sure that all clamps, guards and heat shields are installed correct
ly to
prevent vibration, rubbing against other parts and excessive heat
during
operation.
5. Check for the following:
a. End fittings damaged, leaking or displaced.
•
b. Outer covering chafed or cut and wire reinforcing exposed.
c. Outer covering ballooning locally.
d. Evidence of kinking or crushing of the flexible part of the hose.
e. Armoring embedded in the outer cover.
DRILLING SOLUTIONS
6-3
Section 6- Maintenance
Burn Prevention
1. Do not touch any part of an operating engine or its components.

ed.
2. Allow the engine to cool before any repair or maintenance is perform
lines, fittings
3. Relieve all pressure in air, oil, fuel or cooling systems before any
or related items are disconnected or removed.
Coolant
breathe rs
1. Use caution when removing filler cap, grease fittings, pressure taps,
or drain plugs.
under
a. At engine operating temperature, the engine coolant is hot and
pressure. The radiator and all lines to heaters or the engine contain hot
water. When pressure is relieved rapidly, this hot water can turn into steam.
Always allow the hot cooling system components to cool before draining.
Any contact with hot water or steam can cause severe burns. Check the
coolant level only after the engine has been stopped and the filler cap is
cool enough to remove with your bare hand.
2. Hold a rag over the cap or plug to prevent being sprayed or splashed by liquids
under pressure.
3. Remove the cooling system filler cap slowly to relieve pressure.
l
4. Cooling system additive (conditioner) contains alkali. To prevent persona
injury, avoid contact with the skin and eyes and do not drink.
Oils
any
1. Hot oil and components can cause personal injury. Do not allow hot oil or
components to contact the skin.
2. Keep all exhaust manifold and turbocharger shields in place to protect hot
exhaust from oil spray in case of a line, tube or seal failure.
Batteries
1. Battery electrolyte contains acid and can cause injury. Avoid contact with the
of
skin and eyes. Wash hands after touching batteries and connectors. Use
gloves is recommended. Batteries give off flamma ble fumes which can
an
explode. Ensure there is proper ventilation for batteries which are located in
enclosure.
2. Always thaw a frozen battery before jump starting. Frozen batteries can
explode.
3. Do not smoke when observing the battery electrolyte levels.
4. Always wear protective glasses when working with batteries.

5. Never disconnect any charging unit circuit or battery circuit cable from
the
battery when the charging unit is operating. A spark can cause the flamma
ble
vapor mixture of hydrogen and oxygen to explode.
Fire or Explosion Prevention
1. Fire may result from lubricating oil or fuel sprayed on hot surface
s causing
personal injury and property damage. Inspect all lines and tubes for wear
or
deterioration. They must be routed, supported or clamped securely. Tighten
all
connections to the recommended torque. Leaks can cause fires,
2. Determine whether the engine will be operated in an environment
in which
combustible gases could be drawn through the air inlet system. These gases
could cause the engine to overspeed, which in turn could seriously damage
the
engine and result in bodily injury or property damage.
3. All fuels, most lubricants and some coolant mixtures are flammable.
4. Diesel fuel is flammable. Gasoline is flammable. The mixtures of
diesel and
gasoline fumes are extremely explosive.
5. Do not smoke while refueling or in a refueling area. Do not smoke
in areas
where batteries are charged, or where flammable materials are stored.
6. Batteries give off flammable fumes which can explode. Keep all
fuels and
lubricants stored in properly marked containers and away from all unautho
rized
persons. Store all oily rags or other flammable material in a protective contain
er
in a safe place.
7. Do not weld or flame cut on pipes or tubes that contain flammable fluids.
Clean
them thoroughly with a nonflammable solvent before welding or flame cutting
on them. Remove all flammable materials such as fuel, oil and other debris
before they accumulate on the engine. Do not expose the engine to flames,
burning brush, etc., if possible.
8. Shields (if equipped), which protect hot exhaust components from oil
or fuel
spray in the event of a line, tube or seal failure, must be installed correctly.
9. Provide adequate and proper waste oil disposal. Oil and fuel filters must be
properly installed and housing covers tightened to proper torque when being
changed.
10. Batteries must be kept clean, covers kept on all cells, recommended cables
and connections used and battery box covers kept in place when operatin
g.
11. When starting from an external source, always connect the positive (+) jumper
cable to the POSITIVE (+) terminal of the battery of the engine to be started
.
To prevent potential sparks from igniting combustible gases produced by some
batteries, attach the negative (-) boost ground cable last, to the starter
NEGATIVE (-) terminal (if equipped) or to the engine block. See the Operati
on
section of this manual for specific starting instructions.
DRILLING SOLUTIONS
6-5
12. Clean and tighten all electrical connections. Check regularly for loose or frayed
electrical wires. Refer to maintenance schedules for intervals. Have all loose or
frayed electrical wires tightened, repaired or replaced before operating the
engine.
13. All of the wiring must be kept in good condition, properly routed and firmly
attached. Routinely inspect wiring for wear or deterioration. Loose, unattached,
extra or unnecessary wiring must be eliminated All wires and cables must
conform to the recommended gauge and be fused if necessary. Do not use
smaller gauge wire or bypass fuses. Tight connections, recommended wiring
and cables properly cared for will help prevent arcing or sparking which could
cause a fire.
Fire Extinguisher
1. Have a fire extinguisher available and know how to use it.

2. Inspect the fire extinguisher and have it serviced as recommended on its
instruction plate.
Crushing or Cutting Prevention
1. Support equipment and attachments properly when working beneath them.

2. Never attempt adjustments while the engine is running unless otherwise
specified in this manual.
3. Stay clear of all rotating and moving parts. Guards should be in place whenever
maintenance is not being performed.
4. Keep objects away from moving fan blades. They will throw or cut any object
or tool that falls or is pushed into them.
5. Wear protective glasses when striking objects to avoid injury to your eyes.
6. Chips or other debris can fly off objects when struck. Make sure no one can be
injured by flying debris before striking any object.
Mounting and Dismounting
1. Clean steps, handholds and areas of the drill you will be working on or around.
2. Always use the steps and handholds when mounting and dismounting with a
three point stance.
3. Do not climb on or jump off the drill. Do not stand on components that cannot
support your weight. Use an adequate ladder.
Engine Pre-Start
1. Inspect the drill for potential hazards.

2. Be sure all protective guards and covers are installe

to make adjustments or checks. To help prevent an accident caused
parts, work carefully around them.
3. Do not disable or bypass automatic shutoff
prevent personal injury and drill damage.
d if a drill must be started

by rotating
circuits. They are provided to
4. Never start an engine with the governor linkage discon

nected.
5. Make provisions for shutting off the air or fuel supply
to stop the engine if there
is an overspeed condition on start-up after performing repair or mainte
nance to
the engine.
Engine Starting
1. Do not start the engine or move any of the controls

if there is a warning tag
attached to the controls. Check with the person who attached the
tag before
starting.
2. Make sure no one is working on the engine, or close to the
engine or the engine
driven components before starting the engine. Always inspec
t the engine
before and after starting.
•
3. Start the truck engine only from the truck cab. Never short
across the starter
terminals or the batteries as this could bypass the engine neutral-start
system
as well as damage the electrical system.
4. Start the deck engine only from the operator's station. Never
short across the
starter terminals or the batteries as this could bypass the engine
neutral-start
system as well as damage the electrical system.
5. Always start the engine according to the required "Engine Starting Proced
ure"
described in this manual to prevent major engine component
damage and
personal injury.
6. Shutdown the engine according to "Engine Shutdown Instructions" in the
Operation section to avoid overheating and accelerated wear of
the engine
components.
7. Only use the Emergency Stop button in an emergency. Do Not start the engine
until the problem causing the emergency stop has been located and
corrected.
8. On initial startup or overhaul, be prepared to stop the drill should an overspeed
condition occur. This may be accomplished by cutting the fuel and
air supply to
the engine.
9. Check the jacket water and oil temperature gauges frequently during
the
operation of jacket water and/or lube oil heaters to ensure proper
operation.
10. Diesel engine exhaust contains products of combustion that may be harmfu
l to
•
your health. Always start and operate the engine in a well ventila
ted area and,
if in an enclosed area, vent the exhaust to the outside.
DRILLING SOLUTIONS
6-7
Starting Aids
WARNING
Explosion Hazard. Do not use volatile starting aids such as ether,
propane or gasoline in the engine air intake system. Glow plugs and/or
e,
grid heater will ignite vapors, which can cause severe engine damag
personal injury or death.
Engine Stopping
ions in the Operation
1. Stop the engine according to the Engine Stopping instruct
components.
Section to avoid overheating and accelerated wear of the engine
Do Not start the drill
2. Only use the emergency stop button in an emergency.
until the problem is resolved.
the engine should an
3. On initial startup or overhaul, be prepared to stop
and
overspeed condition occur. This may be accomplished by cutting the fuel
air supply to the engine.
Maintenance Information
other services
To prevent minor irregularities from developing into serious conditions, several
The purpose of
or checks are recommended for the same intervals as the periodic lubrication.
of the drill by
these services or checks is to ensure the uninterrupted and safe operation
revealing the need for adjustment caused by normal wear.
instructions are
Prior to conducting any maintenance work, ensure that the following
observed:
1. The drill should be parked on a firm, level surface.

2. Ensure the engine is shut down and allowed to cool.
3. Disconnect the battery cables and cover exposed terminals before working on
the drill's electrical system.
4. Stop the engine and allow the hydraulic oil pressure to fall before working on
the hydraulic hose installations or connections.
5. Stop the engine and allow compressor air pressure to completely relieve from
the receiver tank before working on the compressor, receiver tank and hose
installations or connections.
6. Thoroughly wash all fittings, caps, plugs, etc. with nonflammable, nontoxic
ing
cleaning solution before servicing to prevent dirt from entering while perform
the service.

When there is a need for service personnel to work on the drill

danger zone and this involves activation of one or several drill
shall only be done under the following conditions:
in the working area or

functions, such work
1. There shall always be two people present: both being fully instruc
ted on the
safety issues. One of them, from the main operator's station, shall
supervise
the safety of the service man doing the work.
2. The supervisor shall have immediate access to the emerg
ency stop in all
situations.
3. The area where the service work is to be performed shall
be properly
illuminated.
4. Communication between the service man and the superv
isor at the main
operator's station shall be established in a reliable manner.
5. Only when the drill is shut down completely and the means of
starting are
isolated is a person allowed to perform repair and maintenance work
alone on
the drill.
•
Fluids, Oil and Fuel Filters
1. When draining fluids, ensure that adequate sealable containers

are available
and that every care is taken to prevent spillage.
2. Always ensure waste fluids are disposed of in an environmentally
safe manner.
3. Always ensure that used filters are stored in secure containers and
disposed of
in an environmentally safe manner.
6-9
6-2 MAINTENANCE SCHEDULE
Schedule Information
and the interval at
The maintenance schedule shows those items requiring regular service
should be geared to the items
which they should be performed. A regular service program
g conditio ns. In the
listed under each interval. These intervals are based on average operatin
frequen t mainten ance than
event of extremely severe, dusty or wet operating conditions, more
specified may be necessary.
nance
NOTE: Refer to the Actual Manufacturer's Operation and Mainte
and servic e mainte nance
manual for the maintenance schedules
procedures for the deck engine.
nance
NOTE: Refer to the Actual Manufacturer's Operation and Mainte
sched ules and servic e mainte nance
manual for the maintenance
procedures for the Carrier Vehicle.
requirements from the

Before each consecutive interval is performed, all of the maintenance
previous interval must also be performed.
Table 1: Maintenance as Required
Description Action Lubrication
Compressor Air Cleaner Check - Air Cleaner See Parts Manual

Indicator
Check - Connections and

Ducts for leaks
Empty - Dust Cup
Clean - Pre Cleaner Tubes
Check - Rain Guard
Change - Elements only as See Filter Elements and

required Kits Chart
Cleanliness Clean the Drill
Loose Bolted Connections Check - Tighten to proper See Torque specifications

torque
Feed Cable Check - Feed Cable sag

and adjustment
Wire Rope Check - Wear and stretch

conditions


Receiver Separator Tank Replace Separator See Filter Elements and
Element Kits Chart
Compressor Air Hose and Inspect Hoses, Retighten See Section 7
Clamps Clamp Bolts
Compressor Discharge Inspect Hoses, Retighten
Hose and Clamps Clamp Bolts
Deck Engine Fuel Tank Check - Fuel Level and fill No. 2-D S500 (LSD) Diesel
to full Fuel
Truck Engine Fuel Tanks Check - Fuel Level and fill No. 2-D S15 (ULSD)
to full Diesel Fuel
Rotary Head Swivel Lubricate Bearing and MPG-EP2 Grease
Packing
Table 2: Maintenance at 10 Hours or Daily

Overpressure Control Check - Overpressure
System
Air Cleaners Check - Air Cleaner
Indicator
Check - Connections and
Ducts for leaks
Empty - Dust Cup
Deck Engine Check - Engine Oil Level. CAT DEO-ULS (15W40)
Add if low.
Check - Engine Belts and
Tensioner
Drain - Water from Fuel
Primary Filter/Water
Separator
Cooling System (Radiator, Check - Radiator Coolant 50/50 Mix of Caterpillar
HOC and COC) Level ELC concentrate and
demineralized water, or
ELC 50/50 premix.
Clean - Cooling Fins
Deck Engine Fuel Tank Fill Tank after every shift No. 2-D S500 Diesel

Truck Engine Fuel Tanks Fill Tanks after every shift No. 2D S15 Diesel
Receiver Tank Check - Compressor Oil XHP605 (high pressure)

Level
Drain - Water from

Receiver Tank
Hydraulic Reservoir Check - Oil Level on Tank ISO AW32

Sight Gauge
Drain - Water from

Hydraulic Reservoir
Rotary Tophead Check - Rotary Head Oil SAE 80W90

Level
Grease Rotary Head Exxon Mobil Ronex Extra

Swivel & Yoke Assembly Heavy Duty Moly 2
Grease Upper Rotary

Head Bearing
Derrick Pivot Pins: 5 shots of grease into each MPG-EPS Grease

grease fitting See Actual Manufacturer
Carousel Bearings
Sheaves
Cylinder Ends
Rotary Head Swivel Yoke
Rotary Head Guide Rollers
Holding Wrenches
Chain/Pipe Wrench
Gearbox Drive Shaft and
U-Joints
Retract Gate Arms
Mud Pump Shaft Seal
Rod Holder (Option)
Jib Hoist/Boom
Sand Reel Shaft Bearing
DHD Lubricator Check Oil Level. Add if Rock Drill Oil
Low

•

Truck Engine Check - Engine Oil Level. CAT DEO-ULS (15W40)
Add if low.
Truck Transmission Check - Transmission Oil SAE 50
Level
Truck Power Steering Check - Oil Level SAE 10W40
Truck Cooling System Check - Radiator coolant 50/50 Mix of Caterpillar
Level. Clean Cooling Fins. ELC concentrate and
ELC 50/50 premix.
Housekeeping Clean the Drill
Table 3: Maintenance at 50 Hours or Weekly
•
Batteries (Truck and Deck Check - Electrolyte Level Distilled Water (H2O)
Engine)
Check - Keep Terminal
Posts cleaned and tight
Main Winch/Auxiliary Hoist Periodic Inspection of
Cable and Wire Rope cable/rope condition
CAT Water Injection Pump Initial Crankcase Oil ISO-68, (SAE40 anti rust)
change
Pump Drive Gearbox Inspect for Oil Leaks.
Clean Breather
Check - Oil Level 80W90 Gear Oil
Auxiliary Winch Change the Initial Oil SAE90 Lubricating Oil
Tighten Winch Mounting
Bolts
Table 4: Maintenance at 100 Hours

Main Winch
•
Change the Initial Oil Exxon Sparton 150 or
equivalent AGMA 4EP
Tighten Winch Mounting
Gear Oil
Bolts
JB Water Injection Pump Initial Crankcase Oil SAE 30 Texaco Meropa or
change SAE Shell Omala 100
DRILLING SOLUTIONS
6-13
Engine (Deck) Change - Engine Oil CAT DEO-ULS (15W40)
Change - Engine Oil Filters See Filter Elements and

Kits Chart
Replace - Fuel Filter(s)
Check - Engine SCA Level Refer to Engine Manual
Check - Belt Tension
Engine (Truck) Change - Engine Oil CAT DEO-ULS (15W40)
Change - Engine Oil Filters See Filter Elements and

Kits Chart
Replace - Fuel Filter(s)
Replace - Coolant Filter
Check - Engine SCA Level Refer to Engine Manual
Check - Belt Tension
Truck Transmission Check Transmission Oil SAE50
Truck Power Steering Check Power Steering Oil SAE 10W40
Truck Differentials Check Differential Oil SAE 80W90
Drivelines and U-Joints Grease Bearing EXXON MOBIL RONEX

Assemblies on U-Joints Extra Heavy Duty Moly 2
Grease
Hydraulic Reservoir Change - Hydraulic Tank See Filter Elements and

Breather Kits Chart
Compressor Clean - Compressor Oil

Strainer
Change - Compressor Oil See Filter Elements and

Filters Kits Chart
Pump Drive Gearbox Change - Initial Oil 80W90 Gear Oil
Water Injection Pump (Cat) Change - Crankcase Oil ISO-68, (SAE40 anti rust)
Water Injection Pump (JB) Change Crankcase Oil at SAE30 Texaco Meropa
750 Hours. 100 or SAE30 Shell Omala
100 oil.l

Description
Main Winch
Action
Check - Oil Level

Lubrication
Exxon Sparton 150 or

equivalent AGMA 4EP
Gear Oil
Tighten - Winch Mounting
Bolts
Clean and Lubricate Cable See Instructions
and Rope
Auxiliary Winch Change Auxiliary Winch Exxon Sparton 150 or
Oil equivalent AGMA 4EP
Gear Oil
Compressor Air Hose and Inspect Hose, Retighten See Section 7
Clamps Clamp Bolts
Compressor Discharge See Section 7
Hose and Clamps
• Description
Receiver Tank
Hydraulics
Action
Change Compressor Oil

Change Hydraulic Oil
Replace Main Return Oil
Lubrication
XHP605 (high Pressure)

ISO AW32
See Filter Elements and
Filters Kits Chart
Replace Case Drain Oil
Filter
Rotary Head Change - Rotary Head Oil SAE 90W Gear Oil
Pump Drive Gearbox Change - Gearbox Oil 80W90 Gear Oil
Main Winch Change - Main Winch Oil Exxon Sparton 150 or
equivalent AGMA 4EP
Gear Oil
Tighten - Winch Mounting
Bolts
Water Injection Pump Change - Crankcase Oil ISO-68 (SAE40 anti rust)
•
Carousel Change Gearbox Oil 80W90 Gear Oil

Engine Check Engine Valve See Actual Manufacturer's

Clearance Service Manual
Receiver Tank Change Receiver See Filter Elements and

Separator Element Kits Chart
Replace Discharge Hose See Parts Manual

and Hose Clamps
Cooling System Drain and Flush Engine 50/50 Mix of Caterpillar

Cooling System. Replenish ELC concentrate and
Coolant. See Actual demineralized water, or
Manufacturer's Service ELC 50/50 premix.
Manual
Truck Engine Maintenance

The following maintenance information shows those items on the truck engine requiring
regular service and the interval at which they should be performed
NOTE: Refer to the Actual Manufacturer's Operation and Maintenance

manuals for the maintenance schedules and procedures for the Carrier
Engine and Carrier Vehicle.
NOTE: Refer to the Actual Manufacturer's Carrier manual for the service
procedures for the Carrier Engine and Carrier Vehicle.
Maintenance Interval Schedule
Ensure that all safety information, warnings and instructions are read and understood before
any operation or any maintenance procedures are performed.
The user is responsible for the performance of maintenance, including all adjustments, the use
of proper lubricants, fluids, filters and the replacement of components due to normal wear and
aging. Failure to adhere to proper maintenance intervals and procedures may result in
diminished performance of the engine and/or accelerated wear of components.
Use mileage, fuel consumption, service hours or calendar time, WHICH EVER OCCURS
FIRST, in order to determine the maintenance intervals. Products that operate in severe
operating conditions may require more frequent maintenance.

• Section 6 - Maintenance T3W Instruction Manual
NOTE: Before each consecutive interval is performed, all maintenance

from the previous interval must be performed.
Table 10: Truck Engine Maintenance Interval Schedule
Description Action
When Required:
Battery: Replace
Battery or Battery Cable: Disconnect
Cooling System Coolant Sample (Level 1) Obtain
Cooling System Coolant Sample (level 2) Obtain
Engine Air Cleaner Element: Clean / Replace
Engine Oil level Gauge Calibrate
Fuel System: Prime
•
Severe Service Application: Check
Daily:
Cooling System Coolant Level: Check
Engine Air Cleaner Service Indicator: Inspect
Engine Oil Level: Check
(Fuel) Primary Filter/Water Separator: Drain
Fuel System Water Separator Drain
Walk Around Inspection: Walk Around Inspection
PM Level 1 - Every 48,000 km (30,000 miles) or 15,520 Liters (4100 US gallon) of
Fuel or 500 Service Hours
Air Compressor Filter Clean / Replace
Alternator Inspect
Battery Electrolyte Level Check
Belt Inspect
Belt Tensioner Inspect
•
Cooling System Supplemental Coolant Test / Add
Additive (SCA)
Cylinder Head Grounding STud Inspect / Clean / Tighten
Engine Crankcase Breather Clean

Description Action
Engine Oil Sample Obtain
Engine Oil and Filter Change
Fuel System Primary Filter Clean / Replace
Fuel System Secondary Filter Replace
Fuel Tank Water and Sediment: Drain
Hoses and Clamps Inspect / Replace
Between 24,000 and 96,000 km (15,000 and 60,000 miles)
Compression Brake Inspect / Adjust
Electronic Unit Injector Inspect / Adjust
Engine Valve Lash Inspect / Adjust
Valve Actuators Inspect / Adjust
PM Level 2 - Every 320,000 km (200,000 miles) or 125,000 Liters (33,000 US

gallon) of Fuel or 4000 Service Hours or 2 Years
After cooler Core Clean / Test
Cooling System Coolant (DEAC) Change
Cooling System Water Temp Regulator Replace
Fan Drive Bearing Lubricate
Radiator Clean

gallon) of Fuel or 6000 Service Hours or 3 Years
Air Compressor Inspect
Compression Brake Inspect / Adjust / Replace
Crankshaft Vibration Damper Inspect
Engine Clean
Turbochargers Inspect
Valve Actuators Inspect / Adjust
Every 483,000 km (300,000 miles) or 3 Years

Engine System Coolant Extender (ELC) Add

Alternator:
Description
Every 966,000 km (600,000 miles) or 6 Years

Inspect
Action

gallon) of Fuel or 12,000 Service Hours or 6 Years
Compression Brake Inspect / Adjust / Replace

Deck Engine Maintenance

The following maintenance information shows those items on the deck engine requiring
regular service and the interval at which they should be performed
NOTE: Refer to the Actual Manufacturer's Operation and Maintenance

manuals for the maintenance schedules and procedures for the Deck
Engine.
Maintenance Interval Schedule
Ensure that all safety information, warnings and instructions are read and understood before
any operation or any maintenance procedures are performed.
The user is responsible for the performance of maintenance, including all adjustments, the use
of proper lubricants, fluids, filters and the replacement of components due to normal wear and
aging. Failure to adhere to proper maintenance intervals and procedures may result in
diminished performance of the engine and/or accelerated wear of components.
Use mileage, fuel consumption, service hours or calendar time, WHICH EVER OCCURS
FIRST, in order to determine the maintenance intervals. Products that operate in severe
operating conditions may require more frequent maintenance.
NOTE: Before each consecutive interval is performed, all maintenance

from the previous interval must be performed.
Table 11: Deck Engine Maintenance Interval Schedule
Description Action
When Required:
Battery: Replace
Battery or Battery Cable: Disconnect
Engine Air Cleaner Element: Clean / Replace
Fuel System: Prime
Severe Service Application: Check
Daily:
Cooling System Coolant Level. I Check
Engine Air Cleaner Service Indicator: Inspect
Engine Oil Level: Check
(Fuel) Primary Filter/Water Separator: Drain
6-20
DRILLING SOLUTIONS
Description Action
Walk Around Inspection: Walk Around Inspection
Initial 250 Service Hours (or at first oil change)

Every 250 Service Hours

Cooling System Supplemental Coolant Test / Add
Additive (SCA)
Engine Oil and Filter Change
Starting Motor Inspect

Converted Systems)
Initial 500 Hours (for New Systems, Refilled Systems and
Every 500 Service Hours

Belts Inspect / Adjust / Replace
Turbocharger Inspect
Water Pump Inspect
Every 3000 Service Hours or 3 Years

Cooling System Coolant (DEAC) Change
Cooling System Coolant Extender (ELC) Add
Cooling System Water Temp Regulator Replace
Engine Protective Devices Check
Every 8000 Service Hours or 3 Years

Driven Equipment Check
Every 12,000 Service Hours or 6 Years

Cooling System Coolant (ELC) Change
Hours or 1 Year
Every 14,400 L (3750 US gallon) of Fuel or 250 Service
Battery Electrolyte Level Check
Electronics Grounding Stud Inspect / Clean / Tighten
Engine Crankcase Breather Clean
Engine Oil Sample Obtain
Primary Fuel/Water Separator Element Replace
6-21
DRILLING SOLUTIONS
Description Action
Secondary Fuel Filter Replace
Hoses and Clamps Inspect / Replace
Radiator Clean
Every 114,000 L (30,000 US gallon) of Fuel or 3000 Servi
ce Hours
After cooler Core Clean / Test
Every 170,400 L (45,000 US gallon) of Fuel or 3000 Servi
ce Hours
Crankshaft Vibration Damper Inspect
Engine Clean
Engine Mounts Inspect
Engine Speed / Timing Sensors Check / Clean / Calibrate
Engine Valve Rotors Inspect
Fan Drive Bearing Lubricate
Every 380,000 L (100,000 US gallon) of Fuel or 10,00
0 Service Hours
Overhaul Considerations Check Fuel and Oil Consumption
Overhaul
Fan Drive Bearing Replace
NOTE: Refer to the Actual Manufacturer's Oper

ation and Maintenance
manual for the maintenance schedules and proc
edures for the Deck
Engine.
6-22
DRILLING SOLUTIONS
•
6-3 REFILL CAPACITIES/LUBRICANTS/FUEL
Hazardous Substance Precaution
A HAZARDOUS SUBSTANCE PRECAUTION

operators of Drilling Solutions
The following information is provided to assist the owners and
your Drilling Solutions
equipment. Further information may be obtained by contacting
distributor.
of this drill and may be hazardous to
The following substances are used in the manufacturing
health if used incorrectly.
Table 12:
• Anti Freeze
Hydraulic Oil
Engine Lubricating Oil
Compressor Oil
Preservative Grease
Rust Preventive
Avoid ingestion, skin contact and breathing fumes
Engine Fuel Avoid ingestion, skin contact and breathing fumes
Battery Avoid ingestion, skin contact and breathing fumes
SAE Gear Oil Avoid ingestion, skin contact and breathing fumes
Rock Drill Oil Avoid ingestion, skin contact and breathing fumes
tion of this drill and may be

The following substances may be produced during the opera
hazardous to health.
Table 13:
•
Engine Exhaust Fumes Avoid breathing fumes
Engine Exhaust Fumes Avoid buildup of fumes in confined spaces
6-23
DRILLING SOLUTIONS
Electric Motor Dust Avoid breathing in during maintenance
(Brushes/Insulation)
Brake Lining Dust Avoid breathing in during maintenance
General Information
Lubrication is an essential part of preventive maintenan
ce, affecting to a great extent the
useful life of the unit. Periodic lubrication of the movin
g parts reduces to a minimum the
possibility of mechanical failures.
Different lubricants are needed and some components
in the unit require more frequent
lubricant than others. Therefore, it is important that the
instructions regarding types of
frequency of the application be explicitly followed.
The lubrication chart that follows in this section show
s those items requiring regular service
and the interval at which they should be performed. Detai
ls concerning fuel, oil and other
lubricants follow the lube chart. A regular service progr
am should be geared to the items listed
under each interval. These intervals are based on avera
ge operating conditions. In the event
of extremely severe, dusty or wet operating conditions,
more frequent lubrication than
specified may be necessary.
Specific recommendations of brand and grade of lubric
ants are not made here due to regional
availability, operating conditions and the continual
development of improved products. Where
questions arise, refer to the component manufactur
er's manual and a reliable supplier.
All oil levels are to be checked with the drill parke
d on a level surface and while the oil is cold,
unless otherwise specified.
On plug type check points, the oil levels are to be
at the bottom edge of the check port.
All grease fittings are SAE STANDARD unless other
wise indicated. Grease non-sealed fittings
until grease is seen extruding from the fitting. One
ounce (28 grams) of EP-MPG equals one
pump on a standard one pound (0.45 kg) grease gun.
Over lubrication on non-sealed fittings will not harm
the fittings or components, but under
lubrication will definitely lead to a shorter lifetime.
Unless otherwise indicated, items not equipped
with grease fittings (linkages, pins, levers,
etc.) should be lubricated with oil once a week.
Motor oil, applied sparingly, will provide the
necessary lubrication and help prevent the forma
tion of rust. An anti-seize compound may be
used if rust has not formed. Otherwise, the componen
t must be cleaned first.
Grease fittings that are worn and will not hold the
grease gun, or those that have a stuck check
ball, must be replaced.
To prevent minor irregularities from developin
g into serious conditions, several other
services or checks are recommended for the same
intervals as the periodic lubrication.
1. Thoroughly wash all fittings, caps, plugs, etc. with
a non-flammable, non-toxic
cleaning solution before servicing to prevent dirt from
entering while performing
the service.
6-24
DRILLING SOLUTIONS
2. Lubricants must be at operating temperature when draining.

with regard to
3. During regular lubrication service, visually check the entire unit
capscrews, nuts and bolts being properly secured.
are found
4. Spot check several capscrews and nuts for proper torque. If any
loose, a more thorough investigation must be made.
, stop the drill
5. If a defect is detected which requires special maintenance service
neces sary, contac t the local
operation until the defect has been corrected. If
Drilling Solutions distributor for assistance.
Lubrication Table
Chart. These
Periodic lubrication requirements are listed in the following Lubrication
ated areas of the drill.
requirements include lubricant checks and greasing design
Table 14: Fluid Level Specifications
Description Fluid Remarks
Truck Engine Oil (C13) CAT DEO-ULS Engine not running for 10 minutes.
(15W40) Check dipstick. Maintain level to
Deck Engine 011 (C15) "FULL" mark on dipstick
Truck Engine Cooling Fill with a 50/50 mix of Keep coolant level between the
System (Radiator) Caterpillar Extended "ADD" and "MAX' levels on the de-
Life Coolant (ELC) aeration tank.
Deck Engine Cooling concentrate and
System (Radiator) demineralized water, or
ELC 50/50 premix.
Truck Transmission MIL-L-2104B SAE 50 Keep fluid level to "FULL" mark on

dipstick.
Power Steering SAE 10W40 Keep fluid level to "FULL" mark on

dipstick.
Truck Differentials 80W90 Fill to "Oil Level/Fill" plug
Compressor Oil XHP605 (HP) Purge water from tank or run

compressor to make air. Oil level
should be between bottom of sight
glass (with compressor not
running) and middle of sight glass
(with compressor not running).
Hydraulic Oil ISO AW32 Check at sight gauge on reservoir.

With all cylinders retracted, level
should be between 4.5"
(114.3mm) from top of tank (high)
to 5.5"(139.7mnn) from top of tank
(low).
6-25
DRILLING SOLUTIONS

Truck Fuel Tanks No. 2-D S15 Diesel Fill to full mark on fuel gauge
Deck Engine Fuel Tank No. 2-D S500 Diesel Fill to full mark on fuel gauge
Rotary Head SAE 80W90 Gear Oil Check oil level at sight gauge on
rotary head with spindle not
turning. Oil level should not be
below midline of sight glass or
above 3/4 line of sight glass.
Batteries (Truck and Distilled Water With engine not running, fluid level
Deck engines) is low when below ring or ring is
visible and too high when slots are
not visible.
Battery specific gravity Check with Hydrometer 1.24 temperature compensated is
or level of charge low and 1.28 temperature
compensated is high.
Pump Drive Gearbox SAE 80W90 Engine not running. Keep oil level
between Low and High marks on
dipstick (if available) or keep oil
level with gearbox oil level port.
Main Winch (12K) Exxon Sparton 150 or Remove the large plug located in
equivalent AGMA 4EP the center of the drum support.
Gear Oil, ISO VG 150 The oil should be level with the
bottom of this opening.
Main Winch (18K) Oil level should be in the middle of
the oil level sight glass on the end
of the winch.
Main Winch (30K)
Oil level should be in middle of oil
level sight glass next to motor on
end of winch.
Auxiliary (Service) SAE90 Lubricating Oil Remove the large plug located in
Winch (4K)
the center of the drum support.
The oil should be level with the
bottom of this opening.
Sand Reel (3K) SAE90 Lubricating Oil Rotate drum to place the drain/fill
plug at the 3 o'clock position. Oil
should be level with the bottom of
this opening.
Cat Water Injection ISO-68 (SAE 40 anti- Oil should be in the middle of the
Pump rust) sight glass.
Cat Pump Oilers
Oilers should be completely full
6-26
DRILLING SOLUTIONS
•
John Bean Water SAE30 Texaco Meropa Oil should be at bottom of level
Injection Pump 100 or SAE30 Shell plug.
Omala 100 oil.
Carousel Rotation 80W90 Gear Oil With derrick horizontal, remove oil
Gear Box level plug. Oil should be at bottom
of level plug.
Refill Capacities
who must perform drill
The following fluid capacities are provided for servicing personnel
resources are not
maintenance in remote locations where complete shop facilities and
ng person nel an approx imation of the fluid
available. These capacities will give the servici
ensure that the specifi ed method of
capacities of the components to be serviced. Always
checking for accurate fluid levels is used.
Table 15: Approximate Refill Capacities
•
Component Lubrication Approximate Quantity
Hydraulic Reservoir ISO AW32 100 gallon (378.5 liter)
Receiver Tank XHP605 28.5 gallon (107.8 liter)
Rotary Head SAE90 Gear Oil 1 gallon (3.78 liter)
Pump Drive Gearbox 80W90 Gear Oil 1.125 gallon (4.25 liter)
12K Main Winch Exxon Sparton 150 or 6 pints (2.8 liter)

equivalent AGMA 4EP
18K Main Winch 9 pints (4.2 liter)
Gear Oil, ISO VG 150
30K Main Winch 15 pints (7.09 liter)
SAE90 Lubricating Oil 3.2 pints (1.5 liter)

3K Sand Reel
SAE 90 Lubricating Oil 2.3 pint (1.1 liter)
4K Service Winch
CAT DEO-ULS 15W40 40 quart (38 liter)
Deck Engine (C15)
CAT DEO-ULS 15W40 42 quart (40 liter)
Truck Engine (C13)
50/50 mix of Caterpillar 25 gallon (94.6 liter)
Deck Engine Coolant
Extended Life Coolant 28 quart (26.5 liter) Refer
Truck Engine Coolant (ELC) concentrate and to OEM manual.
•
ELC 50/50 premix.
No. 2-D S500 Diesel 150 gallon (567.8 liter)
Fuel Tank (Deck Engine)
No. 2-D S15 Diesel 50 gallon (189 liter)
Fuel Tank (Navistar 7600)
6-27
DRILLING SOLUTIONS
Component Lubrication Approximate Quantity

Fuel Tank (Paystar 5600i) No. 2-D S15 Diesel 100 gallon (379 liter)
Fuel Tank (Peterbuilt) No. 2-D S15 Diesel One 60 gallon (227 liter)
One 80 gallon (302 liter)
CAT 12 gpm Water CAT Pumps Special Multi- 40 ounces (1.18 liters)
Injection Pump Viscosity IS068 oil.
CAT 25 gpm Water
84 ounces (2.48 liters)
Injection Pump
FMC John Bean 18 gpm SAE30 Texaco Meropa 64 ounces (1.89 liter)
Water Injection Pump 100 or SAE30 Shell Omala
FMC John Bean 25 gpm 100 oil.
64 ounces (1.89 liter)
Water Injection Pump
FMC John Bean 35 gpm

64 ounces (1.89 liter)
DHD Lubricator Tank Rock Drill Oil. Always 7 gallon (26.5 liter)
check with DHD OEM for
correct DHD lube oil.
Filter Elements and Kits

Table 16: Filter Elements & Kits Chart
Description Filter/Element Quantity Part No.

Deck Engine (C15 Tier 3) Primary Filter Element 1 50616390
Air Cleaner
Safety Filter Element 1 50616408
Gasket Kit 1 50621796
Deck Engine (C15 Tier 3) Oil Filter 1 57890444
Engine Filters
Primary Fuel Filter 1 57886301
Secondary Fuel Filter 1 57294829
Coolant Service Filter 1 57928913
HR2.5 Compressor Air Primary Filter Element 1 50616390
Cleaners (900HR2.5 and
1070HR2.5) Safety Filter Element 1 50616408
Gasket Kit 1 50621796
6-28
DRILLING SOLUTIONS
Description Filter/Element Quantity Part No.
HR2.5 Compressor Filters Oil Filter 2 36860336

(900HR2.5 and 1 57569758
Receiver Tank Separator
1070HR2.5
Element
Strainer Element 1 35370063
Hydraulic System Hydraulic Return Filters 3 57828626
Drain Filter Element 1 57895278
Hydraulic Tank Breather 1 57828543
Hydraulic Tank Air Filter 1 57828527
6-29
Hydraulic Oil
The quality of the hydraulic oil is important to the satisfactory performance
of any hydraulic
system. The oil serves as the power transmission medium, system coolan
t and lubricant.
Selection of the proper oil is essential to ensure proper system performance
and life.
The drill left the factory filled with HUMBLE HYDRAULIC H oil. The followin
g shows the
specifications:
Table 17: Hydraulic Oil Specification
EXXON HUMBLE HYDRAULIC H 32
ISO Flash °C Pour °C Viscosity Viscosity

Viscosity (°F) (°F) Index
Grade cSt at 40°C cSt -100°C
32 206 (403) -18 (0) 32 5.4 95
Grade AW32 is a general specification. Grade ISO AW32 is a general

specification. Hydraulic
oil must conform to Parker Hydraulics Pump Division HF-0 Standards (4-11-7
8) and ISO
Viscosity Grade 32.
The following are approved oils for Parker Hydraulics Pump Division
HF-0 Standard.
Table 18: Approved Oils
Oil company Oil Product

Amoco Amolite: HF Oil No. 32
Exxon Nuto - H 32
Gulf Harmony AW32
Illinois Oil Products Supreme R&O Antiwear Hydraulic Oil
Sun Oil Sunvis 816 WR (32)
Texaco Rando Oil No. 32
Texaco AWX (With EC HI TEC ADD PACKS)
Atlantic Richfield Co. (ARCO) Duro AW-32
6-30
DRILLING SOLUTIONS
Lubricant Oil & Grease
Extreme Pressure Multipurpose Lubricant

and meet the
This gear lubricant is compounded to achieve high load carrying capacity
requirements of either API-GL-5 or MIL-L-2105C. Unless otherwi se specifie d, SAE-90
viscosity oil may be used for year round service.
Table 19: Extreme Purpose Multipurpose Lubricant
Application Quantity Type
Rotary Head 1 gallon (3.78 liter) S.A.E. 90W Gear Oil
Planetary Drive Gearbox 4.5 quart (4.25 liter) 80W90 Gear Oil
Carousel Speed Reducer 80W90 Gear Oil
3K Sand Reel 3.2 pints (1.5 liter) SAE90 Lubricating Oil
•
4K Service Winch 2.3 pint (1.1 liter) SAE90 Lubricating Oil
Low temperature usage is restricted as follows:

Table 20: Low Temperature Usage
EP Multipurpose Lubricant
SAE Viscosity Number Ambient Temperature F°/(C°)
75W -40°F (-40°C)
80W -15°F (-26°C)
85W +10°F (-12°C)
90W +20°F (-7°C)
140W +40°F (+5°C)
250W +50°F (+10°C)
6-31
Winch Lubricant
The following table represents the lubricant used in the 12K, 18K and
30K main winch:
w N
Failure to use the proper type and viscosity of planetary gear

oil may
contribute to intermittent brake clutch slippage which could
result in
property damage, severe personal injury or death. Some gear
lubricants
contain large amounts of EP (extreme pressure) and anti-fr
iction
additives which may contribute to brake clutch slippage or
damage to
brake friction discs or seals. Oil viscosity with regard
to ambient
temperature is also critical to reliable brake clutch operation.
OEM tests
indicate that excessively heavy or thick gear oil may contr
ibute to
intermittent brake clutch slippage. Make certain that the gear
oil viscosity
used in your winch is correct for your prevailing ambient tempe
rature.
Table 21: Prevailing Ambient Temperature
Temperature Range Required Lubricant

-25°F to 130°F (-31.6°C to 54.4°C) Mobilgear SHC 150 or 220 Synthetic or
equivalent
10°F to 80°F (-12.2°C to 26.6°C) Exxon Sparton EP150 or equivalent
AGMA 4EP Gear Oil, ISO VG150
25°F to 130°F (-3.8°C to 54.4°C) Exxon Sparton EP220 or equivalent
AGMA 5EP Gear Oil, ISO VG220
Texaco Meropa 150, previously used as factory fill, may no longer

be widely available due to
market conditions. Planetary hoists are factory filled with Exxon
Sparton 150, or equivalent.
The chart below relates the Texaco products to four (4) curren
tly available oils. Consult your
oil supplier for other equivalent oils if required.
Table 22: Equivalent Available Oils
Texaco Exxon Mobil Shell Chevron

Meropa 150 Sparton EP150 Mobilgear 629 Omala 150 Gear Compounds EP150
Meropa 220 Sparton EP220 Mobilgear 630 Omala 220 Gear Compounds EP220
6-32
DRILLING SOLUTIONS
Water Injection Pump Lubricant
The required lubricating oil for water injection pumps is as follows:

Table 23: Water Injection Pump Lubricant
Manufacturer Required Lubricant
Cat Water Injection Pump CAT Pumps Special Multi-Viscosity IS068
FMC John Bean Water SAE30 Texaco Meropa 100 or SAE Shell Omala 100
Injection Pump
Compressor Fluids
The T3W Waterwell Drill is available as a high pressure drill only. Therefore, use only XHP605
compressor oil.
Table 24: Compressor Fluids
• Design Operating
350 psi
Pressure
Ambient Temperature
-10°F to 125°F (-23°C to

52°C)
Specification
IR XHP605. ISO viscosity

grade 68, group 3 or 4 with
rust inhibitors designed for
air compressor service.
NOTE: Compressor oil carryover (oil consumption) may be greater with

the use of alternate fluids.
Engine Lubricating Oil

filter change
The use of quality engine lubricating oils, combined with appropriate oil drain and
intervals, is a critical factor in maintaining engine performance and durability .
oil for
Note: Cat DEO-ULS (Diesel Engine Oil-Ultralow Sulfur) multigrade is the preferred
use in Cat C13 and Cat C15 engines.
temperature
The proper SAE viscosity grade of oil is determined by the minimum ambient
tempera ture during engine operation.
during cold engine startup and the maximum ambient
e SAE OW oil,
If ambient temperature conditions at engine startup require the use of multigrad
SAE OW-40 viscosity grade is preferred over SAE OW-30.
•
ent for the
Note: Generally, use the highest oil viscosity that is available to meet the requirem
temperature at startup.
6-33
DRILLING SOLUTIONS
Table 25: SAE Viscosity
Engine Oil Viscosities for Ambient Temperatures
Ambient Temperature
Viscosity Grade Minimum Maximum
SAE OW-30 -40°C (-40°F) 30°C (86°F)
SAE OW-40 -40°C (-40°F) 40°C (104°F)
SAE 5W-30 -30°C (-22°F) 30°C (86°F)
SAE 5W-40 -30°C (-22°F) 50°C (122°F)
SAE 10W-30 -18°C (0°F) 40°C (104°F)
SAE 10W-40 -18°C (0°F) 50°C (122°F)
SAE 15W-40 -9.5°C (15°F) 50°C (122°F)
For the latest applicable engine lubricating oil specifications, contact the
engine manufacturer,
your dealer or your local Drilling Solutions distributor.
Extreme Pressure Multi-Purpose Grease
Look for a lithium soap base grease with a high load carrying capacity.
The following
properties are recommended:
Table 26: EP Multi-Purpose Grease
High Load Properties

Timkin OK Load 40 lb. (18.14 kg) minimum
Dropping Point 350°F (177°C) minimum
Oil Viscosity 75 SUS minimum at 210°F (99°C)
Water Resistance Excellent
Under normal conditions, the following consistency grades are recomm

ended:
Table 27: Normal Operating Properties
Normal Operating Condition Consistency Grades

NLGI Number 0 Subzero fahrenheit (celsius) temperatures
NLGI Number 1 Or Number 2 Ambient temperatures 0°F to 100°F (-17.8°C to 38°C)
NLGI Number 2 or Number 3 Temperatures over 100°F (38°C)
6-34
DRILLING SOLUTIONS
Multi-Purpose Grease
With the exception of the rotary head, the following grease can be used:
Table 28: Multi-Purpose Grease Specfication
Description Specifications
Manufacturer: Amalie Oil Company
Type: Multi-Purpose Grease, EP1 (#673-6819)
Quantity: 120 lb. Drum (54.4 kg)
Soap Type & Color: LI-12-0H, Light Brown
NLG1 Grade: 2
Work Penetration, D17, 77°F (25°C): 265 - 295
Dropping Point, 0-2265°C (0-2265°F): 350°F (177°C minimum)
Rust, D-1743 (max): 1
•
Timken, D-2905, OK Load: -
Filler, WT.: -
Oxidation, D-942 (100 hrs): 7
VIS @ 100°C (212°F) cSt: 15.5
VIS @ 210°F (99°C) SUS: 82
Pour Point Degree Celsius: -15°C
Pour Point Degree Fahrenheit: +5°F
Product Number: 5819
6-35
Rotary Head Grease
Atlas Copco recommends using Exxon Mobil Ronex Extra Heavy Duty Moly 2
grease for the
rotary head grease points. The following shows the specifications:
Table 29: Rotary Head Grease Specification
Description Specifications
Manufacturer: Exxon Mobil
Type: Ronex Extra Heavy Duty Moly 2
Quantity: 1 lb. (.45 kg)
Thickener Type: Lithium Complex
Pumpable Down To: -10°C (14°F)
NLGL Grade: 2
Color: Gray - Black
Base Oil Viscosity, ASTM D
CST @ 40°C: 460

SUS @ 100°F: 2500
Dropping Point, ASTM D 225: 250+°C (380+°F)
Rust Protection, ASTM D 1743: Pass
Texture: Smooth
Moly Percentage: 3
Note 1: MOLY 2 is a compound with special
extreme pressure and anti-wear additives
to protect bearing surfaces at high load
carrying capability.
Note 2: For applications requiring lower pumpable
temperatures, contact engineering.
6-36
DRILLING SOLUTIONS
•
Section 6 - Maintenance T3W Instruction Manual
Coolant Specifications
Coolant
Coolant is normally composed of three elements: Water, Additives and glycol.
Water
Water is used in the cooling system to transfer heat. Distilled or deionized water is
recommended for use in the engine cooling systems. DO NOT use the following types of water
in cooling systems: hard water, softened water that has been conditioned with salt, and sea
water. If distilled water or deionized water is not available, use water with the properties that
are listed in the following table.
Table 30: Minimum Acceptable Water Requirements
Property Maximum Limit
•
Chloride (CI) 40 mg/L (2.4 grains/US gallon)
Sulfate (SO4) 100 mg/L (5.9 grains/US gallon)
Total Hardness 170 mg/L (10 grains/US gallon)
Total Solids 340 mg/L (20 grain/US gallon)
Acidity pH of 5.5 to 9.0
Additives
Additives help to protect the metal surfaces of the cooling system. A lack of coolant additives
or insufficient amounts of additives enable the following conditions to occur: corrosion,
formation of mineral deposits, rust, scale, pitting and erosion from cavitation of the cylinder
liner and foaming of the coolant. Additives must be added at the proper concentration.
Overconcentration of additives can cause the inhibitors to drop out-of-solution. The deposits
can enable the following problems to occur:
1. Formation of gel compounds

2. Reduction of heat transfer
3. Leakage of the water pump seal
4. Plugging of radiators, coolers and small passages
6-37
Glycol
Glycol in the coolant helps to provide protection against the following conditions: boiling,
freezing and cavitation of the water pump and the cylinder liner. For optimum perform
ance,
use a 1:1 mixture of a water/glycol solution.
Coolant Recommendations
The following coolants are the primary types of coolants that are used in Caterpillar
engines.
1. Preferred - Caterpillar Extended Life Coolant (ELC) or a commercial extende
d
life coolant that meets the Caterpillar EC-1 specification.
2. Acceptable - Caterpillar Diesel Engine Antifreeze/Coolant (DEAC) or
a
commercial heavy-duty coolant/antifreeze that meets "ASTM D4985" or "ASTM
D5345" specifications.
Caterpillar recommends a 1:1 mixture of water and glycol. This mixture will provide
optimum
heavy-duty performance as a coolant/antifreeze.
Note: Caterpillar DEAC does not require a treatment with an SCA at the initial
fill. Commercial
heavy-duty coolant or antifreeze that meets "ASTM D4985" or ASTM D5345"
specifications
may require a treatment with an SCA at the initial fill. Read the label or the instructi
ons that
are provided by the OEM of the product.
The following table is a list of the coolants that are recommended and the service
life
(calendar) of the coolants. The service life of coolant is also limited by use (service
hours).
Refer to the specific engine's Operation and Maintenance Manual "Mainte
nance Interval
Schedule" (Maintenance Section). To achieve this service life, the coolant
s must be
properly maintained. The maintenance program includes S-O-S coolant
analysis.
Table 31: Coolant Service Life
Coolant Type Service Life

Caterpillar ELC Six Years
Caterpillar DEAC Three Years
Commercial Heavy-Duty Coolant/Antifreeze that Two Years
meets "ASTM D5345"
Commercial Heavy-Duty Coolant/Antifreeze that One Year
meets "ASTM D4985"
Caterpillar SCA and Water Two Years
Commercial SCA and Water One Year
6-38
DRILLING SOLUTIONS
Diesel Fuel (Cat Engines)
Distillate Diesel Fuel

Caterpillar recommends that all distillate diesel fuel, including ULSD fuel (fuel less than or
equal to 15 ppm sulfur using ASTM D 2622 or DIN 51400) meet the requirements of the
Caterpillar Specifications for Distillate Diesel Fuel.
In North America, diesel fuel that is identified as No. 1-D or No. 2-D in "ASTM D975" generally
meet the specifications. Caterpillar recommends diesel fuels that are distilled from crude oil.
Diesel fuels from other sources could exhibit detrimental properties that are not defined or
controlled by this specification.
Note: Caterpillar recommends that the fuel be filtered through a fuel filter with a rating of less
than five (5) microns absolute at the point at which the fuel is dispensed into the vehicle.
Notice: Operating with fuels that do not meet Caterpillar's recommendations can cause the
following effects: starting difficulty, poor combustion, deposits in the fuel injectors, reduced
service life of the fuel system, deposits in the combustion chamber and reduced service life of
the engine.
S15 (ULSD) is defined by the U.S. Environmental Protection Agency (EPA) as U.S. diesel fuel
•
with a sulfur content not to exceed 15 ppm (parts per million). S15 and S500 are designations
for diesel fuels that meet 15 ppm and 500 ppm maximum sulfur content, respectively, as
defined in the American Society for Testing and Materials (ASTM standard D975 Table 1). In
different regions of the world ULSD may refer to different maximum sulfur content values, but
ULSD and S15 are often used interchangeably in North America (U.S. and Canada). The S15
and S500 designations also apply to the Canadian diesel market.
Table 32: Requirements for Diesel Fuel (ASTM D975-97)
Grade Grade Grade Grade
Property LS #1 LS #2 No. 1-D No. 2-D
Flash Point °C, min. 38 52 38 52
Water and sediment,% vol, max. 0.05 0.05 0.05 0.05
Distillation temp., °C, 90% (Min.) - 282 - 282
Distillation temp., °C, 90% (Max.) 288 338 288 338
1.3 1.9 1.3 1.9

Kinematic Viscosity, mm2/s at 40°C (Min.)
2.4 4.1 2.4 4.1
Kinematic Viscosity, mm2/s at 40°C (Min.)
0.15 0.35 0.15 0.35
•
Ramsbottom carbon residue, on 10%,%
mass, max.
Ash,% mass, max. 0.01 0.01 0.01 0.01
0.10
6-39
DRILLING SOLUTIONS
Grade Grade Grade Grade

Property LS #1 LS #2 No. 1-D No. 2-D
Sulfur,% mass, max 0.05 0.05 0.05 0.05
2.00
Copper Strip Corrosion. Max 3 hours at No. 3 No. 3 No. 3 No. 3
50°C.
Cetane Number, min. 40 40 40 40
One of the following properties must be met:
(1) Cetane index 40 40
(2) Aromaticity,% vol, max 35 35
6-40
DRILLING SOLUTIONS
6-4 MAINTENANCE AS REQUIRED
General Information
WARNING1
before you operate or perform any maintenance, service or repair on the
drill.
and understand Section 4 - Operating Controls.
Unexpected drill motion or moving parts can cut or crush. Shut down the
Safety should be the main concern for anyone working on or around the
•
drill. Do not perform any function that could put someone in danger.
Always wear correct safety gear while working on or around the drill. This
includes an approved hard hat, safety glasses, steel toe shoes/boots,
gloves, respirator and ear protection. Do not wear loose fitting clothing
that can become caught on rotating components.

4. Always perform safety checks prior to starting and using the drill.
6. Never stop the drill on a slope or surface that is liable to collapse.
crushing risk.
8. Before starting engine, always check to see that the controls are in the OFF or
neutral position on the operator's control panel and the parking brake is
applied.
•
10. Always apply the parking brake before leaving the truck cab.

Maintenance As Required
The following preventive maintenance and service in this "Maintenance As Required"section
requires attention on an as needed basis before, during and after the drill operation shift. This
is in addition to the 8 hour daily maintenance procedures. Performance of this inspection can
result in longer life and maximum productivity from the drill. Refer to the actual manufacturer's
service manuals for "As Required" maintenance and service on the carrier.
Air Cleaners
The following are detailed instructions for performing routine maintenance procedures on the
engine and compressor air cleaners.
L'L CAUTION
Raw, unfiltered air can cause engine or compressor damage. Never service air cleaners
while the drill is running.
Air born dust may be hazardous. Wear proper personal protective equipment while
handling air cleaners and elements.
Air Cleaner Indicators
Check the air cleaner visual restriction indicator before every shift, during every shift and after
every shift.
AIR CLEANER
VISUAL
RESTRICTION
INDICATOR
DUST CUP DUST CUP

CLAMP
Clean and inspect the compressor air cleaner visual restriction indicator. It should be GREEN.
If the indicator shows RED, indicating a plugged air cleaner, clean or replace the filter
elements. After servicing the element, reset the restriction indicator to GREEN when the
element is replaced in the air cleaner housing.
The compressor air cleaner must be checked to verify the restriction indicator is not sticking.
Check by pressing in the rubber boot. The internal green/red indicator should move freely.

Connections and Ducts

Check air cleaners and ducts for leaks before every shift, during every shift and after every
shift. Ensure all connections between the air cleaner and air compressor are tight and sealed.
Ensure all connections between the air cleaner and engine are tight and sealed.
NOTE: Dust that gets by the air cleaner system can often be detected by
looking for dust streaks on the air transfer tubing or just inside the intake
manifold inlet.
Empty Dust Cups
As daily routine maintenance, and as required in extremely dusty conditions, the dust cup on
the air cleaner must be emptied of accumulations.
NORMAL INVERTED
POSITION POSITION
VAC UATOR VALVE
•
CASKET
QUICK RELEASE
DUST CUP
CUP
CLAMP
On air cleaners equipped with dust cups, the cup must be emptied when it becomes 2/3 full.
The frequency of dust cup servicing varies with the operating conditions. It may be necessary
to empty the dust cup daily.
1. Loosen the dust cup clamps and remove the dust cups on the air cleaner.
2. Empty any accumulations of dust and dirt and replace the dust cup. Secure the
dust cup clamps.
3. When reinstalling the dust cup, make sure it seals all the way around the air
cleaner body.
4. Inspect the o-ring between the dust cup and the air cleaner body. If it is
damaged in any way, it must be replaced.
On air cleaners equipped with a quick release dust cup, simply release the latch on the dust
cup and allow it to swing down and empty. When it is empty, close the dust cup and lock it in
•
place with the latch.
On air cleaners equipped with vacuator valves, the dust cup service is cut to a minimum. A
quick check to see that the vacuator valve is not inverted, damaged or plugged is all that is
necessary.

Most carrier engine air cleaners use a vacuator valve on the air cleaner that is mounted
outside on the side of the carrier cab. See the carrier actual manufacturer's service manual for
information on the carrier air cleaner.
Air Cleaner Pre-Cleaner
The Donoclone tubes in the air cleaner pre-cleaner may need to be cleaned.
GASKET
;D-RING)
CUP CLAMP
DUST CUP
1. Loosen the dust cup clamps and remove the dust cups on both the compressor
and engine air cleaners.
2. Empty any accumulations of dust and dirt.
3. Inspect the o-ring between the dust cup and the air cleaner body. If it is
4. The tubes in the filter pre-cleaner may become lightly plugged with dust which
can be removed with a stiff fiber brush. If heavy plugging is evident, remove the
lower body section and clean with compressed air or water not to exceed 160°F
(71°C).
PRE-CLEANER
L CAUTION
Never clean Donoclone tubes with compressed air unless both the safety and primary
elements are installed in the air cleaner. Do not steam clean the tubes in the pre-
cleaner.
6-44
DRILLING SOLUTIONS
Air Cleaner Rain Guard

Check the bolts fastening the rain guard around the pre-cleaner body and make sure they are
secure. If the bolts become loose, it will allow the rain guard to fall down over the openings in
the pre-cleaner and restrict the flow of air into the air cleaner.
Air Cleaner Elements
The air cleaner is the dry type with two elements: a primary element that is replaceable and
can be cleaned, and a safety element that should only be replaced and never cleaned.
CLAMP
SAFETY ELEMENT
SAFETY ELEMENT RESTRICTION
INDICATOR AND COTTERPIN
UPPER BODY PRIMARY ELEMENT

ASSEMBLY
WING NUT & WASHER
DUST COVER
• When the visual restriction indicator is RED, clean and replace the air cleaner elements. The
following maintenance procedure must be followed.
1. Unclip the three clamps holding the dust cover.

2. Remove the dust cover.
3. Remove the wing nut and washer. Carefully withdraw the primary air cleaner
element.
PRIMARY
ELEMENT
• 4. Inspect the safety element restriction indicator (Safety Signal). If the indicator
is RED, replace the safety element.

NOTICE
Make sure new elements arrive enclosed in plastic or in a protective
membrane. DO NOT install elements that have been sitting on the shelf
unprotected. This is a dust hazard.
NOTICE
Make sure that the safety element wing nut is tight. Never attempt to clean
a safety element. Change safety elements after three primary element
changes or as indicated by the Safety Service Indicator.
5. Clean the inside of the cover and the housing with a clean, damp cloth.
6. To clean the primary element, perform the following:
Wet Cleaning
a. To dry clean the element, carefully direct compressed air (not to exceed
100 psi or 5 bar pressure) at an angle onto the inside surface from no closer
than 1 inch (25.4mm) from the filter.
b. To wet clean the element, soak for 15 minutes in lukewarm water, not
exceeding 160°F (71°C), mixed with a commercially available detergent.
Rinse until water runs clear (40 psi maximum).
c. After the cleaning, the element must be thoroughly dry before using. Do not
use compressed air to dry the element.
NOTICE
Replace the primary element after six cleanings or annually, whichever
comes first.
7. Examine the new or newly cleaned primary element for torn or damaged pleats,
bent end covers, liners and gaskets.
8. Ensure the primary element wing nut and washer are not cracked or damaged.
Replace if necessary.

SAFETY
ELEMENT
3A=E-Y ELEMENT
NET:AT:2P AN:
0C7TE.7-FIN
9. The safety element should be replaced at this time if:
a. Examination of the primary element reveals a torn or perforated element.

b. Change safety element after three primary element changes or one (1) year
duration.
c. Change safety element as indicated by the Safety Element Restriction
Indicator.
•
d. Change safety element if the air cleaner visual restriction indicator is RED
after servicing the primary element.
10. Clean the inside of the air cleaner housing before removing safety element.
11. To replace the safety element, remove the cotterpin and restriction indicator.
Carefully remove the safety element. Dispose of the used element properly.
12. Install new safety element and secure it with the restriction indicator and
cotterpin.
13. Carefully install the cleaned or new primary element and secure it with the wing
nut and washer.
14. Install the dust cover.
15. Inspect all air intake piping and joints between the air cleaners and the engine
air inlet and the compressor air inlet to ensure that no dusty air can enter.
16. Ensure all clamps are tight.
After servicing the elements, reset the restriction indicator to GREEN when the element is
replaced in the air cleaner housing.
The engine and compressor air cleaners must be checked to verify the restriction indicators
are not sticking. Check by pressing in the rubber boot. The internal green/red indicator should
move freely.
•
NOTICE
Never leave the air cleaner open longer than necessary.

NOTICE
The two most common servicing problems are over servicing and improper servicing.
1. Over Servicing - New filter elements increase in dust cleaning efficiency as

dust builds up on the media. It will trap smaller particles by closing the area
between particles. Remember that if the filter is working properly, it will look
dirty. Also, if a filter looks clean, it may not be serviceable. The operator display
will indicate when the filters require servicing.
2. Improper Servicing - Your engine and compressor are very vulnerable to
abrasive contaminants during the service process. The most common cause of
engine and compressor damage is due to careless servicing procedures. A
handful of dust introduced into the inlet of the engine or compressor can cause
a catastrophic failure of the engine or the compressor. Be very careful when
replacing elements not to introduce dirt into the inlet tube.
Air Cleaner Service Tips
Follow these simple service tips. You'll keep your air cleaners working at their best to protect
your compressor continuously.
1. To begin with, let restriction levels be your guide. Use a restriction indicator.
2. Service elements only when the restriction reaches the service level
recommended by the engine, compressor or equipment manufacturer. It's only
above that point that air cleaner restriction begins to reduce performance
levels.
3. If the engine or compressor performance is poor, but restriction is still within
limits, do not change that element! The air cleaner is probably not at fault.
4. To get extra service hours out of each filter element, make sure the air inlet is
away from any heavy dust clouds caused by operation. And make sure exhaust
carbon cannot enter the air cleaner.
5. Check to see that all connections are tight and leak free and that breakaway
joints, both intake and exhaust, are aligned and sealing.
6. Make sure that the vacuator valve, on air cleaners so equipped, is not plugged.
Is the cup joint sealing? This should take care of most of the air cleaner related
performance problems.
7. When restriction readings finally indicate a change, remove the primary
element very carefully. Use a damp cloth to wipe out all excess dust in the air
cleaner.
8. If you reuse the elements, clean them with care. Rapping, tapping or pounding
dust out of them is dangerous. Severe damage to the filter will result.
9. A thorough cleaning with air or water is recommended in many cases. But be
careful. Too much pressure can break the filter paper and destroy the element.

10. Carefully check new or properly cleaned elements for damage before installing.
11. Never attempt to clean a safety element. Change safety elements only after
three primary element changes or as indicated by a SafetySignal-rm Service
indicator.
12. Make it a habit not to disturb the element until restriction again reaches the
service limit.
Clean the Drill

The complete drill must be given a weekly cleaning. Daily cleaning will be required if material
is adhering to the derrick or truck working parts.
1. Make sure the inside of the truck cab and access to the truck cab is clean. Make
sure the operator's areas, steps and grab rails are clean. Oil, grease, snow, ice
or mud in these areas can cause you to slip and fall. Clean your boots of excess
mud before getting in the cab or on the drill.
2. Check the derrick feed installation for debris buildup around the sheaves.
•
3. Thoroughly wash all fittings, caps, plugs, etc. with a nonflammable, nontoxic
cleaning solution before servicing to prevent dirt from entering while performing
the service.
NOTICE
Protect all electric components and control panels against entry of water
or steam when using high pressure cleaning methods. Cover the fuel and
hydraulic fill cap breathers located on each tank.
4. After cleaning, check for defects in the air cleaner ducts.
a. Check intake for accumulation of debris that could restrict air flow.
b. Check air cleaner mounting hardware for security.
c. Check all hoses for cracks, chafing or deterioration and replace at the first
sign of probable failure.
Loose Bolted Connections
If any loose nuts or bolts are found during the frequent walk-around and the daily inspections,
ensure they are properly torqued. Refer to "Torque Specifications" for the required torque for
all bolt sizes and grades. Always replace self-locking nuts if they have been loosened.

Feed Cable
Two feed cable (pull back) connections are provided on the top of the rotary head swivel yoke
and two (pull down) connections are provided on the bottom of the rotary head swivel yoke to
attach the feed cables. The feed cables are adjustable for wear and stretch. The lower feed
(pull down) cables are adjusted from the cable anchors, which are mounted on the swivel
yoke, and the upper feed (pull back) cables are adjusted from the cable anchor eye mounted
on the traveling sheave frame. Check all cable periodically for signs of wear and deterioration.
CABLE LAYOUT OF
FEED SYSTEM
CABLE
PULLBACK
(LEFT)
CABLE
PULLDOWN
CABLE (LEFT)
PULLDOWN
/S.)! (RIGHT)
CABLE
PULLBACK
(RIGHT)
Adjust Feed Cable
1. Back off the jam nuts on the cable anchors. Hold each feed cable stationary
with a large pipe wrench so the cable will not turn while adjusting.
2. Start with the pullback (upper feed) cables. They run from the swivel yoke
housing to the traveling sheave. Turn anchor adjusting nut until the total
amount of deflection at mid span of the cable is 1/4 inch (6.35mm). Both upper
feed cables are to be adjusted equally.
3. After the pullback cables are adjusted properly, adjust the pulldown (lower
feed) cables in the same manner. They run from the swivel yoke housing to the
back of the derrick base. Total deflection in the cable should be 1/4 inch
(6.35mm) at midspan.
4. Re-check deflection of the pullback cables (upper feed cables) and readjust if
necessary.
5. Tighten jam nuts against the anchor nuts.
6. If one side of the feed system leads the other when raising and lowering the
rotary head, tighten the top adjusting nut of the leading feed cable side. Note:
Tighten until the other side begins to lead, then loosen until both sides move
together. This adjustment may result in the tension on one side of the feed
system to be more than the other, which is acceptable as long as neither feed
cable sags more than 1/4 inch (6.39mm).

7. Raise the derrick and lower the rotary head until the spindle contacts the
centralizer. Check to see if the spindle is exactly in line with the centralizer.
8. If the spindle is not in line with the centralizer, it can be corrected by adjusting
either side of the feed system.
a. Lower the derrick. Loosen the upper adjusting nut and tighten the lower
adjusting nut to move the spindle away from the cable being worked on
figure 6-4-8).
b. Loosen the lower adjusting nut and tighten the upper adjusting nut to move
the spindle toward the cable being worked on.
c. The adjusting nut on one end of the cable anchor assembly must be
tightened the same number of turns (including fractional turns) that were
loosened on the other end of the cable anchor assembly so the cable
tension is not changed.
Cable & Wire Rope

The wire rope industry recognizes the ASME (American Society for Mechanical Engineers)
•
standards for the criteria to set the end of the service life of wire ropes on cranes and towers,
based on visible indicators of wire rope deterioration.
Replacement Guideline
The standards for cranes and towers allow six (6) broken wires in a wire rope lay length, or
three (3) broken wires in one strand, in a wire rope lay. The lay length is 5.5 times the wire
rope diameter (B30.4-B30.8).
The overhead hoist standard criteria is twelve (12) broken wires in a wire rope lay length, or
four (4) broken wires in one strand per lay length (B30.2 and B30.16).
There is no industry wide recognized standard for wire rope on drills, but the above standards
can be used as a guide to determine a safe practical point for wire rope replacement. Cable
feed on the pullback side on a drill is similar to a drilling derrick, as the cables support the drill
pipe string and the rotary transmission device. The cable feed on the pulldown side of the drill
does not reflect any of the ASME standard conditions. The only load these cables see is the
hydraulically applied loads. There is no dead weight being supported and no component free
fall will occur due to complete failure of the wire rope. However, a tensioned rope failure is
possible, so replacement should not be delayed beyond the above determined replacement
point.
Also, note that any broken wires protruding from the wire rope create a snagging hazard.
These wires should be trimmed flush to the wire rope diameter. These trimmed broken wires
need to be recorded and logged as to their exact locations as part of the broken wire count
•
criteria for determining wire rope replacement.
The following drawing shows the wire rope broken down. The wire rope is made up of strands
woven around a core. Each strand is made up of individual wires. If a wire rope breaks four (4)
wires from the same strand within the lay length, it should be replaced according to ASME
standards.

CORE WIRE
ONE STRAND
CENTER WIRE
START STOP
START HERE STRAND
ONE (1) LAY LENGTH
END HERE
ONE REVOLUTION
WIRE ROPE
One lay length is the distance along the wire rope that it takes one strand to make one
revolution. The diameter of a wire rope is taken at the highest points. It is not taken across the
flats of the strands.
Wire Rope
Winch ropes, including their anchorage and other load carrying components of the winch
system, e.g. sheave bearings, rope sheaves and drill hooks, shall be checked at least once a
week.
Wire ropes shall be examined and discarded in accordance with 3.5 of ISO 4309:1990. In table
3.5 of ISO 4309:1990, classification groups M1 and M2 shall be used. On drill rigs with normal
hook load of more than 1000KN, the winch rope shall be regularly paid out and shortened
according to a plan laid down by the manufacturer on basis of experience.
Wire rope used in drilling operations becomes unusable because of wear and wire breakage
and should be discarded according to certain criteria.
1. Replace when four (4) randomly distributed broken wires are found in one lay.
2. Replace when wire rope shows wear of one third (1/3) of the original diameter
of the outside wire.
3. Replace when evidence of any heat damage from any cause is found.
4. Replace when any kinking or cracking occurs.
Wire Rope Clamps
Incorrect installation of the rope clamps can cause premature rope failure and/or possible
bodily injury.

•
r t r
WO ft
. 0.1av t ---@=:1L-2
1 WRONG WAY
•„f
WRONG WAY Clips Are Reversed
Clips Are Staggered
•ikt
0
07-"ir A
il 1 1
RIGHT WAY
it All Nuts Should Be Down
been applied.
1. Nuts should always be retightened after the initial load has
ctions and using the
2. A termination made in accordance with the following instru
number of clips shown has an approximate 80% efficie ncy rating. This rating is
pulley is used in
based upon the catalog breaking strength of wire rope. a If
clip.
place of a thimble for turning back the rope, add one additional
regular or Lang lay wire
3. The number of clips shown is based upon using right
or XIPS.
rope, 6 x 19 Class or 6 x 37 Class, fibre core or IWRC, IPS
•
rope, 8 x 19 Class, fibre
4. The number of clips shown also applies to right lay wire
core, IPS, sizes 1-1/2 inch and smaller; and right regula r lay wire rope, 18 x 7
smalle r.
Class, fibre core. IPS and XIPS, SIZES 1-3/4 inch and
er of clamps and size,
5. The important things are using proper thimble size, numb
and installing them properly. See Wire Rope Clamp chart.
Table 33: Correct Usage of Wire Rope Clips
Amount of Rope Torque in Foot

Minimum to Turn Back in
Clip Size Inches Number of Clips Pounds
Inches
Dimensions are in inches and are approximate

2 3-1/4 -
1/8
2 3-3/4 -
3/16
2 4-3/4 15
1/4
2 5-1/2 30
5/16
2 6-1/2 45
3/8
2 7 65
7/16
•
3 11-1/2 65
1/2
3 12 95
9/16
3 12 95
5/8
6-53
DRILLING SOLUTIONS
Minimum Amount of Rope

Clip Size Inches to Turn Back in Torque in Foot
Number of Clips Pounds
Inches
3/4 4 18 130
7/8 4 19 225
1 5 26 225
1-1/8 6 34 225
1-1/4 6 37 360
1-3/8 7 44 360
1-1/2 7 48 260
1-5/8 7 51 430
1-3/4 7 53 590
2 8 71 750
2-1/4 8 73 750
2-1/2 9 84 750
2-3/4 10 100 750
3 10 106 1200
Wire Rope Installation
Unless a revolving stand is available, we recom

mend unwinding the cable coil prior to
installing on winch drum. This prevents the cable
from becoming twisted during the winding
operation.
A WARNING
The cable clamp is not designed to hold
the full load alone. NEVER
attempt to lift a load with less than five (5) wrap
s of cable on the drum.
Take the free end of the wire rope and insert it throu
gh the small opening of the anchor pocket.
Loop the wire rope and push the free end about 3/4
of the way back through the pocket. Install
the wedge, then pull the slack out of the wire rope.
The wedge will slip into the pocket and
secure the wire rope into the drum. The anchor is
designed to accommodate several sizes of
wire rope. You may anchor 3/8 inch and 7/16 inch
(10mm and 11 mm) wire rope by inserting
the wedge large end first. You may anchor 1/2 inch
and 9/16 inch (13mm and 14mm) wire rope
by inserting the wedge small end first.
6-54
DRILLING SOLUTIONS
•
INSERT LARGE END FIRST INSERT SMALL END FIRST

FOR TB" AND 7/16" (10MM FOR 1/2" AND 9/16" (13MM
AND 14MM) WIRE ROPE
AND11MM) WIRE ROPE
NOTE:
SEE PARTS BOOK FOR
CORRECT PART NUMBER
FOR REPLACEMENT
CABLE ANCHORS OR
WEDGES
1. Wind cable onto the drum.

cable.
a. Leather gloves should be used when handling winch
d be taken to wind
b. The cable winds in on TOP of the winch drum. Care shoul
as possi ble.
the cable on the winch drum as evenly and as tight
the winch drum; one
2. Always use two persons when winding the cable onto
cable from a safe
•
the
person to operate the controls and the other to guide
distance to obtain as level a winding job as possible.
r attempt to maintain
3. When winding winch cable on the winch drum, neve
s use "hand-over-
tension by allowing winch cable to slip through hands. Alway
hand" technique.
Notes:
head is in the retracted
1. Check feed cable tightness only when the rotary
head is in the retract
position. The cables become "tighter" when the rotary
the derrick sheaves
position. Over tightened cables will unnecessarily wear
and bearings.
ends.
2. New cables will stretch and seat in new cable anchor
ve the slack but do not
3. Suggest for regular maintenance adjustment to remo
lt to feather the feed
tension cables excessively as it only makes it more difficu
system when making or breaking a drill pipe joint.
operator to make up and
4. Feed cables not tensioned excessively will assist the
ge. Some customers
detach drill pipe joints with minimal drill pipe thread dama
protection.
have installed a telescoping spindle adapter for additional
n the cables because
5. Cables stretch under load. This is normal. Do not tighte
with NO LOAD on the
they are loose in a deep hole. Only check adjustment
•
head.
been known to unscrew
6. Tighten the jam nuts securely. Cables rotate and have
the improperly secured nuts right off the adjus ters.
6-55
DRILLING SOLUTIONS
Receiver Separator Element

Maintenance on the receiver separator element is
on an "as required" basis. A change of the
separator element is required when there is exces
sive oil carryover with the compressed air.
Hot oil or components can burn. Avoid contact

with hot oil or components.
1. Park the drill on a stable, level surface and
shut down the engine. Allow time
for the drill to cool down.
2. Relieve all air pressure in the receiver tank.
High pressure can cause severe injury or death

. Do not attempt to remove
any plugs or open the drain valve before making
sure all air pressure has
been relieved from the system. Completely
relieve pressure before
removing filler plug, drain valve, fittings or recei
ver cover.
3. Remove the bolts from the receiver tank cover
and remove the cover
4. Pull the separator element from the receiver
tank.
SEPARATOR
ELEMENT
VERTICAL
RECEIVER
TANK
5. Inspect the element for failure mode.
6-56
DRILLING SOLUTIONS
lines.
6. Discard the used element in accordance with local guide
or cover before installing
7. Clean any old gasket material from the receiver tank
the new receiver element.
t the new receiver
8. Remove the new receiver element from box and inser
holes in the receiver
element into the receiver tank. Ensure the scavenge
at the bottom of the
element are located properly. There will be several holes
receiver element.
gasket is equipped with a
9. When installing the new element, make sure that the
ve the staple.
staple in the gasket on the element flange. Do not remo
10. Reattach the front cover and tighten the bolts.
ratures.
11. After startup, check for any leaks at operating tempe
Compressor Air Hose and Clamps

" instructions shown in Section 7
Refer to the "Dixon Boss Clamp Selection and Installation
t and install Dixon Boss Clamps.
"Systems & Troubleshooting" for the proper way to selec
Air Hose & Clamps

due to "Cold-Flow" present
1. Periodic clamping bolts re-tightening is necessary
value listed on "BOSS
in all rubber hoses. Tighten to recommended torque
.
CLAMPS" chart in Section 7 "Systems & Troubleshooting"
Boss clamps. If hoses are
2. Examine and change out worn hoses and weakened
clamps hold the hose
to be changed out, change the Boss clamps also. Boss
clamps (including nuts
connections under a large amount of pressure. Boss
Once removed, discard.
and bolts) are for single use only. Do not reuse.
Fuel Systems
condensation inside the tanks. This is
Maintain the fuel tanks at a high level to minimize water
shift or day. The fuel tanks should
best accomplished by filling the fuel tanks at the end of each
fuel tank moves below the 1/4 tank
be filled when the fuel indicator on the fuel gauge for the
mark.
OPERATOR'S CONSOLE
. FUEL
GAUGE
FUEL
GAUGE -
DISCHARGE WATER
TEMPERATURE irmPEaRHIRE
TRUCK DASHBOARD
6-57
DRILLING SOLUTIONS
1. Deck Engine Fuel Tank - Periodically check

the fuel level and fill to full with
No.2-D S500 (LSD) Diesel Fuel. Refer to Secti
on 6-3 Refill Capacities /
Lubricants/Fuel for recommended distillate diese
l fuel.
2. Truck Engine Fuel Tank(s) - Periodically check
the fuel level and fill to full with
No.2-D S15 (ULSD) Diesel Fuel. Refer to Secti
on 6-3 Refill Capacities /
Lubricants/Fuel for recommended distillate diese
l fuel.
Rotary Head Swivel

Visually inspect the unit for leakage, damage or
wear daily, at shift change, or every 10 hours
of operation.
NOTICE
If a problem is found during visual inspection

, DO NOT USE THE UNIT until the problem
is corrected.
After the unit has been running for one hour, lubric
ate the bearings through the grease point
in the lower portion of the bearing housing, while
the spindle is rotating. Lubricate the packing
every 3 - 4 hours through the grease point in the
packing box (mud pump, if equipped, must
be off). Lubricate the trunnion pins through the
grease points at the end of each pin.
PACKING BOX ASSEMBLY

GREASE EVERY 3-4 HOURS OF
DRILLING OPERATION.
BEARING HOUSING.
GREASE 10 HOURS OR DAILY
TRUNNION PINS (2).

BEARING HOUSING.
ROTARY HEAD
SWIVEL
THE SWIVEL MUST BE GREASED AT
LEAST ONCE A DAY DURING OHD
OPERATIONS AND ONCE AN HOUR
WHILE MUD DRILLING
ROTARY HEAD ROLLERS.

GREASE ONCE PER SHIFT
OR EVERY 10 HOURS
REFER TO THE ROTARY HEAD SWIVEL

MANUAL FOR MORE DETAILED CARE
AND USAGE INSTRUCTIONS.
6-58
DRILLING SOLUTIONS
6-5 MAINTENANCE (8-10 Hours)
General Information
A WARNING
ns and Guidelines
Read and understand Section 2 - Safety Precautio
service or repair on the
before you operate or perform any maintenance,
drill.
and instruments, read
If you are not experienced with the drill's controls
or crush. Shut down the
Unexpected drill motion or moving parts can cut
ing on or around the
Safety should be the main concern for anyone work
some one in danger.
drill. Do not perform any function that could put
or around the drill. This
Always wear correct safety gear while working on
steel toe shoes/boots,
includes an approved hard hat, safety glasses,
loose fitting clothing
gloves, respirator and ear protection. Do not wear

trolled movement.
2. Always chock the wheels if there is a possibility of uncon
the drill.
4. Always perform safety checks prior to starting and using
g.
5. Always operate the drill at full engine power when drillin
to collapse.
6. Never stop the drill on a slope or surface that is liable
collapse or cause a
7. Never stop the drill against a high wall that is liable to
crushing risk.
the controls are in the
8. Before starting the deck engine. always check to see that
"off" or "neutral" position on the operator's control panel.
r direction to alert
9. Always sound the horn before moving the drill in eithe
g the drill in motion.
personnel and allow sufficient time before puttin
cab.
10. Always apply the parking brake before leaving the truck
6-59
DRILLING SOLUTIONS
Overpressure Control System Test

The T3W feed system provides more than enou
gh feed capability to lift the drill by
the bit. To reduce the possibility of tipping the overfeeding
drill over due to operator error from overfeeding,
the Overpressure Control has been added to
the feed circuits. The Overpressure Control
system test must be performed at the start of
each shift.
The Over Pressure Control does not relie

ve the operator from the responsibility of
having control of the drill at all times. Whil
e the Over Pressure Control reduces the
chances of a tipover, the operator must see
that he does not overfeed the drill to this
extent.
NOTICE
The operator must ensure the jacks are loca
ted on firm ground. Nothing can prevent the
drill from upsetting if the ground or shoring
under the jack gives way.
NOTICE
LIABILITY FOR TIPPING A UNIT OVER LIES
SOLELY WITH THE DRILLER.
1. Locate the drill on a level, graded surface.
Raise and level the drill on all jacks
until the tires are about one inch (25.4mm)
off the ground (the pistons in the
overpressure valves on the drilling end jacks
are no longer depressed).
2. Remove all drill rod, stabilizers, hammers, etc.
from the rotary head.
4. Lower the empty rotary head and stall the rotar
y head at the bottom of the
derrick using fast feed.
5. Raise the left rear jack off the ground and verify
that feed pressure drops below
600 psi. Read pressure from the feed gauge
on the console.
NOTICE
If the Feed Pressure does not drop below

600 psi, troubleshoot and repair
the circuit.
6. Repeat step 4 and step 5 using the right rear
jack.
7. Repeat step 4, step 5 and step 6 using slow
feed.
6-60
DRILLING SOLUTIONS
•
Air Cleaners
nance procedures on the
The following are detailed instructions for performing routine mainte
e and maintenance manuals
compressor air cleaner. Note: See actual manufacturer's servic
for maintenance information on the carrier air cleaner.
,A CAUTION
ge. Never service the air
Raw, unfiltered air can cause engine and compressor dama
cleaners while the engine is running.
Air Cleaner Indicators

shift, during every
1. Check the air cleaner visual restriction indicator before every
shift and after every shift.
• VISUAL
RESTRICTION
INDICATOR
DUST CUP
2. Clean and inspect the engine and compressor air cleane

DUST CUP
CLAMP
tors show
rs visual restriction
RED, indicating a
indicators. They should be GREEN. If the indica
plugged air cleaner, clean or replace the filter eleme nts.
to GREEN when the
3. After servicing the element, reset the restriction indicator
element is replaced in the air cleaner housin g.
or is not sticking.
4. The air cleaner must be checked to verify the restriction indicat
interna l green /red indicator should
Check by pressing in the rubber boot. The
move freely.
Connections and Ducts

shift, during every shift and
Check air cleaner connections and ducts for leaks before every
rs, air compressor and engine
after every shift. Ensure all connections between the air cleane
inlets are tight and sealed.
•
detected by
NOTE: Dust that gets by the air cleaner system can often be
or just inside the intake
looking for dust streaks on the air transfer tubing
manifold inlet.
6-61
DRILLING SOLUTIONS
Empty Dust Cups
As daily routine maintenance, and as required in extremely

dusty conditions, the dust cup on
the air cleaner must be emptied of accumulations.
NORMAL INVERTED
POSITION POSITION
CASKET VACUATOR VALVE
QUICK RELEASE
CUP DUST CUP
CLAMP
DUST CUP
On air cleaners equipped with a dust cup, the cup must be

emptied when it becomes 2/3 full.
The frequency of dust cup servicing varies with the operating
conditions. It may be necessary
to empty the dust cup daily.
1. Loosen the dust cup clamp and remove the dust

cup on both the compressor
and engine air cleaners.
2. Empty any accumulations of dust and dirt and replac
e the dust cup. Secure the
dust cup clamp.
3. When reinstalling the dust cup, make sure it seals
all the way around the air
cleaner body.
4. Inspect the o-ring gasket between the dust cup and
the air cleaner body. If it is
On air cleaners equipped with a quick release dust cup, simply
release the latch on the dust
cup and allow it to swing down and empty. When it is empty
, close the dust cup and lock it in
place with the latch.
On air cleaners equipped with vacuator valves, the dust cup
service is cut to a minimum. A
quick check to see that the vacuator valve is not inverted,
damaged or plugged is all that is
necessary.
Most carrier engine air cleaners use a vacuator valve on the
air cleaner that is mounted
outside on the side of the carrier cab. See the carrier actual
manufacturer's service manual for
information on the carrier air cleaner.
6-62
DRILLING SOLUTIONS
•
Deck Engine
Typical Cat C15

Alternator
Belt
Lube Oil
Primary Filters
Fuel
Filter Coolant Filter not shown
Secondary Fuel Filter
Engine Oil Level

Perform this maintenance with the
Check the engine oil level daily by viewing the dipstick.
engine shut off.
• Hot oil or components can burn. Hot oil and hot component
Do not allow hot oil or hot components to contact the
s can cause personal injury.
skin.
1. The drill must be on a level, stable surface when check

sure the measurement is correct.
2. Wait at least 5 minutes after shutting off the engine
ing the oil level to be
to check the oil level. This

allows time for the oil to drain into the oil pan.
with a lint free dry cloth and
3. Pull out the dipstick (oil level gauge), wipe it clean
push the dipstick back in.
the dipstick.
4. Pull out the dipstick again and check the oil level on
"FULL" (high) mark on
5. Maintain the oil level between the "ADD" (low) mark and
crank case above the "HIGH" mark.
the oil level gauge (dipstick). Do not fill the
CAUTION
"L" (low) mark or

Never operate the engine with the oil level below the
above the "H" (high) mark.
r to the Lubricant
6. Remove the oil filler cap and add oil, if necessary. (Refe
Specifications in this section for details on engin e oil.)
7. Clean the oil filler cap and reinstall.

e has run for about 1
8. Repeat process and check oil level again after engin
minute.
6-63
DRILLING SOLUTIONS
Belts
Under normal operating conditions, the engine drive

belts should be inspected daily. Belt
damage can be caused by incorrect tension, incorrect
size or length, pulley misalignment,
incorrect installation, severe operating environment and
oil or grease on the belts.
Inspect the alternator belt and the fan drive belts for
wear and cracking. Replace the belts if
the belts are not in good condition. Replace the belts
according to the information in the Cat
OEM Operation and Maintenance Manual "Maintenan
ce" Section.
Adjust the belt tension in order to minimize belt slippa
ge. Belt slippage will decrease the life of
the belts. If the belts are too loose, the belts will vibrat
e. This vibration is enough to cause
unnecessary wear on the belts and on the pulleys. If
the belts are too tight, unnecessary
stresses are placed upon the pulley bearings and upon
the belts. These stresses will shorten
the life of the belts and of the pulley bearings.
Check belt tension according to the information in the
Cat OEM Operation and Maintenance
Manual "Specifications" Section.
Primary Fuel Filter/Water Separator
El Fr,lFl
BOWL
DRAIN
PRIMARY FUEL FILTER / WATER SEPARATOR
Fuel leaked or spilled onto hot surfaces or electrical

components can cause a fire. To
help prevent possible injury, turn the start switch
off when changing fuel filters or water
separator elements. Clean up fuel spills immediate
ly.
NOTICE
Use a suitable container to catch any fuel that migh
t spill. Clean up any spilled fuel
immediately.
6-64
DRILLING SOLUTIONS
•
NOTICE
oughly clean the area around a fuel
Do not allow dirt to enter the fuel system. Thor
Fit a suitable cover over disconnected
system component that will be disconnected.
fuel system component.
r. If water is present, drain the water from
The bowl should be monitored daily for signs of wate
the bowl.
ted drain. Catch the draining water in a
1. Open drain. The drain is a self-ventila
suitable container. Dispose of the water properly.
2. Close drain.
NOTICE
normal engine operation. Ensure that the

The water separator is under suction during
ent air from entering the fuel system.
drain valve is tightened securely to help prev
•
Cooling System
Radiator Coolant Level

routine maintenance procedure.
The coolant level must be checked daily as part of the 8 hour
ed and cool. Ensure the coolers are not too
Check the coolant level when the engine is stopp
hot to touch.
the coolant level in the sight glass. Some
If the cooler is equipped with a sight glass, maintain
nt level mark on it. Maintain the coolant
truck engine radiators have a surge tank with a coola
re, if necessary.
level to the correct mark by adding coolant mixtu
COOLANT
FILLER CAP
COOLANT
LEVEL
SIGHT
GAUGE
6-65
Add Coolant Mixture
A Ili
Injury can occur when removing the radi
ator cap. Steam or fluid escaping from the
radiator can burn. Inhibitor contains alka
li. Avoid contact with skin and eyes. Alw
shut down the engine and allow it to coo ays
l down before removing the radiator cap.
Remove the cap slowly to relieve pressure
. Avoid contact with steam or escaping fluid
.
Do not remove the radiator cap from the

cooler(s) while the engine is hot. Wait unti
temperature is below 120°F (50°C) before l the
removing the pressure cap. Failure to do
can result in personal injury from heated so
coolant spray or steam. Remove the filler
slowly to relieve coolant system pressure cap
.
NOTICE
If the coolant level is below the minimum
level, the low level probe will activate the
engine shutdown. In the case of repeated
low level shutdowns, call for service to
investigate cause of coolant loss.
CAUTION
Do not add cold coolant to a hot engine.

Engine castings can be damaged. Allow
engine to cool to below 120°F (50°C) befo the
re adding coolant.
HYDROMETER
1. A refractometer must be used to accurately measure the

freeze point of the
coolant.
2. Do not use a floating ball hydrometer. Floating ball hydr
ometers can give an
incorrect reading.
'WARNINd.
Pressurized System: Hot coolant can caus
e serious burns. To open the cooling syst
filler cap, stop the engine and wait until em
the cooling system components are coo
Loosen the cooling system pressure cap l.
slowly in order to relieve the pressure.
6-66
DRILLING SOLUTIONS
•
slowly in order to relieve pressure, then

1. Remove the cooling system filler cap
remove the cap. Do not allow coolant to splash out.
cap removed. Allow the coolant to warm
2. Start and run the engine with the filler
open.
up, the coolant level to stabilize and the thermostat to
3. Visually check the coolant level again.
to bring coolant level to the desired full level
4. Add coolant mixture, if necessary,
Section 6-3 REFILL CAPACITIES
marks or between the sight gauges. Refer to
ions"for recommended coolant.
/ LUBRICANTS / FUEL, "Coolant Specificat
t. If the gasket is damaged, discard
5. Check the condition of the filler cap gaske
not hold the correct
the old filler cap and install a new one. If the cap does
pressure, replace the cap.
. Check for proper operating
6. With the engine running, look for coolant leaks
temperature.
Clean Radiator(s) and Oil Coolers

to adhere to the cooling fins of the
If the drill has suffered leaks of oil or fuel, dirt will tend
reduce the cooling efficiency. Therefore,
radiator and oil coolers. This accumulation of dirt will
•
and cooling surfaces given a thorough
any leaks of oil or fuel should be immediately repaired
cleaning.
fins on the radiator, charge air cooler,
Check daily for signs of clogging on the exposed cooling
of the routine maintenance procedure.
compressor oil cooler and hydraulic oil cooler as part
s of the operating environment.
Adjust the frequency of cleaning according to the effect
e, insects, leaves,
1. Inspect the radiators for damaged fins, corrosion, dirt, greas
debris from the coolers.
oil and other debris. Remove any leaves, rags or other
may prevent air from
2. Clean the fins of any dust, oil or other contaminants that
passing freely over the cooler fins.
soap.
3. The cooler should be washed with a solution of water and
NOTICE
may degrade the fin material and

Do not use caustic solutions on the coolers as they
cause a leak.
cleaning methods, ensure that

When using compressed air, water jets or steam
eyes and exposed parts of the body.
appropriate protective clothing is worn to protect
than 30 psi (205 kPa) for cleaning
Maximum air pressure at the nozzle must be less
purposes.
6-67
DRILLING SOLUTIONS
Pressurized air is the preferred method for remo

ving loose debris. Direct the air in the opposite
direction of the fan's air flow. Hold the nozzle appr
oximately 0.25 inch (6mm) away from the
fins. Slowly move the air nozzle in a direction that
is parallel with the tubes. This will remove
debris that is between the tubes.
Pressurized water may also be used for cleaning.
The maximum water pressure for cleaning
purposes must be less than 40 psi (275 kPa).
Use pressurized water in order to soften mud.
Clean the core from both sides.
Use a degreaser and steam for removal of oil and
grease. Clean both sides of the core. Wash
the core with detergent and hot water. Thorough
ly rinse the core with clean water.
After cleaning, start the engine and accelerate
the engine to high idle rpm. This will help in the
removal of debris and drying of the core. Stop
the engine. Use a light bulb behind the core in
order to inspect the core for cleanliness. Repe
at the cleaning if necessary.
Inspect the fins for damage. Bent fins may be
opened with a "comb". Inspect these items for
good condition: welds, mounting brackets, air
lines, connections, clamps and seals. Make
repairs if necessary.
1. If clogging is dried on dirt, use liquid or air

to remove from the cooling fins. If dry
dust is present, use low pressure compressed
air to clean.
2. In case of severe clogging due to fluid leaks,
apply diesel fuel or a commercial
cleaning detergent. Let it soak in and then wash
off with water jet.
Fuel Tanks
Care and maintenance of the fuel system is impo
rtant to the proper operation of any diesel
engine. Some of the more critical items which can
cause poor operating efficiency, malfunction
or damage to the engine and fuel system are listed
below:
Dirt
Dirt can only enter the fuel system through the

filler cap opening of the fuel tank by the tank
being filled with dirty fuel, dirt from the hose nozz
le or by failing to clean the area around the
tank cap before opening.
The fuel system is equipped with filters that will
handle the dirt up to a point. These filters must
be replaced on a periodic basis in a preventive
maintenance program, as previously
mentioned
Water
Water may enter the fuel tank either by purchasin

g fuel which contains water, or water may
contaminate the fuel in storage at the service locat
ion. Another source of water in the fuel is
from condensation from air entering the tank cap
breather hole. To prevent condensation, it is
recommended that all fuel tanks be filled when
a vehicle returns from a run and not let the tank
sit overnight with less than a full tank.
The filters can handle some water, but when wate
r goes beyond them, the water will gall the
injector body and score the fuel pump body and
gears.
6-68
DRILLING SOLUTIONS
•
er since it can freeze and stop

Water is an additional problem when in the fuel in cold weath
le that can be put into the
the flow of fuel to the engine. There are commercial additives availab
d from the water separator
fuel to prevent the water from freezing. Enough fuel must be draine
daily to remove all water that may have collected in it.
Air
system, causing the engine
A loose suction line in the fuel system will permit air to enter the
to idle roughly and not function properly under a load.
Fuel System Maintenance

ed on a regular basis. The
The fuel system hoses and fittings must have their tightness check
ctorily:
following steps will help keep the fuel system functioning satisfa
g.
1. Let no contamination (dirt or water) enter the tank filler openin
2-D S500 LSD for
2. The fuel for the diesel engine must be of good quality (No.
be obtained
deck engine and No. 2-D S15 ULSD for truck engine) and should
from a reliable supplier.
•
fuel tank is filled.
3. Have a clean fuel nozzle and loading area where vehicle
g. Be sure the vent
4. Have fuel tanks filled at the end of each shift before parkin
filler neck.
in the fuel cap is open. Do not fill fuel tank above bottom the
of
5. Replace filters on a regular basis.

6. Keep all fuel system hoses and fittings tight.
n inside the tank. This is
Maintain fuel tank(s) at a high level to minimize water condensatio
shift or day.
best accomplished by filling the fuel tanks at the end of each
the potential fire hazard, leaks
Check fuel tanks and fuel lines for possible leaks. Because of
grade of fuel in accordance
must be corrected as soon as they are spotted. Select the proper
with the information in 6.3 Refill Capacities / Lubricants / Fuel.
down engine, extinguish all

Fuel is flammable. May cause serious injury or death. Shut
. Always wipe up any spilled
open flames, and do not smoke while filling the fuel tanks
fuel immediately.
d on the cab
1. Check the fuel levels by reading the fuel level gauges locate
dashboard and operator's control console.
fuel system will
2. Never allow fuel tanks to completely empty, otherwise the entire
•
require bleeding.
filler cap.
3. When fuel is added, clean the fill cap area and open the fuel
ubricants/
4. Fill tank with the correct grade of fuel. Refer to 6.3 Refill Capacities/L
Fuel for more details.
6-69
DRILLING SOLUTIONS
Receiver Separator
The receiver tank contains the lubricating oil for the compresso
r. The oil is removed from the
air by centrifugal force, gravity, velocity and filtration. The receiv
er tank has an oil sight glass
that shows the oil level at all times. The oil level glass should
be at least half full when the drill
is shut down and oil must show in the glass when the drill
is running.
Check Compressor Oil Level
Periodically check the compressor oil level in the receiver tank.

A loss of compressor oil could
be an indication of excess oil carryover with the compressed
air and would require a separator
element change.
NOTICE
Checking the oil level in a T3W is different from most drills.
The compressor must be
operating and making air in order to correctly check oil
level.
OIL
LEVEL
SIGHT
GAUGE
DRAIN VALVE
Check the receiver separator oil level at the sight glass oil
level gauge on the receiver as
shown above. The procedure to check the fluid level is as
follows.
1. Start the deck engine and turn the compressor switch
"on".
2. The fluid must be in the center of the oil level sight glass
on the receiver tank.
3. If oil level is low, shut down the drill and relieve all pressu
re from receiver tank.
6-70
DRILLING SOLUTIONS
WARNING
or the drain valve
Do not attempt to open the filler plug, any drain plugs
ed from the system.
before making sure all air pressure has been reliev
High pressure can cause severe injury or death .
d through a 10 micron filter) through the fill
4. Add fresh, clean synthetic oil (filtere
cap area to bring the oil to the correct full level.
A CAUTION
into the drill string.

Over filling the receiver tank can cause oil carry-over
use XHP605 Oil. For details on
5. High pressure compressors (350 psi) must
6-3 Refill Capacities/
compressor oil, refer to "Compressor Fluids" in section
Lubricants/Fuel Specifications.
Drain Water from Receiver Tank

of the receiver tank. If water is
Water condenses and must be drained daily from the bottom
g life will be considerably reduced.
allowed to condense into the compressor oil, the bearin
WARNING
letely relieve pressure before
High pressure can cause severe injury or death. Comp
cover.
removing filler plug, drain valve, fittings or receiver
allow any of the
1. Locate and open the receiver tank drain valve and
accumulated water to drain into a container.
2. When oil starts to flow, close the drain valve.
3. Dispose of all accumulation in accordance with local regulations.
Hydraulic Reservoir
the 8 hour routine
The hydraulic reservoir oil level must be checked daily as part of
maintenance procedure.
NOTICE
onent failure. A clean,
Dirt in the hydraulic system will lead to premature comp
the drill's proper function. Take
contaminant free system is extremely important to
system to ensure its complete
extra care when working around or on the hydraulic
be betwe en the maximum and minimum
cleanliness. When operating, the oil level must
levels.
6-71
DRILLING SOLUTIONS
Hydraulic Oil Level
The hydraulic oil tank is located on the left side of the drill
beside the pipe rack. A sight glass
and temperature gauge are mounted facing the helper's
platform. Check the oil level with all
cylinders retracted to get the correct level. Add oil, if neces
sary, through the hand fill pump.
HYDRAULIC
OIL LEVEL
GAUGE
HAND PUMP
(FILL)
HYDRAULIC
OIL TEMP
GAUGE
The following procedure is proper for checking the hydra

ulic oil level in the reservoir. If the
hydraulic oil level is low, add hydraulic oil through the hand
fill pump.
,L CAUTION
Excessive hydraulic oil can rupture the hydraulic tank
and cause injury or property
damage. Do not fill hydraulic tank with cylinders exten
ded. Retract all cylinders and fill
tank to indicated level.
1. The drill must be level.

2. Check the reservoir oil level by viewing the sight gauge.
3. The oil level in the hydraulic tank depends on the extended
or retracted
positions of the hydraulic cylinders. It is important to
observe and note the
following information when reading the level gauge:
a. The oil level with all hydraulic cylinders retracted (derrick down
and leveling
jacks up should be even with the mark on the oil level sight
gauge.
b. The top of the oil level MUST be visible when the engine is runnin
g AND
also when the engine is stopped. There must be oil show
ing on the gauge
at all times. Add oil to bring to levels defined above.
NOTICE
If no oil is showing on the gauge, stop the engine imme
diately and call for
service assistance to investigate the cause of oil loss.
6-72
DRILLING SOLUTIONS
•
gh a 5 micron filter) anti-wear

4. If necessary, add fresh, clean (filtered throu
level to the FULL level on
hydraulic oil through the hand fill pump to bring tank
icants/Fuel for details on
the sight gauge. Refer to 6.3 Refill Capacities/Lubr
hydraulic oil.
erature gauge located under
5. During operation, monitor the hydraulic oil temp
the hydraulic oil level sight gauge.
Drain Water from Hydraulic Tank

of the hydraulic tank are used to drain off
Two moisture bleeder valves located on the bottom
se moisture from the hydraulic tank
any moisture accumulated in the hydraulic tank. Relea
tion.
daily, at shift change or every 10 hours of drill opera
• MOISTURE BLEEDER VALVE

(Left Side Under Tank)
1. Place a container under the moisture bleed

contain the escaping fluid.
MOISTURE BLEEDER VALVE
(Right Side Under Tank)
er valve that will be drained to
until water starts flowing.

2. Turn the petcock on the left moisture bleeder valve
3. When oil start to flow out, tighten the petcock.
er valve.
4. Make sure there are no leaks around the moisture bleed
bleeder valve.
5. Repeat step 1 through step 4 to the other moisture
regulations.
6. Dispose of all accumulation in accordance with local
Rotary Tophead
with the derrick up and the rotary head
Check the rotary head daily. Perform this maintenance
at the bottom of the derrick.
NOTICE
, DO NOT use the drill until the problem

If a problem is found during a visual inspection
is corrected.
6-73
DRILLING SOLUTIONS
Riding the rotary head can cause severe injur

y or death. Do not ride the rotary head.
li:4;k1011
Climbing a raised derrick can cause severe
injury or death. Do not climb a raised
derrick.
Falling derrick can cause severe injury or deat

h. Ensure all locking pins are in locked
position.
Rotating shafts or drill string can cause seve

re injury or death. Do not service the rotary
head with the drill string in motion.
Rotary Head Oil Level
1. Move the drill to a stable, level surface.

2. Raise the derrick and bolt the derrick to
the derrick foot rests with the derrick
anchor bolts.
3. If necessary, remove the drill pipe in the rotar
y head and lower the rotary head
to the bottom of the derrick.
4. Inspect the rotary head housing for leaks.
Inspect the hydraulic hoses and
fittings for leaks.
5. Inspect the fluid level sight glass for damage
6. Check the rotary head oil level. Oil must be visib
le near the center of the sight
glass located on the side of the rotary head.
6-74
DRILLING SOLUTIONS
ing procedure:
If the fluid level is low, add fluid using the follow
be raised and the rotary head must be
1. The drill must be level. The derrick must
at the bottom of the derrick.
ve the fill plug.
2. Clean the area around the fill plug and remo
until the oil level is visible in the center
3. Add SAE 80W90 oil through the fill port
/Lubricants/Fuel for details on
of the sight glass. Refer to 6.3 Refill Capacities
hydraulic oil.
e the fill plug and tighten.
4. Once the proper oil level is reached, replac
Rotary Head Swivel, Yoke and Rollers

daily, at shift change, or at every 10
Visually inspect the drill for leakage, damage or wear
hours of operation.\
NOTICE
, DO NOT USE THE DRILL until the

If a problem is found during a visual inspection
problem is corrected.
PACKING BOX ASSEMBLY

GREASE EVERY 3-4 HOURS OF
DRILLING OPERATION.
BEARING HOUSING.
TRUNNION PINS (2).

BEARING HOUSING.
ROTARY HEAD
SWIVEL
THE SWIVEL MUST BE GREASED AT

LEAST ONCE A DAY DURING DHD
OPERATIONS AND ONCE AN HOUR
WHILE MUD DRILLING
ROTARY HEAD ROLLERS.

GREASE ONCE PER SHIFT
0; F.-'/EZ' /0 HOURS
REFER - -HE ; -EAD SWIVEL

mANUAL FOR ....ORE DETAiLED CARE
ANC USAGE INSTRUCTIONS
6-75
DRILLING SOLUTIONS
After the drill has been running for one hour, lubric
ate the bearings through the grease point
in the lower portion of the bearing housing, while
the spindle is rotating. Lubricate the packing
every 3-4 hours through the grease point in the
packing box (the mud pump, if equipped, must
be off). Lubricate the trunnion pins through the
grease points at the end of each pin.
Lubrication
The following grease procedures must be carri
ed out as part of the 10 hour or daily
maintenance schedule. routine
Derrick Pivot Pins
1. Shut down engine.

2. Apply grease gun pressure to the derri
ck pivot pin lube points (both sides) until
all of the old grease has been purged out and
new grease appears.
3. Wipe off all excess grease.
Carousel Bearings
The carousel contains bearings at the upper and

lower ends of the carousel main shaft.
1. The upper and lower bearings on the caro
usel main shaft require 5 pumps of
grease daily, at shift change, or every 10
hours of drill operation. Wipe off excess grease.
Sheaves
There are two (2 groove) feed cable sheaves on

the traveling sheave cage. There are two
large feed cable sheaves at the top of the derri
ck and two more large feed cable sheaves at
the bottom of the derrick. In addition, there are
two draw works sheaves and two jib boom
sheaves located at the top of the derrick.
1. Lower the derrick to the horizontal position.

2. Shut down the engine.
3. Using a manlift, clean the grease nipples on the
sheaves.
4. Inject five shots of MPG-EP2 grease into each grea
se nipple or until all of the
old grease has been purged out and new grea
se appears.
5. Wipe off excess grease.
6. It is particularly important that the lower feed cable
sheaves at the bottom of the
derrick be kept clean. Allowing cuttings to build
up on these sheaves could
result in a failure of the sheave itself or in the cable
.
6-76
DRILLING SOLUTIONS
Cylinders
er will have a grease fitting at both the
Grease the cylinders on the drill daily. A typical cylind
lubricated. A typical T3W will have two
rod end and the cylinder end of the cylinder. Both need
ers with grease points on each jack
(2) derrick raise cylinders, four (4) leveling jacks cylind
jib boom extend cylinder, one (1) or two
cylinder can, one (1) jib boom swing cylinder, one (1)
(1) breakout wrench cylinder, one (1)
(2) feed cylinder(s), one (1) table retract cylinder, one
g) wrench air cylinder.
upper breakout (air) wrench and one (1) table (slidin
1. Lower the derrick into the horizontal position.

derric k.
3. Use a manlift, if necessary. Do not climb on
4. Clean all grease nipples on the cylinders.
e nipple.
5. Inject five shots of MPG-EP2 grease into each greas
Rotary Tophead, Swivel and Rollers

daily, at shift change or every 10 hours
Visually inspect the unit for leakage, damage or wear
of operation.
NOTICE
DO NOT RUN THE ROTARY HEAD until
If a problem is found during a visual inspection,
the problem is fixed.
k and bolt it down.
1. Move the drill to a stable, level surface. Raise the derric
and lower the rotary head
2. If necessary, remove the drill pipe in the rotary head
and swivel yoke to the bottom of the derrick.
and guide rollers.
3. Clean all the grease nipples on the swivel yoke assembly
e nipple.
4. Inject five shots of MPG-EP2 grease into each greas
Breakout (Holding) Wrenches

e points require 5 pumps of grease daily,
The upper and lower breakout (holding) wrench greas
at shift change, or every 10 hours of drill operation.
6-77
DRILLING SOLUTIONS
1. The lower breakout holding wren

ch has two grease points in the sliding porti
of the wrench and two grease points at the on
pivot points of the wrench.
2. The upper breakout holding wren
ch has only one grease point at its pivot.
Chain/Pipe Wrench
1. Clean all the grease nipples on the

chain/pipe wrench assembly.
2. Inject five shots of MPG-EP2 grea
se into each grease nipple.
Gearbox Drive Shaft
The following grease procedure must be carri

ed out as part of the 10 hour or daily
maintenance schedule. routine
A WARNING
Shut down engine and remove ignition
key from ignition switch. Rotating shaft
cause injury or death. Do not operate with can
the guard removed.
2. Leave guard in place.
3. Reach in through the opening in guard to
clean the drive shaft U-joint grease
zerks.
4. If necessary, momentarily press starter butto
n (with key ON/OFF switch in
OFF position) to line up access to the grease
nipples.
5. Inject 5 shots of EXXON MOBIL RONEX Extra
Heavy Duty Moly 2 grease into
the drive shaft grease zerks. Wipe off exce
ssive grease.
Retract Gate Arms
There are four (4) retract gate arms located

at the top of the derrick.
5 PUMPS OF GREASE
INTO FITTINGS AT EACH
RETRACT GATE ARM
- - VERIFY LOCKING COLLAR IS

TIGHT AT EACH RETRACT
GATE ARM
6-78
DRILLING SOLUTIONS
1. Lower the derrick into the horizontal position.

on derric k.
3. Use a manlift, if necessary. Do not climb
arms.
4. Clean all grease nipples on the retract gate
e fitting on each of the 4 retract gates
5. Pump 5 shots of grease into the greas
tion.
daily, at shift change, or every 10 hours of drill opera
gate is tight. A loose locking collar will
7. Verify the locking collar on each retract
rotary head and cause
allow the retract gate to move into the path of the
extensive damage to the feed system.
Mud Pump Grease Points

which mud pump is installed on the drill.
The number of grease points will vary depending on
for the mud pump shaft seal, for the mud
There are grease points on the mud piping valves,
t shaft).
pump bull gear shaft and for the pump jack shaft (inpu
asse mbly.
1. Clean all the grease nipples on the mud pump
2. Pump 5 shots of grease into the grease fittings.
Rod Holder Option

in the vertical position.
If necessary, raise the derrick and lock the derrick
1. Shut down engine.

2. Clean all the grease nipples on the rod holder.
the rod holder.
3. Pump 5 shots of grease into each grease fitting on
Jib Hoist/Boom
s of grease daily, at shift change, or every
The jib hoist/jib boom grease points require 5 pump
e the fittings located at the top of the
10 hours of drill operation. Note: Use a manlift to greas
derrick crown. The jib boom grease points are:
1. The rod end of the boom swing cylinder.

2. The boom swing cylinder pivot.
3. Both ends of the boom extend cylinder.
4. The boom extend cylinder pivot.
5. The jib boom arm pivot.
6-79
DRILLING SOLUTIONS
6. Four places on the jib boom arm slide

(two on top, two on bottom).
7. Front and rear cable sheave pins.
Sand Reel
The sand reel grease points require 5 pumps

of grease daily, at shift change, or every 10 hour
of drill operation. There are five grease points s
located on the sand reel, shafts and levers. In
addition, there are two (one each) grease poin
ts on the sand reel sheaves at the top of the
derrick.
1. Clean all the grease nipples.

2. Pump 5 shots of grease into the grease
fitting s.
4. Note: Lower the derrick to horizontal posi
tion and use a manlift to grease the
sand reel sheaves at the top of the derrick.
DHD Lubricator
DHD's (Down Hole Drill) achieve high productiv

ity in hard rock applications by adding
percussion to the drilling process. In harder
rock, the rotary method cannot supply sufficient
load on the bit inserts to crack the rock and prod
uce a chip.
The DHD lubricator must always be used when
ever the DHD is being operated. Use the
correct oil for the DHD and the season. Make
sure there is sufficient DHD Oil in the lubricato
to lubricate the DHD during each shift. r
ADD DHD
OIL HERE
OIL LEVEL
SIGHT GLASS
1. A sight glass on the side of the lubricator

shows the amount of oil in the DHD
lubricator tank.
6-80
DRILLING SOLUTIONS
•
NOTICE
from the DHD.
Use only approved DHD oil to obtain maximum life
the container. Oil can be
2. Add approved DHD Oil through the fill plug on top of
added while the drill is running, if necessary.
NOTICE
the fill cap.
Make sure all dirt and cuttings are removed around
Truck
e manuals for specific information
Refer to the actual manufacturer's service and maintenanc
truck cooling system.
on maintenance for the truck, truck transmission and the
Truck Engine
" marks on the dipstick. Refer to
Maintain the engine oil level between the "ADD" and "FULL
•
als for specific information on
the actual manufacturer's service and maintenance manu
Engine Lubricating Oil.
Truck Transmission
e manuals for speci fic information
on maintenance for the truck transmission.
Truck Power Steering

on maintenance for the truck power steering unit.
Truck Cooling System

on maintenance for the truck cooling system.
Housekeeping
cleaning will be required if material
The complete drill must be given a weekly cleaning. Daily
is adhering to the derrick or truck working parts.
•
sure the operator's areas,
1. Make sure the inside of the truck cab is clean. Make
mud in these areas can
steps and grab rails are clean. Oil, grease, snow, ice or
before getting in the
cause you to slip and fall. Clean your boots of excess mud
cab or on the drill operator's platform.
6-81
DRILLING SOLUTIONS
2. Check the derrick feed installation for

debris buildup around the sheaves.
3. Thoroughly wash all fittings, caps, plug
s, etc. with a nonflammable, nontoxic
cleaning solution before servicing to prevent
dirt from entering while performing
the service.
NOTICE
Protect all electrical components and

control panels against entry of
water or steam when using high pressure
cleaning methods. Cover the
fuel and hydraulic fill cap breathers loca
ted on each tank.
4. After cleaning, check for defects in the
air cleaner ducts.
a. Check intake for accumulation of debr
is that could restrict air flow.
b. Check air cleaner mounting hardware
for security.
c. Check all hoses for cracks, chafing or
deterioration and replace at the first
sign of probable failure.
6-82
DRILLING SOLUTIONS
•
6-6 MAINTENANCE (50 Hours or Weekly)
General Information
s and Guidelines
Read and understand Section 2 - Safety Precaution
e, servic e or repair on the
before you operate or perform any maintenanc
drill.
instruments, read
If you are not experienced with the drill's controls and
. Shut down the
Unexpected drill motion or moving parts can cut or crush
or around the drill. Do not perform
Safety should be the main concern for anyone working on
• any function that could put someone in danger.

Always wear correct safety gear while working on or aroun
approved hard hat, safety glasses, steel toe shoes/boots,
d the drill. This includes an
gloves, respirator and ear
protection. Do not wear loose fitting clothing that can becom

e caught on rotating components.
2. Always chock the wheels if there is a possibility of uncon

trolled movement.

the drill.
4. Always perform safety checks prior to starting and using
.
5. Always operate the drill at full engine power when drilling
collapse.
6. Never stop the drill on a slope or surface that is liable to
collapse or cause a
crushing risk.
the controls are in the
8. Before starting the deck engine, always check to see that
"off" or "neutral" position on the operator's control panel.
direction to alert
9. Always sound the horn before moving the drill in either
motion.
personnel and allow sufficient time before putting the drill in
•
cab.
6-83
DRILLING SOLUTIONS
Batteries
Keeping the battery posts clean and maintaining the
proper electrolyte level will aide in
obtaining optimum battery life. The following battery
maintenance must be carried out as part
of the 50 hour routine maintenance schedule.
Batteries contain an acid and can cause injury.

Skin and eye contact with battery fluid
can cause injury. Avoid skin and eye contact with
battery fluid. If contact occurs, flush
the area immediately with water.
ectilMITAI
Battery fumes can ignite and explode. Do not smok

e when observing battery fluid level.
Electrolyte Level
1. Remove filler caps. Maintain electrolyte level to

bottom on fill plug openings.
If the addition of water is necessary, use distilled

water. If distilled water
is not available, use clean water that is low
in minerals. Do not use
artificially softened water.
2. Batteries should not require more than 1 ounc
e (29.5 ml) of water per cell per
week.
3. Specific gravity should be 1.225 g/cm3 or abov
e.
4. Do not over fill. Over filling can cause poor perfo
rmance or early failur e.
Battery Terminals
Keep the batteries clean and the connections tight.
1. Loosen and remove cable clamps from all battery termi

nals.
2. Clean all battery terminals.
3. Clean all cable clamps.
4. Install and tighten cable clamps to battery terminals.
5. Coat cable clamps and terminals with silicone lubric
ant, petroleum jelly or
MPGM grease.
6-84
DRILLING SOLUTIONS
•
Winch/Sand Reel Cable

hour routine maintenance schedule.
The following must be carried out as part of the 50
ck can cause severe injury or

Do not climb a raised derrick. Climbing a raised derri
to service the winch and sand reel.
death. Lower the derrick to the horizontal position
I 74 ;1
,
Do not use the winch in any manner

Never lift or transport personnel with the winches.
of operation which may endanger any individual.
EL CAUTION
it is under tension. Cable should
Stay at least 10 feet (3.048 cm) away from cable while
broken strands are noted.
be inspected whenever unwound and replaced when
,•)ai a•ailci
sc t r
load. At least five (5) wraps of cable

Cable clamps are not designed to hold rated winch
must remain on the drum at all times.
Wire Rope
carrying components of the traveling
Wire ropes, including their anchorage and other load
es and drill hooks shall be checked
block and winch system, e.g. sheave bearings, rope sheav
at least once a week.
ble because of wear and wire breakage
Wire rope used in drilling operations becomes unusa
4309:1990. In table 3.5 of ISO 4309:
and should be discarded in accordance with 3.5 of ISO
On drills with normal hook load of more
1990, classification groups M1 and M2 shall be used.
and shortened according to a plan laid
than 1000KN, the winch rope shall be regularly paid out
.
down by the manufacturer on the basis of experience
wires are found in one lay.
1. Replace when four (4) randomly distributed broken
(1/3) the original diameter
2. Replace when the wire rope shows wear of one third
of the outside wire.
any cause is found.
3. Replace when evidence of any heat damage from
•
4. Replace when any kinking or cracking occurs.
ce As Required for additional
Refer to Cable & Wire Rope information in 6.4 Maintenan
information on wire rope and wire rope clamps.
6-85
DRILLING SOLUTIONS
Periodic Inspection
1. Inspect rigging, winch and hydraulic hose

s at the beginning of each work shift.
Defects should be corrected immediately.
2. Be certain that at least five (5) full wrap
s of cable remain on the drum at all
times: otherwise, the cable clamps may not hold
the load.
3. Replace cable that has been kinked or has
broken strands because it may fail
without warning at low loads.
4. Inspect drive lugs on clutch and drum for
rounding or cracking.
5. Inspect gear teeth for excessive wear. Wea
r should not exceed 1/16" (1.59
mm).
Cat Water Injection Pump

Change the initial water injection pump oil after
the first 50 hours of operation. Thereafte
water injection pump oil change maintenance r,
must be carried out as part of the 500 hour
routine maintenance schedule and every 500
hours thereafter.
The water injection pump oil should be at oper

ating temperature for draining. Be
careful. Hot oil and components can burn.
Change Initial Oil
1. Position the drill on a stable, level surface.

2. Place a container with a capacity of at least 3
quart (2.84 liter) under the drain
point to collect the used oil.
3. Remove both fill plug and drain plug. Allow oil
to drain completely.
4. After oil has drained, clean and replace drain
plug.
5. Clean and remove the level plug.
6. Refill the oil through the fill port until oil appe
ars at level plug. Fill with ISO-68,
SAE40 (anti rust) oil.
7. Clean and install fill plug and level plug.
8. Operate the drill and water injection and chec
k for any leaks.
6-86
DRILLING SOLUTIONS
•
Pump Drive Gearbox
Oil Leaks
part of the 50 hour maintenance
Inspect the hydraulic pump drive gearbox for leaks as
schedule. Follow the steps shown below.
bottom of the case.
1. Look for signs of oil on the case and around the
e of the case and around the
2. If there are signs of oil leakage, clean the outsid
another source.
bottom. Verify signs of oil are from the case and not
corre ctive action.
3. If a leak is verified, contact maintenance and take
Check Oil Level

determine the maintenance interval.
The type of service and the operating conditions will
ed as part of the 50 hour routine
However, it is recommended that the oil level be check
leaks. Because the lubricant system is
maintenance schedule. At the same time, check for oil
oil be kept clean.
the heart of the unit, it is especially important that the
•
NOTICE
ged whenever the oil shows any

The oil in the pump drive gearbox should be chan
nced by discoloration or strong
traces of dirt or the effects of high temperature, evide
odor.
al operating temperature when

Hot oil or components can burn. Oil must be at norm
ts. Do not allow used oil to drain into
draining. Avoid contact with hot oil or componen
the ground. Dispose of properly.
ADD GEARBOX
OIL -ERE
PUMP DRIVE
GEARBOX C-EC' GEARBOX
OIL _EVEL TH
DIPSTICK
6-87
DRILLING SOLUTIONS
Z, CAUTION
Do not add or check the oil level with the engi
ne running.
1. Move the drill to a level surface.
2. Stop engine before checking or adding oil.
3. Clean around the oil level dipstick and the
oil fill plug before checking or adding
oil.
4. Check the oil level within the gearbox with
the dipstick. Remove the dipstick
and wipe it clean. Insert and withdraw the dipst
ick to read the oil level within the
gearbox.
5. If necessary, add 80W90 Gear Oil and fill
to the correct level. Always use clean
oil from clean containers. Do not overfill. This
will cause overheating. Refer to
Sec. 6-3 Refill Capacities/Lubricants/Fuel
for recommended oil specifications.
6. Check and clean the gearbox breather.
6-88
DRILLING SOLUTIONS
•
Winch (Auxiliary)
on the T3W. A regular
There are two (2) different sizes of (auxiliary) winches available
minimize the need for
program of preventive maintenance for the auxiliary winch will
free servic e. All service intervals are
emergency servicing and insure long life and trouble
specified for operating hours of the drill.
NOTICE
onent service life. The

The service intervals that are suggested will optimize comp
after gainin g experience with a
intervals may be gradually increased or decreased
enden t oil analysis.
particular lubricant and the recommendations of an indep
operation, then every 500
The gear oil should be changed after the first fifty (50) hours of
first. The gear oil must be changed
operating hours or twelve (12) months, whichever occurs
ion of the brake clutch and
to remove wear particles that impede the reliable and safe operat
these sugge sted minimum
erode bearings, gears and seals. Failure to change gear oil at
result in proper ty damage,
intervals may contribute to intermittent brake slippage which could
severe personal injury or death.
rature changes significantly
•
The gear oil should also be changed whenever the ambient tempe
appropriate. Oil viscosity with
and an oil from a different temperature range would be more
ion. Make certain that the gear
regard to ambient temperature is critical to reliable brake operat
ling ambie nt temperature. Failure to use
viscosity used in your winch is correct for your prevai
ute to brake slippage which
the proper type and viscosity of planetary gear oil may contrib
could result in property damage, severe personal injury or death.
Refer to Section 6-3 Refill
For normal operating temperatures, use SAE 90 lubricating oil.
specif ication s.
Capacities/Lubricants/Fuels for further recommended oil
cause severe injury or death.

Do not climb a raised tower. Climbing a raised tower can
e the winch .
Lower the tower to the horizontal position to servic
the winch in any manner of

Never lift or transport personnel with the winch. Do not use
operation which may endanger any individual.
CAUTION
under tension. Cable should

Stay at least 10 feet (3.048 m) away from cable while it is
n strands are noted.
be inspected whenever unwound and replaced when broke
6-89
4K Winch (PL5)

3. Shut off the engine.
4. There are two fill & drain ports on this winch.
One is on the drum and one is on
the end of the winch opposite the motor end.
5. The easiest way to drain the oil would be to
use a suction pump and drain the
winch from the fill and drain port located on the end of
the winch.
FILL & DRAIN

PORT
(1/2-14 NPT)
6. Place a container with a capacity of at least

1gallon (3.7 liters) under the drain
7. Use an Allen wrench to remove the fill & drain
plug.
8. Remove the drain plug, insert a suction pump
drain tube and allow the oil to
drain smoothly into the suitable container.
9. Using a suitable hose or funnel, refill the housing
with SAE90 lubricating oil
through the fill & drain port until oil is level with the
fill & drain port. Winches
which are being serviced may not require as much
oil due to incomplete
draining of the original winch oil. The approximate capac
ity of the 4K winch is
2.3 pints (1.1 liter). Refer to section 6.3 Refill Capacities
/Lubricants/Fuel for
further recommended oil specifications.
10. Clean and install the drain plug.
11. Remove the container and dispose of the used
oil in accordance with local
guidelines.
Mounting Bolts - Tighten all winch base mounting bolts
to recommended torque after the first
one hundred (100) hours of operation, then every five
hundred (500) operating hours or six (6)
months, whichever occurs first.
6-90
DRILLING SOLUTIONS
•
3K Winch (M8 Sand Reel High Rope Capacity)
1. Move the drill to a stable, level surface

2. Lower the derrick to the horizontal pos ition.
n (3.7 liters) under the drain
4. Place a container with a capacity of at least 1gallo
and allow the oil to drain
5. Use an Allen wrench to remove the drain plug
smoothly into the suitable container.
BREATHER BREATHER
RELIEF
RELIEF VALVE VALVE &
& FILLER PORT FILLER
PORT
LEVEL
PORT
• DRAIN PORT
6. Using a suitable hose or funnel, refill the housi
Winches which are being serviced may not require

incomplete draining of the original winch oil. The appro
n 6.3
DRAIN PORT
ng with SAE90 lubricating oil

through the breather relief valve and filler port until oil is
Refill
level with the level port.
as much oil due to
ximate capacity of the
Capacities/Lubricants/
3K winch is 3.2 pints (1.5 liter). Refer to sectio
Fuel for further recommended oil specifications.
7. Clean and install the oil level plug.
the breather relief
8. Clean and install the breather relief valve. Do not paint over
valve or replace it with a solid plug.
accordance with local
9. Remove the container and dispose of the used oil in
guidelines.
mended torque after the first
Mounting Bolts - Tighten all winch base mounting bolts to recom
ed (500) operating hours or six (6)
one hundred (100) hours of operation, then every five hundr
6-91
6-7 MAINTENANCE (100 Hours)
General Information
ARNING
Read and understand Section 2 - Safety
Precautions and Guidelines
before you operate or perform any maintena
nce, service or repair on the
drill.
If you are not experienced with the drill's

controls and instruments, read
and understand Section 4 - Operating
Controls.
Unexpected drill motion or moving parts

can cut or crush. Shut down the
Safety should be the main concern for anyone

working on or around the drill. Do not perform
any function that could put someone in dang
er.
Always wear correct safety gear while working
on or around the drill. This includes an
approved hard hat, safety glasses, steel toe
shoes/boots, gloves, respirator and ear
protection. Do not wear loose fitting cloth
ing that can become caught on rotating comp
onents.
The following operational hints should be obse
rved:
2. Always chock the wheels if there is a poss
ibility of uncontrolled movement.
3. Do not lubricate the drill while the engine
is running.
4. Always perform safety checks prior to
starting and using the drill.
5. Always operate the drill at full engine powe
r when drilling.
6. Never stop the drill on a slope or surface that
is liable to collapse.
7. Never stop the drill against a high wall that
is liable to collapse or cause a
crushing risk.
8. Before starting the deck engine, always check
to see that the controls are in the
"off" or "neutral" position on the operator's contr
ol panel.
9. Always sound the horn before moving
the drill in either direction to alert
10. Always apply the parking brake before leavi
ng the truck cab.
6-92
DRILLING SOLUTIONS
•
Winch (Main)
available on the T3W, along with two (2)
There are three (3) different sizes of (main) winches
ibed later.
different sizes of auxiliary winches which will be descr
winch will minimize the need for
A regular program of preventive maintenance for the
le free service. All service intervals are
emergency servicing and insure long life and troub
specified for operating hours of the drill.
NOTICE
ize component service life. The

The service intervals that are suggested will optim
after gaining experience with a
intervals may be gradually increased or decreased
an independent oil analysis.
particular lubricant and the recommendations of
ed (100) hours of operation, then every
The gear oil should be changed after the first one hundr
s first. The gear oil must be changed
1000 operating hours or six (6) months, whichever occur
safe operation of the brake clutch and
to remove wear particles that impede the reliable and
oil at these suggested minimum
erode bearings, gears and seals. Failure to change gear
which could result in property damage,
intervals may contribute to intermittent brake slippage
• severe personal injury or death.

The gear oil should also be changed whenever the ambie
and an oil from a different temperature range would
viscosity used in your winch is correct for your prevailing

the proper type and viscosity of planetary gear oil may
could result in property damage, severe personal injury
Required lubricant for these (main) winches is Exxon
nt temperature changes significantly
be more appropriate. Oil viscosity with
regard to ambient temperature is critical to reliable brake
operation. Make certain that the gear
ambient temperature. Failure to use
contribute to brake slippage which
or death.
Sparton 150 or equivalent AGMA 4EP
/Fuels for further recommended oil
gear oil. Refer to Section 6-3 Refill Capacities/Lubricants
specifications.
r can cause severe injury or death.

Do not climb a raised tower. Climbing a raised towe
ce the winch.
Lower the tower to the horizontal position to servi
not use the winch in any mann er of

Never lift or transport personnel with the winch. Do
operation which may endanger any individual.
CAUTION
it is under tension. Cable should

Stay at least 10 feet (3.048 m) away from cable while
broken strands are noted.
be inspected whenever unwound and replaced when
6-93
DRILLING SOLUTIONS
12K Winch

4. To drain the oil, install a short piece of 1
inch pipe in the larger threads of the
drain hole. If necessary, insert a bar into the anch
or pocket and manually rotate
the drum in the direction to hoist a load until the
drain holes are aligned.
OIL LEVEL
VENT PLUG PORT
ABOVE OIL LEVEL
CENTERLINE PORT
DRAIN
PORT

4 quarts (3.78 liters) under the drain
6. Use a 5/16 inch Allen wrench to remove
the drain plug through the pipe.
7. Remove the drain plug, insert a suction
drain tube and allow the oil to drain
9. Using a suitable hose or funnel, refill the hous
ing with Exxon Sparton 150 or
equivalent AGMA 4EP, ISO VG 150 gear oil throu
gh the fill hole until oil is level
with the bottom of the fill/level hole. Winches whic
h are being serviced may not
require as much oil due to incomplete draining
of the original winch oil. The
approximate capacity of the 12K winch is 6 pints
(2.8 liter). Refer to section 6.3
Refill Capacities/Lubricants/Fuel for further recomme
nded oil specifications.
10. Clean and install the fill/level plug.
11. Remove the container and dispose of the
used oil in accordance with local
guidelines.
12. Whenever the gear oil is changed, remove the
vent plug, clean in solvent and
reinstall. Do not paint over the vent plug or repla
ce it with a solid plug.
Mounting Bolts - Tighten all winch base mounting
bolts to recommended torque after the first
one hundred (100) hours of operation, then every
five hundred (500) operating hours or six (6)
6-94
DRILLING SOLUTIONS
•
18K Winch

in the larger threads of the
4. To drain the oil, install a short piece of 1 inch pipe
drain hole. If necessary, insert a bar into the ancho r pocket and manually rotate
the drum in the direction to hoist a load until the drain holes are aligned.
OIL LEVEL
SIGHT GLASS
VENT
PLUG
FILL &
DRAIN
•
PORT
(7.57 liters) under the drain

5. Place a container with a capacity of at least 2 gallon
plug through the pipe.
6. Use an Allen wrench to remove the fill & drain
and allow the oil to drain
7. Remove the drain plug, insert a suction drain tube
threads of the drain
9. To fill with oil, install a short piece of 1 inch pipe in the larger
manually rotate the
hole. If necessary, insert a bar into the anchor pocket and
until the fill & drain port is in the 12:00
drum in the direction to hoist a load
O'clock position.
Sparton 150 or
10. Using a suitable hose or funnel, refill the housing with Exxon
fill hole until oil is in
equivalent AGMA 4EP, ISO VG 150 gear oil through the
es which are being serviced may
the middle of the oil level sight glass. Winch
g of the origina l winch oil. The
not require as much oil due to incomplete drainin
liter). Refer to section 6.3
approximate capacity of the 18K winch is 9 pints (4.2
oil specif ications.
Refill Capacities/Lubricants/Fuel for further recommended
dance with local
11. Remove the container and dispose of the used oil in accor
guidelines.
clean in solvent and
12. Whenever the gear oil is changed, remove the vent plug,
•
reinstall. Do not paint over the vent plug or replac e it with a solid plug.
mended torque after the first
Mounting Bolts - Tighten all winch base mounting bolts to recom
ed (500) operating hours or six (6)
one hundred (100) hours of operation, then every five hundr
6-95
DRILLING SOLUTIONS
30K Winch

2. Lower the derrick to the horizontal posit
ion.
4. The fill/drain plug is located on the end of
the drum flange, away from the motor.
Rotate drum barrel to place the fill/drain plug at
the bottom, 6 o'clock position.
Remove the plug and capture the gear oil in a suita
ble container with a capacity
of at least 3 gallon (11.3 liters). Recycle or
dispose of used oil in an
environmentally responsible manner. While the
oil is draining, collect oil from
mid-stream for oil analysis.
OIL FILL OIL LEVEL

& DRAIN -4- HOIST SIGHT GLASS
VENT ___......._.......
nn
6t .
OIL FILL
ACCESS
HOLE
5. Rotate the drum to place the drain/fill

plug at the 3 o'clock position. Fill the
housing with Exxon Sparton 150 or equivalent AGM
A 4EP, ISO VG 150 gear
oil through the drain/fill hole until oil is in the midd
le of the oil level sight glass.
Winches which are being serviced may not
require as much oil due to
incomplete draining of the original winch oil. The
approximate capacity of the
30K winch is 15 pints (7.1 liter). Install the plug
securely after refilling gear
cavity. Refer to section 6.3 Refill Capacities/Lubr
icants/Fuel for further
recommended oil specifications.
6. Remove the vent relief plug located in the brak
e cylinder above the motor.
Clean the vent relief plug in solvent and reinstall.
Do not paint over the vent
plug or replace it with a solid plug. Drum seal leaks
will result if the relief vent
hole is restricted.
Mounting Bolts - Tighten all winch base mounting
bolts to recommended torque after the first
one hundred (100) hours of operation, then every
five hundred (500) operating hours or six (6)
6-96
DRILLING SOLUTIONS
•
John Bean Water Injection Pump

100 hours of operation. Thereafter,
Change the initial water injection pump oil after the first
d out every 750 hours.
water injection pump oil change maintenance must be carrie
temperature for draining. Be

The water injection pump oil should be at operating
Change Initial Oil
18 gpm and 25 gpm

WATER INJECTION PUMP
•
35 gpm WATER OIL LEVEL
INJECTION PUMP PLUG
OIL FILL
DRAIN IS
DRAIN._I UNDERNEATH
1. Position the drill on a stable, level surface.

liter) under the drain
2. Place a container with a capacity of at least 3 quart (2.84
completely.
3. Remove both fill plug and drain plug. Allow oil to drain
4. After oil has drained, clean and replace drain plug.
the oil through the oil fill
5. 18 gpm and 25 gpm Water Injection Pumps - Refill
rs at the oil fill port.
port (approximately 2 quart or 1.89 liters) or until oil appea
Fill with clean SAE30 non-detergent oil.
gh the oil fill port
6. 35 gpm Water Injection Pumps - Refill the oil throu
rs at the oil level plug on
(approximately 2 quart or 1.89 liters) or until oil appea
eterge nt oil.
the back of the pump housing. Fill with clean SAE30 non-d
•
injection pumps).
7. Clean and install fill plug and level plug (35 gpm water
leaks.
8. Operate the drill and water injection and check for any
6-97
DRILLING SOLUTIONS
General Information
Read and understand Section 2 - Safety Precautio

ns and Guidelines before you operate
or perform any maintenance, service or repair
on the drill.
If you are not experienced with the drill's cont
rols and instruments, read and
understand Section 4 - Operating Controls.
Unexpected drill motion or moving parts can cut
or crush. Shut down the engine before
working on the drill.
Safety should be the main concern for anyone work
ing on or around the drill. Do not perform
Always wear correct safety gear while working on
or around the drill. This includes an
approved hard hat, safety glasses, steel toe shoe
s/boots, gloves, respirator and ear
protection. Do not wear loose fitting clothing
Do not wear oil stained or damaged garments.
1. Do not increase engine speed to high idle

until the engine has been warmed up.
2. Always chock the wheels if there is a poss
ibility of uncontrolled movement.
3. Do not lubricate the drill while the engine is
running.
4. Always perform safety checks prior to start
ing, operating or performing any
maintenance on the drill.
5. Always sound the horn before moving
the drill in either direction to alert
6. Always use safe judgement when driving on
unstable surfaces where there
may be a risk of overturning or when loading onto
a transporter where there is
7. Always operate the drill at full engine power when
drilling.
8. Never stop the drill on a slope or surface that is
liable to collapse.
9. Never stop the drill against a high wall that is
liable to collapse or cause a
crushing risk.
10. Before starting engine, always check to see that
the control levers and drill feed
controls are at stop, neutral or off position.
11. Always apply the parking brake before leaving
the truck cab.
6-98
DRILLING SOLUTIONS
•
Deck Engine Oil and Filter Change
. Do not allow hot oil or hot

Hot oil and hot components can cause personal injury
components to contact the skin.
NOTICE
ing.
Oil must be at normal operating temperatures when drain
nded waste particles settle on
Do not drain the oil when the engine is cold. As oil cools, suspe
ed with the draining cold oil. Drain
the bottom of the oil pan.The waste particles are not remov
draining method allows the
the crankcase with the engine stopped and the oil warm. This
properly.
waste particles that are suspended in the oil to be drained
waste particles being recirculated
Failure to follow this recommended procedure will cause the
to the OEM Engine Manual for
through the engine lubrication system with the new oil. Refer
•
additional information.
Drain the Engine Oil

engine. Wait at least 5
1. Position the drill on a stable, level surface and shut off
time for the oil to
minutes after shutting off engine to drain the oil. This allows
drain into the oil pan.
. The temperature
2. Ensure oil is warm by viewing water temperature gauge
should not exceed 140°F (60°C) before draining oil.
liter), under the drain
3. Place container, with a capacity of at least 20 gallon (75
e crankcase oil.
point. Use one of the following methods to drain the engin
the drain valve
a. If the engine is equipped with a drain valve, turn
drained, turn the
counterclockwise in order to drain the oil. After the oil has
drain valve knob clockwise in order to close the drain valve.
oil drain plug in
b. If the engine is not equipped with a drain valve, remove the
a shallow sump,
order to allow the oil to drain. If the engine is equipped with
pan.
remove the bottom oil drain plugs from both ends of the oil
ed and installed.
4. After the oil has drained, the oil drain plug(s) should be clean
nsible manner.
5. Recycle or dispose of used oil in an environmentally respo
6-99
Replace the Oil Filter
Change oil filters at every oil change. Be sure to use

the correct filter for your engine. Refer to
Engine Manual supplied with your drill for a complete
discussion of engine filters.
1. Remove the oil filter using a filter wrench.
2. Cut the oil filter open with an Oil Filter Cutter.
Break apart the pleats and inspect
the oil filter for metal debris. An excessive amount of
metal debris in the oil filter
may indicate early wear or a pending failure.
Use a magnet to differentiate between the ferrous
metals and the nonferrous
metals that are found in the oil filter element. Ferrous
metals may indicate wear
on the steel and cast iron parts of the engine.
Nonferrous metals may indicate wear on the alum
inum parts, brass parts or
bronze parts of the engine. Parts that may be affec
ted include the following
items: main bearings, rod bearings, turbocharger beari
ngs and cylinder heads.
Due to normal wear and friction, it is not uncommo
n to find small amounts of
debris in the oil filter. Consult your Caterpillar deale
r in order to arrange for a
further analysis if an excessive amount of debris is
found in the oil filter.
3. Clean the sealing surface of the filter mounting
base. Be sure the entire old filter
gasket is removed.
jfr
APPLY A SMALL
AMOUNT OF
CLEAN THE
CLEAN ENGINE ---__
SEALING
OIL TO NEW SURFACE
FILTER GASKET
4. Apply a small amount of clean engine oil to the new

oil filter gasket.
NOTICE
Do not fill the oil filters with oil before installing
them. This oil would not
be filtered and could be contaminated. Con
taminated oil can cause
accelerated wear to the engine components.
5. Install the oil filter. Tighten the oil filter until the oil
filter gasket contacts the
base. Tighten the oil filter by hand according to the
instructions that are shown
on the oil filter. Do not overtighten the oil filter.
6-100
DRILLING SOLUTIONS
•
Fill the Engine Crankcase

l Capacities / Lubricants /
1. Remove the oil filler cap. Refer to section 6-3 "Refil
Fuel" for more information. Fill the crankcase with the proper amount of engine
oil.
NOTICE
can cause engine
Under filling or overfilling the crankcase with oil
damage.
NOTICE
engine with the fuel
To prevent crankcase bearing damage, crank the
ng the engin e. Do not crank the
OFF. This will fill the oil filters before starti
engine for more than 30 seconds.
IDLE" for two minutes. Perform
2. Start the engine and run the engine at "LOW
this procedure in order to ensure that the lubric ation system has oil and that the
oil filters are filled. Inspect the oil filter for oil leaks.
•
to the sump for a minimum of
3. Stop the engine and allow the oil to drain back
ten minutes.
the oil level. Maintain the oil level
4. Remove the oil level gauge in order to check
.
between the "ADD" and "FULL" marks on the oil level gauge
Deck Engine Fuel System Filters
Replace Primary Filter (Water Separator) Element

in the fuel may cause an electronic
Water in the fuel can cause the engine to run rough. Water
water , the element should be
unit injector to fail. If the fuel has been contaminated with
changed before the regularly scheduled interval.
in order to help extend the life of the
The primary filter/water separator also provides filtration
rly. If a vacuum gauge is installed,
secondary fuel filter. The element should be changed regula
50 to 70 kPa (15 to 20 inches Hg).
the primary filter/water separator should be changed at
Replace the Element
•
components can cause a fire.
Fuel leaked or spilled onto hot surfaces or electrical
1. Close the main fuel supply valve.
6-101
DRILLING SOLUTIONS
2. Remove element from the element mounting base

while bowl is attached.
ELEMENT
BOWL
DRAIN
3. Dispose of the contents of the filter. Remove

bowl from element. The bowl is
reusable. Do not discard the bowl. Dispose of the used
element.
4. Remove the 0-ring from the gland of the bowl.
Clean the following components:
bowl, 0-ring and Mounting Base. Inspect the 0-rin
g for damage and for
deterioration. Replace the 0-ring, if necessary.
5. Lubricate the 0-ring with clean diesel fuel.
6. Install bowl on a new element. Tighten the
bowl by hand. Do not use tools in
order to tighten the bowl.
NOTICE
The primary filter/water separator may be pre-filled
with fuel to avoid rough
running/stalling of the engine due to air. Do not fill the
secondary filter with fuel
before installation.The fuel would not be filtered and
could be contaminated.
Contaminated fuel will cause accelerated wear to fuel
system parts.
7. Lubricate the top seal of element with clean diese
l fuel. The element may be
filled with fuel at this time. Install the new element
on the mounting base.
Tighten the element by hand.
NOTICE
The water separator is under suction during normal
engine operation. Ensure
that the vent plug is tightened securely to help prevent
air from entering the fuel
system.
8. Open the main fuel supply valve.
9. Start the engine and check for leaks. Run the engin
e for one minute. Stop the
engine and check for leaks again.
Detecting leaks is difficult while the engine is running.
The primary filter/water
separator is under suction. A leak will allow air to enter
the fuel. The air in the
fuel can cause low power due to aeration of the fuel. If
air enters the fuel, check
the components for overtightening or under tightening.
6-102
DRILLING SOLUTIONS
•
Replace Fuel System Secondary Filter
rical components can cause a fire. To

Fuel leaked or spilled onto hot surfaces or elect
h off when changing fuel filters or water
help prevent possible injury, turn the start switc
ediately.
separator elements. Clean up fuel spills imm
NOTICE
oughly clean the area around a fuel

Do not allow dirt to enter the fuel system. Thor
Fit a suitable cover over any
system component that will be disconnected.
disconnected fuel system components.
NOTICE
might spill. Clean up any spilled fuel

Use a suitable container to catch any fuel that
immediately.
OFF position or disconnect the
•
1. Stop the engine. Turn the ignition switch to the
Maintenance Manual "Battery
battery. Refer to the Engine OEM Operation and
ntenance Section) for more
or Battery Cable - Disconnect" topic (Mai
ped).
information. Shut off the fuel supply valve (if equip
fuel pressure from the fuel system
2. It may be necessary to relieve residual
to five minutes until the fuel
before the fuel filter is removed. Wait for one
in order to catch any fuel that
pressure has lowered. Use a suitable container
may spill.
fuel filter.
3. Remove the used fuel filter and discard the used
. Ensure that all of the old
4. Clean the gasket sealing surface of the fuel filter base
gasket is removed.
5. Apply clean diesel fuel to the new filter gasket.
NOTICE
e installing. The fuel would not

Do not fill the secondary fuel filter with fuel befor
taminated fuel will cause
be filtered and could be contaminated. Con
accelerated wear to fuel system parts.
NOTICE
ent premature wear out from
In order to maximize fuel system life and prev
•
efficiency fuel filter is required
abrasive particles in the fuel, a two micron high
for all Caterpillar Electronic Unit Injectors.
6-103
DRILLING SOLUTIONS
6. Install the new fuel filter. Spin the fuel

filter onto the fuel filter base until the
gasket contacts the base. Use the rotation index
marks on the filters as a guide
for proper tightening. Tighten the filter according
to the instructions that are on
the fuel filter. Do not overtighten the filter.
7. Open the fuel supply valve. The engin
e will need to be purged of air. Refer to
the Engine OEM Operation and Maintenance
Manual, "Fuel System - Prime"
topic (Maintenance Section) for more informatio
n.
Cooling System Coolant Sample
NOTICE
Obtain a Coolant Sample (Level 1) if the cool

ant system is filled with any other coolant
than Cat ELC (Extended Life Coolant).
This includes the following types of coolant:
1. Commercial long life coolants that
meet the Caterpillar Engine Coolant
Specification -1 (Caterpillar EC-1).
2. Cat DEAC (Diesel Engine Antifreeze/Co
olant).
3. Commercial heavy-duty coolant/antifreeze.
Table 34: Recommended Interval
Recommended Interval
Type of Coolant Level 1 Level 2
Cat DEAC Every 250 Hours (1) Yearly (2)
Cat ELC Optional (2) Yearly (1)(2)
1. This is the recommended interval for coolant

samples for all conventional
heavy-duty coolant/antifreeze. This is also
the recommended interval for
coolant samples of commercial coolants that mee
t the Cat EC-1 specification
for engine coolant.
2. The Level 2 Coolant Analysis should be perfo
rmed sooner if a problem is
suspected or identified. Refer to Level 1 Sam
ple for the guidelines for proper
sampling of the coolant.
NOTICE
Always use a designated pump for oil sampling,
and use a separate designated pump for
coolant sampling. Using the same pump for both
types of samples may contaminate the
samples that are being drawn. This contamina
te may cause a false analysis and an incorrect
interpretation that could lead to concerns by both
dealers and customers.
Note: Level 1 results may indicate a need for Leve
l 2 Analysis.
6-104
DRILLING SOLUTIONS
•
the recommended sampling interval.

Obtain the sample of the coolant as close as possible to
must establish a consistent trend of
In order to receive the full effect of S-O-S analysis, you
m consistent samplings that are
data. In order to establish a pertinent history of data, perfor
evenly spaced.
coolant:
Use the following guidelines for proper sampling of the
ling bottle before you begin
1. Complete the information on the label for the samp
to take the sample.
sample port. You should not
2. Obtain coolant samples directly from the coolant
obtain the samples from any other location.
you are ready to collect the
3. Keep the lids on empty sampling bottles until
sample.
y after obtaining the sample in
4. Place the sample in the mailing tube immediatel
order to avoid contamination.
5. Never collect samples from expansion bottles.
m.
6. Never collect samples from the drain for a syste
2 analysis if necessary).
7. Submit the sample for Level 1 analysis (or Level
•
to the engine OEM Operation and
For additional information about coolant analysis, refer
dations"topic or consult your
Maintenance Manual, "Refill Capacities and Recommen
Caterpillar dealer.
(SCA)
Cooling System Supplemental Coolant Additive
l coolants such as DEAC and for
This maintenance procedure is required for conventiona
red for cooling systems that are
mixtures of water and SCA. This maintenance is not requi
filled with Caterpillar Extended Life Coolant (ELC).
help prevent personal injury, avoid

Cooling system coolant additive contains alkali. To
system coolant additive.
contact with the skin and eyes. Do not drink cooling
l 1).
Note: Caterpillar recommends an S-0-S coolant analysis (Leve
Coolant/Antifreeze and SCA
NOTICE
tal coolant additive concentration.

Do not exceed the recommended six percent supplemen
•
Coolant Conditioner Test Kit.
Test the concentration of the SCA with the Cat 8T-5296
6-105
DRILLING SOLUTIONS
Water and SCA
NOTICE
Do not exceed the recommended eight percent

supplemental coolant additive concentration.
Test the concentration of the SCA with the Cat
8T-5296 Coolant Conditioner Test Kit. Use the
instructions that follow.
1. Fill the syringe to the "1.0 ml" mark with

the coola
nt.
2. Dispense the 1.0 ml coolant sample from the
syringe into the empty mixing
bottle.
3. Add tap water to the mixing bottle in orde
r to bring the level up to the "10 ml"
mark. Place the cap on the bottle and shake the
bottle.
4. Add 2 to 3 drops of the "NITRITE INDI
CATOR SOLUTION B" to the mixing
bottle. Move the bottle in a circular motion in orde
r to mix the solution.
5. Add 1 drop of "NITRITE TEST SOLUTIO
N A" to the mixing bottle. Move the
bottle in a circular motion in order to mix the
solution.
6. Repeat step 5 until the solution changes color
from red to light gray, green or
blue. Record the number of drops of "NITRITE TEST
SOLUTION A" that were
required to cause the color change.
7. Use the following table to interpret the resul
ts.
Table 35: Test Results
Number of Drops Concentration of SCA Maintenance Required

Less than 25 Less than recommended Add SCA. Retest the
concentration of SCA. coolant.
25 to 30 The recommended None
concentration of SCA.
More than 30 More than recommended Remove the coolant.
concentration of SCA Replace with water
only. Retest the coolant.
Add SCA, If Necessary
A WARNING
Pressurized System: Hot coolant can cause serious

burns. To open the cooling system
filler cap, stop the engine and wait until the cooling
system components are cool.
Loosen the cooling system pressure cap slowly in
order to relieve the pressure.
1. Remove the cooling system filler cap slowly.
6-106
DRILLING SOLUTIONS
•
Note: Always dispose of fluids according to local regulations.

the addition of the
2. If necessary, drain some coolant in order to allow space for
SCA.
NOTICE
deposits on
Excessive supplemental coolant additive concentration can form
coolin g system , reduci ng the engine's
the higher temperature surfaces of the
er could cause cracki ng of
heat transfer characteristics. Reduced heat transf
the cylinder head and other high temperature components.
also result in
Excessive supplemental coolant additive concentration could
rated wear of the
blockage of the heat exchanger, overheating, and/or accele
water pump seal.
coolant additive
Do not exceed the recommended amount of supplemental
concentration.
nt of SCA, refer to the
3. Add the proper amount of SCA. For the proper amou
al, "Refill Capacities and
engine OEM Operation and Maintenance Manu
of SCA depends on the
Recommendations" topic. The proper concentration
•
refer to the
type of coolant that is used. For the proper concentration of SCA,
Capacities and
engine OEM Operation and Maintenance manual, "Refill
Recommendations"topic or consult your Caterpillar dealer.
system filler cap.
4. Clean the cooling system filler cap. Install the cooling
Engine Belts (Inspection)

fan drive belts (truck engine) for
Inspect the alternator belt (deck engine and truck engine) and
good condition.
wear and for cracking. Replace the belts if the belts are not in
OEM Service Manual,
Check the belt tension according to the information in the engine
"Specifications".
components. Vibration of loose
Slippage of loose belts can reduce the efficiency of the driven
belts can cause unnecessary wear on the following components:
1. Belts
2. Pulleys
3. Bearings
nents. This reduces the
If the belts are too tight, unnecessary stress is placed on the compo
service life of the components.
•
Engine Belts (Replacement)
belts in matched sets.
For applications that require multiple drive belts, replace the drive
drive belt to carry more load
Replacing one drive belt of a matched set will cause the new
on the new drive belt could
because the older drive belts are stretched. The additional load
cause the new drive belt to fail.
6-107
DRILLING SOLUTIONS
Alternator Belt Adjustment
1. Remove the belt guard.

2. Loosen the mounting bolts and adjusting bolt.
3. Move the assembly in order to increase or decrease
the belt tension.
4. Tighten adjusting bolt. Tighten mounting bolts.
5. Reinstall the belt guard.
If new drive belts are installed, check the drive belt tensio
n again after 30
minutes of engine operation at the rated rpm.
Adjustment of the Fan Drive Belt (Truck Engine)
1. Remove the belt guard.

2. Loosen the mounting bolt for the pulley.
3. Loosen the adjusting nut for the pulley.
4. Move the pulley in order to adjust the belt tensio
n.
5. Tighten the adjusting nut.
6. Tighten the mounting bolt
7. Reinstall the belt guard.
If new drive belts are installed, check the drive belt tensio
n again after 30
minutes of engine operation at the rated rpm.
Truck Maintenance
Truck Engine

on maintenance for the truck engine.
1. Change the engine oil after 250 hours of operation. Use

an API CG4, 15W40
lubricating oil. Refer to the engine manufacturer's manu
al for the correct
procedure to perform this maintenance.
2. Change the engine oil filter(s) when changing the engin
e oil. Follow engine
manufacturer's recommendations.
3. Change the fuel filter(s) when changing the engin
e oil. Follow engine
manufacturer's recommendations.
4. Change the coolant filter (if equipped) when changing
the engine oil. Follow
engine manufacturer's recommendations.
5. Check the engine SCA level at this time. Refer to the OEM
engin e manual.
6-108
DRILLING SOLUTIONS
•
engine manual.
6. Check the engine belt(s) tension at this time. Refer to the
Truck Transmission
ls for specific information
Refer to the actual manufacturer's service and maintenance manua
on maintenance for the truck transmission.
hours. Add oil if
1. Check the truck transmission oil level every 250 operating
e manua l for the procedure
necessary. Refer to the actual manufacturer's servic
and for the type of transmission fluid used in your vehicle.
Truck Power Steering

on maintenance for the truck power steering system.
ting hours. Add oil id
1. Check the truck power steering fluid level every 250 opera
necessary. Refer to the actual manufacturer's servic e manua l for the procedure
and for the type of power steering fluid used in your vehicle.
Truck Differentials
on maintenance for the truck differentials.
operating hours. Fill
1. Check the gear oil level in the truck differentials every 250
e manual for
to oil level plug if needed. Refer to the actual manufacturer's servic
the procedure and for the type of gear oil used in the differentials.
Drive Lines and U-Joints

universal joints, it is
To insure proper lubrication of all bearing assemblies on the truck
journa l cross bearing seals.
essential that the lubricant be added until it appears at all
with
NOTE: Do not assume that the bearing cavities have been filled
lubricant unless flow is noticed around all bearing seals.
switch. Rotating shaft can

Shut down engine and remove ignition key from ignition
with the guard removed.
cause severe injury or death. Do not operate
appears at the
1. Apply grease gun pressure to lubrication fitting until fresh grease
•
sleeve end of the spline. When
pressure relief hole in the welch plug at the
and contin ue to apply
grease appears, cover the pressure relief hole with finger
pressure until fresh grease appears at the sleeve yoke seal.
6-109
DRILLING SOLUTIONS
General Information
Read and understand Section 2 - Safety Precautions

and Guidelines before you operate
or perform any maintenance, service or repair on the
drill.
If you are not experienced with the drill's controls and
instruments, read and
Unexpected drill motion or moving parts can cut or crush
. Shut down the engine before
Safety should be the main concern for anyone working
on or around the drill. Do not perform
Always wear correct safety gear while working on or aroun
d the drill. This includes an
approved hard hat, safety glasses, steel toe shoes/boots
, gloves, respirator and ear
protection. Do not wear loose fitting clothing that can
become caught on rotating components.
1. Do not increase engine speed to high idle until the

engin e has been warmed up.
2. Always chock the wheels if there is a possibility of
uncon trolled movement.
4. Always perform safety checks prior to startin
g, operating or performing any
5. Always sound the horn before moving the drill in
either direction to alert
personnel and allow sufficient time before putting the drill
in motion.
6. Always use safe judgement when driving on unstable
surfaces where there
may be a risk of overturning or when loading onto a transp
orter where there is
8. Never stop the drill on a slope or surface that is liable to collap
se.
collapse or cause a
crushing risk.
10. Before starting engine, always check to see that the control
levers and drill feed
cab.
6-110
DRILLING SOLUTIONS
Hydraulic Reservoir
as part of the 500 hour
The following hydraulic reservoir maintenance must be carried out
routine maintenance schedule.
Hydraulic Tank Breather

kept clean. It must not
The hydraulic tank pressurized breather filter/relief valve should be
become plugged or saturated with oil.
er filter to prevent
1. Thoroughly clean the area around the hydraulic tank breath
dirt from entering the breather filter port.
Until the breather filter
2. Remove the breather filter from the hydraulic tank port.
is installed, cover the breather port to ensure that no contam ination can get into
the tank housing.
PRESSURIZED
BREATHER FILTER,
RELIEF VALVE
40 MICRON
breather tank
3. Clean and install or replace and install the breather filter into the
port and tighten firmly by hand.
Compressor
as part of the 500 hour
The following compressor system maintenance must be carried out
A WARNIN
hot oil or components.
Hot compressor oil or components can burn. Avoid contact with
groun d. Dispos e of used compressor
Do not allow used compressor oil to drain into the
oil properly.
6-111
DRILLING SOLUTIONS
Do not attempt to remove any plugs or open the drain

valve before making sure all air
pressure has been relieved from the compressor syste
m.
Compressor Oil Strainer
A 40 mesh (150 micron) strainer is mounted just before the

inlet to the oil pump. It protects the
pump and catches any foreign debris, such as hose piece
s and parts of the thermostat, that
could damage the pump. The metal strainer should be remov
ed, cleaned and reinstalled every
500 hours.
1. Thoroughly clean the entire area around the comp

ressor oil strain er.
2. Remove the plug from the end of the strainer.
3. Pull the strainer out of the body and wipe clean
. Remove any debris from the
strainer before replacing.
4. Insert the strainer back into the body.
5. Install the Plug. Tighten securely.
6. Check for leaks.
COMPRESSOR
OIL STRAINER
COMPRESSOR
OIL FILTERS
Compressor Oil Filters
The following compressor oil filter maintenance must be

carried out as part of the 500 hour
Hot compressor oil or components can burn. Avoid

contact with hot compressor oil or
components. Do not let used oil drain into the groun
d. Dispose of properly.
6-112
DRILLING SOLUTIONS
1. Thoroughly clean and wipe all the external dirt and oil from
and the head area to minimize contamination from entering the
2. Place a container under the oil filters to collect any oil escap
removal and to prevent any oil spill from contam inating
3. Unscrew the used filters using a filter wrench. Discard

the
the filter housing
ground
system.
ing during filter
.
the used filters in
accordance with local guidelines.
sure the entire old
4. Clean the sealing surface of the filter mounting base. Make
gasket is removed.
the o-ring seal with
5. Fill the new filters with clean compressor oil and lubricate
clean oil.
Tighten the filters
6. Screw the new oil filters on until the gasket contacts the base.
n index marks,
3/4 of a turn more by hand. Do not over tighten. Use the rotatio
on the filters, as a guide for proper tightening.
temperatures.
7. After startup, check the oil filters for any leaks at operating
Pump Drive Gearbox

the maintenance interval.
The type of service and the operating conditions will determine
x oil be changed after the first five
However, it is recommended that the pump drive gearbo
hours. Because the lubricant
hundred (500) hours of operation, then at every 1000 operating
oil be kept clean. Note: The
system is the heart of the unit, it is especially important that the
oil shows traces of dirt or the
oil in the pump drive gearbox should be changed whenever the
odor.
effects of high temperature, evidenced by discoloration or strong
or components. Oil must be

Hot oil or components can burn. Avoid contact with hot oil
used oil to drain into the
at normal operating temperature when draining. Do not allow
ground. Dispose of properly.
Change Pump Drive Gearbox Oil

BREATHER
AND FILL -----
PLUG
•
OIL
LEVEL__
PLUG -
6-113
DRILLING SOLUTIONS
1. Move the drill to a stable, level surface and shut off

the engine.
(7.5 liter) under the drain
point.
3. Clean around the drain plug, oil fill plug, breather and
oil level plug areas.
4. Remove the drain plug and the breather.
5. Drain the oil while the pump drive is still warm
. At this time, most of the
sediment in the gearbox will be in suspension and will
drain with the old oil.
6. Examine the oil for any contamination or meta
l particles. Metal debris can
reveal an impending pump drive gearbox failure. If
debris is found, find the
reason for the debris and perform the needed repairs.
Allow the oil to drain from
the drain into a container.
7. Clean the magnetic drain plug before installing. Instal
l the drain plug.
8. Refill the pump drive gearbox through the breather/fill
port with 80W90 gear oil
until the oil level reaches the oil level port on the gearb
ox or on dipstick full mark
if supplied (approximately 1.125 gallon/4.25 liter).
Do not overfill. This will
result in the overheating and possible malfunctio
n of the gearbox.
9. Clean the breather and install securely.
10. After startup, check the pump drive gearbox
for any leaks at operating
temperature.
Cat Water Injection Pump
After the initial water injection pump oil change after

the first 50 hours of operation, the
following water injection pump maintenance must be
carried out as part of the 500 hour
routine maintenance schedule and every 500 hours therea
fter.
a WARNING
The water injection pump oil should be at operating
temperature for draining. Be
FILL PLUG
LEVEL PLUG
DRAIN PLUG
6-114
DRILLING SOLUTIONS
1. Position the drill on stable, level surface.

2. Place a container with a capacity of at least 3 quart (2.84 liter) under the drain
3. Remove both fill plug and drain plug. Allow oil to drain completely.
6. 12 gpm Cat Water Injection Pump - Refill the oil through the fill port
(approximately 40 ounces or 1.18 liters) or until oil appears at level plug. Fill
with ISO-68, SAE40 (anti rust) oil.
7. 25 gpm Cat Water Injection Pump - Refill the oil through the fill port
(approximately 84 ounces or 2.48 liters) or until oil appears at level plug. Fill
with ISO-68, SAE40 (anti rust) oil.
8. Clean and install fill plug and level plug.
9. Operate the drill and water injection and check for any leaks.
John Bean Injection Pump
After the initial water injection pump oil change after the first 100 hours of operation, the
following water injection pump maintenance must be carried out every 750 hours.
a WARNING
The water injection pump oil should be at operating temperature for draining. Be
18 gpm and 25 gpm


INJECTION PUMP PLUG
OIL FILL
DRAIN IS
DRAIN j UNDERNEATH
DRILLING SOLUTIONS
6-115
1. Position the drill on stable, level surface.

2. Place a container with a capacity of at least 3 quart (2.84 liters) under the drain
3. Remove both fill plug and drain plug. Allow oil to drain completely.
6. 18 gpm and 25 gpm Water Injection Pumps - Refill the oil through the fill port
(approximately 2 quarts or 1.89 liters) or until oil appears at the oil fill port. Fill
with clean SAE30 non-detergent oil.
7. 35 gpm Water Injection Pump - Refill the oil through the fill port
(approximately 2 quart or 1.89 liters) or until oil appears at the oil level plug on
the back of the pump housing. Fill with clean SAE30 non-detergent oil.
8. Clean and install fill plug and level plug (35 gpm water injection pumps).
9. Operate the drill and water injection and check for any leaks.
Main Winch
There are three (3) different sizes of (main) winches available on the T3W. The main winch oil
level should be checked every five hundred (500) hours or three (3) months of operation,
whichever comes first.
12K Winch

VENT PLUG
ABOVE OIL LEVEL
CENTERLINE PORT
3. To check the oil level, remove the oil level plug located in the center of the drum
support. Maintain the lubricant level in the gear housing level with the bottom
of this opening. Drain and refill the housing if the oil shows signs of moisture or
other contamination. If additional oil is needed, refer to 6.3 Refill Capacities/
Lubricants/Fuel Specifications for oil recommendations.
6-116
DRILLING SOLUTIONS
18K Winch

OIL LEVEL
SIGHT GLASS
VENT
PLUG
FILL it
DRAIN
PORT
on the
3. To check the oil level, view the oil level sight glass located in the center
the gear housing to
non-motor end of the drum. Maintain the lubricant level in
the middle of the oil level sight glass. Drain and refill the housing if the oil shows
•
6.3
signs of moisture or other contamination. If additional oil is needed, refer to
Refill Capacities/Lubricants/Fuel Specifications for oil recommendations.
30K Winch

OIL LEVEL
SIGHT GLASS
end of
3. To check the oil level, view the oil level sight glass located in the motor
•
the
the drum. Maintain the lubricant level in the gear housing to the middle of
refill the housin g if the oil shows signs of
oil level sight glass. Drain and
moisture or other contamination. If addition al oil is needed , refer to 6.3 Refill
Capacities/Lubricants/Fuel Specifications for oil recommendations.
6-117
DRILLING SOLUTIONS
Mounting Bolts
Tighten all winch base mounting bolts to recommended torque

after the first one hundred (100)
hours of operation, then every five hundred (500) operating
hours or three (3) months of
operation, whichever comes first. Refer to 6-14 Torque Specif
ications.
Cable/Rope Lubrication.
Lubrication of the wire rope and cable should be included in

the maintenance schedule.
Cables should be cleaned with a wire brush and solvent and
lubricated every 500 hours with
one of the following or equivalent:
1. Texaco Crater A
2. Brooks Klingfast 85 (Brooks Oil Company)
3. Gulf Senaca 39
4. Whitmore's Wire Rope Lubricant (Whitmore Manufacturin
g Company)
The lubricant can be applied with either a spray or a brush and
is recommended for protection
against corrosion only.
Auxiliary Winch
There are two (2) different sizes of auxiliary winches availab
le for the T3W. The gear oil should
be changed after the first fifty (50) hours of operation, then every
500 operating hours or twelve
(12) months, whichever occurs first.
Do not climb a raised derrick. Climbing a raised derric

k can cause severe injury or
death. Lower the derrick to the horizontal position to servic
e the winch.
4K Winch (PL5)
The instruction for changing the lubricating oil in the 4K winch

are shown in Section 6-6,
"Maintenance (50 Hours or Weekly)'
3K Winch (M8 Sand Reel High Rope Capacity)
The instruction for changing the lubricating oil in the 3K winch

are shown in Section 6-6,
"Maintenance (50 Hours or Weekly)"
Mounting Bolts

hours of operation, then every five hundred (500) operating
hours or six (6) months, whichever
occurs first.
6-118
DRILLING SOLUTIONS
•
Compressor Air Hose and Clamps

Section 7
and Installation" instructions shown in
Refer to the "Dixon Boss Clamp Selection Clamps.
er way to select and install Dixon Boss
"Systems & Troubleshooting" for the prop
Air Hose & Clamps

present
ning is necessary due to "Cold-Flow"
1. Periodic clamping bolts re-tighte e liste d on "BOSS
ended torque valu
in all rubber hoses. Tighten to recomm
& Troubleshooting".
CLAMPS" chart in Section 7 "Systems
and weakened Boss clamps. If hoses are
2. Examine and change out worn hoses
ps also. Boss clamps hold the hose
to be changed out, change the Boss clam
pressure. Remember, Boss clamps
connections under a large amount of
le use only. Do not reuse. Once
(including the nuts and bolts) are for sing
removed, discard them.
6-119
General Information
.A WARMING..
Read and understand Section 2 - Safety Prec
autions and Guidelines before you operate
or perform any maintenance, service or repa
ir on the drill.
If you are not experienced with the drill's cont
rols and instruments, read and
Unexpected drill motion or moving parts can
cut or crush. Shut down the engine before
Safety should be the main concern for anyone
working on or around the drill. Do not perform
Always wear correct safety gear while working
on or around the drill. This includes an
approved hard hat, safety glasses, steel toe shoe
s/boots, gloves, respirator and ear
protection. Do not wear loose fitting cloth
ing that can become caught on rotating componen
Do not wear oil stained or damaged garments. ts.
The following operational hints should be obse

rved:
1. Do not increase engine speed to high idle until
the engine has been warmed up.
2. Always chock the wheels if there is a possibility
of uncontrolled movement.
3. Do not lubricate the drill while the engine is runn
ing.
4. Always perform safety checks prior to starting,
operating or performing any
5. Always sound the horn before moving the drill in
either direction to alert
6. Always use safe judgement when driving on unstable
surfaces where there
may be a risk of overturning or when loading onto
a transporter where there is
7. Always operate the drill at full engine power when drillin
g.
8. Never stop the drill on a slope or surface that is liable
to collapse.
9. Neve r stop the drill against a high wall that is liable to colla
pse or cause a
crushing risk.
10. Before starting engine, always check to see that the contr
ol levers and drill feed
cab.
6-120
DRILLING SOLUTIONS
Receiver Tank
Under normal operating conditions, the compressor oil must be changed every 1000 hours as
part of a routine maintenance program.
A DANGER
High pressure can cause severe injury or death. Do not attempt to remove any plugs or
open the drain valve before making sure all air pressure has been relieved from the
system. Completely relieve pressure before opening drain valve, removing filler plug,
fittings or receiver cover.
- A WARNING
Oil must be at normal temperature when draining. Hot oil or components can burn.
Avoid contact with hot oil or components. Do not allow used oil to drain into the ground.
Dispose of properly.
• OIL
LEVEL
SIGHT
OIL
FILL
GAUGE
DRAIN VALVE
Change Compressor Oil
•
1. Park the drill on a stable, level surface and shutdown the engine.
2. The best time to drain the compressor oil in the receiver tank is when the oil is
warm. At that time the sediment in the receiver separator is in suspension and
will drain with the old oil. Temperature should not exceed 140°F (60°C) before
draining oil.

3. Place a container with a capacity of at least 40 gallon (151 liter) under the drain
point.
4. The engine must not be running and all pressure relieved from the receiver
tank.
5. Clean around the fill area and the drain area to prevent dirt and contamination
from entering the system.
6. Open the drain valve and allow the compressor oil to drain into the container.
Do not allow used oil to drain into the ground. Dispose of the used oil in
7. Close the drain valve and refill the receiver tank through the oil filler. Fill with
XHP605 oil to the center of the oil level sight gauge on the receiver tank with
approximately 28.5 gallon (107.9 liter). See Section 6-3 "Refill Capacities/
Lubricants/Fuel Specifications" for details on the compressor oil. Note: High
pressure compressors use XHP605 oil.
8. Clean and replace the oil filler cap.
Hydraulic Reservoir
The quality of the hydraulic oil is important to the satisfactory performance of any hydraulic
system. The oil serves as the power transmission medium, system coolant and lubricant.
Selection of the proper oil is essential to ensure proper system performance and life. For the
specifications and requirements that the hydraulic oil used in this drill should meet, refer to the
information below and to 6-3 Refill Capacities/Lubricants/Fuel Specifications.
NOTICE
Dirt in the hydraulic system will lead to premature component failure. A clean
contaminant free system is extremely important to the machine's proper function. Take
extra care when working around or on the hydraulic system to ensure its complete
cleanliness.
Change Hydraulic Oil
The hydraulic oil reservoir (and filters) should be changed after any major hydraulic system
repair and every 1000 operating hours or six (6) months, whichever occurs first. Replace
all hydraulic oil filters every time the hydraulic oil is changed.
1. Position the drill on a stable, level surface and retract all hydraulic cylinders.
2. Shut off the engine and allow the hydraulic oil to cool.
Hydraulic oil must be at normal operating temperature when draining. Hot oil
or components can burn. Avoid contact with hot oil or components

•
gallon (378.5 liters) is

3. Ensure that a container with a capacity of at least 100
allow used oil to drain
placed under the drain point to collect used oil. Do not
into the ground.
HYDRAULIC TANK DRAIN PLUG

LOCATED BEHIND LEFT
MOISTURE DRAIN PETCOCK
NOTICE
•
Remove the old return filters before adding clean oil.
(3) return filters' top
4. Remove the six bolts and lock washers from the three
located under each
covers and carefully remove each cover and bypass valve
cover.
HYDRAULIC TANK
MAIN RETURN
FILTERS
y. Do not allow dirty oil

5. Lift the elements out and away from the housing quickl
g.
from the filter elements to drain from the element into the housin
element and removed
6. Make sure all of the old gasket seal is retained in the
from the filter housing.
•
and allow the oil to
7. Now open the drain valve located under the hydraulic tank
drain from the hydraulic tank.
8. Close the drain valve.
lines.
9. Dispose of the used oil in accordance with local guide
6-123
DRILLING SOLUTIONS
10. Inspect the new filter and gaskets for damage.

Do not use a damaged filter.
Inspect o-rings for serviceable condition. If dama
ged, replace o-rings.
11. Install new filter elements and bypass valves.
12. Replace the covers and install the bolts.
13. Clean the quick disconnect fitting on the bottom
of the oil fill hand pump.
HYDRAULIC
OIL LEVEL
GAUGE
HAND PUMP
(FILL)
HYDRAULIC
OIL TEMP
GAUGE
QUICK
DISCONNECT
NOTE: Any contamination entering the hydr

aulic tank during filling will
seriously risk damage to the pumps and
motors. The system uses
filtration only on the return oil and therefore
oil in the tank must be free
of contamination.
14. Connect one end of an oil drain hose to the

quick disconnect on the oil fill hand
pump and the other end into a clean, filtered hydra
ulic supply (drum, tank, etc.).
15. Start pumping and refill the tank with clean, filtere
d hydraulic oil to the full level
on the oil level sight gauge. When adding oil, be
sure to filter it through a 10
micron filter. Refer to 6-3 Refill Capacities/Lubricant
s/Fuel for details.
16. Check the oil level in the reservoir by viewing the
sight gauge. Make sure that
all of the fittings are tight and secure.
17. The oil level in the hydraulic tank depends
on the extended or retracted
positions of the hydraulic cylinders. It is important
to observe and note the
following information when reading the level gaug
e:
a. The oil level with all cylinders retracted (derrick
down and leveling jacks up)
should be even with the mark on the hydraulic reser
voir next to the oil level
gauge.
b. The top of the oil level must be visible when the
engine is running AND also
when the engine is stopped. There must be oil show
ing on the gauge at all
times. Add oil to bring to levels defined above.
6-124
DRILLING SOLUTIONS
18. After completing all scheduled service (hydraulic oil chang

in-tank return filters), start the engine and check for leaks.
19. During operation, monitor the hydraulic oil level sight gauge
temperature gauge located on the side of the hydraulic oil
e and changing all
and hydraulic
reserv oir.
the engine
NOTE: If no oil is showing on the oil level gauge, stop
the cause of oil
immediately and call for service assistance to investigate
loss.
oil is changed.
20. Replace all hydraulic oil filters every time the hydraulic
21. Operate the drill and check for leaks.
Hydraulic Oil Filters

d on the upper operator's
It is important to monitor the Filter Bypass Indicator Light, locate
during drilling operations. If the
console panel under the Emergency Engine Shutdown button,
ement.
filter bypass indicator light is on, the filter elements require replac
whenever the hydraulic oil is
Under normal operating conditions, these filters are replaced
•
changed or at the regular 1000 hour service interval.
drain oil filter on the drill.
There are three hydraulic return oil filters and one hydraulic case
d in the hydraulic tank and available
The system main return filters are in-tank filters locate
passes through these filters
for servicing at the top of the tank. The main return flow to the tank
and into the hydraulic tank.
lic tank next to the hydraulic oil fill
The case drain filter is located on the side of the hydrau
lic tank.
hand pump and filters case drain oil prior to return into the hydrau
the hydraulic press ure has

Do not attempt to service the filters before making sure all
been relieved from the system.
NOTICE
failure. A clean,
Dirt in the hydraulic system will lead to premature component
drill's prope r function. Take
contaminant free system is extremely important to the
to ensur e its complete
extra care when working around or on the hydraulic system
cleanliness.
NOTICE
•
any inspection or work
Care must be taken to ensure that fluids are contained during
all local and federa l regulations
that is performed on these components. Follow
concerning the handling of hydraulic fluid.
6-125
DRILLING SOLUTIONS
Main Return Filters
When the filter bypass light indicates that elem

ent servicing is required, or when the regular
1000 hour service interval is reached, follow the
instructions previously shown under Change
Hydraulic Oil which includes changing the main
return filters.
HYDRAULIC
TANK MAIN
RETURN
FILTERS
Case Drain Filter
The case drain filter is located on the side of

the hydraulic tank next to the hydraulic oil fill
pump. When the filter bypass light indicates hand
that filter element servicing is required, or when
the regular 1000 hour service interval is reac
hed, proceed in the following manner:
HYDRAULIC
HAND PUMP
HYDRAULIC
SIGHT GLASS
HYDRAULIC
CASE DRAIN
FILTER
HYDRAULIC TANK
TEMPERATURE
GAUGE
1. Stop the engine and allow the hydraulic oil

to cool.
WARNING
Hot oil or components can burn. Oil must
be at normal temperature when
draining. Avoid contact with hot oil or com
ponents. Do not allow used oil
to drain into the ground. Dispose of used
oil properly.
6-126
DRILLING SOLUTIONS
2. Wipe all the external dirt and oil from the filter housing and
minimize contamination from entering the system .
3. Place a container under the oil filter to prevent any oil spill
the ground.
4. Carefully remove the spin-on filter by turning the filter housin
the head area to
from contaminating
g in a counter
clockwise direction.
Remove element
5. Empty the oil from the filter housing into a drain container.
from the filter housing.
ines.
6. Discard the old element in accordance with any local guidel
ng solvent.
7. Clean the filter housing and filter head with an approved cleani
the new filter onto
8. Lubricate the new filter gasket with clean, fresh oil and install
the filter head.
and follow the
9. Turn the filter in a clockwise direction to tighten. Hand tighten
tightening instructions on the filter.
10. Pressurize the hydraulic system and check for leaks.
if necessary following
11. Check the oil level in the hydraulic reservoir and add oil
•
the procedures previously mentioned.
Rotary Tophead
Change the rotary tophead oil as part of the 1000 hour
Do not ride the rotary head.

Riding the rotary head can cause severe injury or death.
. Do not climb raised derrick.

Climbing a raised derrick can cause severe injury or death
locking pins are in a locked

A falling derrick can cause severe injury or death. Ensure all
position.
a WARNING
or death. Do not service
Rotating shafts or a rotating drill string can cause severe injury
•
the rotary head with the drill string in motion.
6-127
DRILLING SOLUTIONS
Rotary Tophead Oil
SIGHT FILLER/BREATHER
LEVEL -
GAUGE
REMOVE DRAIN PLUG ON

BOTTOM OF ROTARY HEAD
TO DRAIN
To change the lubricant in the rotary head, follow the

procedure below.
1. Move the drill to a stable, level surface. Raise
and bolt down the derrick.
2. If necessary, remove the drill pipe in the rotary tophe
ad and lower the rotary
tophead to the bottom of the derrick.
4. Ensure oil is warm before draining. At that time
the sediment in the rotary
tophead is in suspension and will drain with the old oil.
(7.5 liters) under the rotary
tophead drain point.
6. Clean around the breather/fill port area to preve
nt debris from entering the
rotary tophead housing during the oil change. Take
care to prevent any
contamination from entering the fill port.
7. Remove the drain plug and allow the oil to drain.
NOTICE
Care must be taken to ensure fluids are contained
during any inspection
or maintenance on this component. Handle
and dispose of fluids
according to local regulations and mandates.
8. Remove the breather/fill plug to allow air into the housi
ng during draining. Allow
the oil to drain into a container. Dispose of the used oil
in accordance with local
guidelines.
9. After the rotary tophead case is drained, clean
the drain plug and install it.
10. Refill the rotary head gearbox through the fill port
with SAE 90W gear oil until
the fluid is in the center of the fluid level sight glass (abou
t 1 gallon/3.78 liter).
6-128
DRILLING SOLUTIONS
11. Clean and install the fill plug.

12. After startup, check the rotary head for any leaks
temperature.
Pump Drive Gearbox

while at operating
ed as part of the 1000 hour

It is recommended that the pump drive gearbox oil be chang
syste m is the heart of the unit, it is
routine maintenance schedule. Because the lubricant
oil in the pump drive gearbox should
especially important that the oil be kept clean. Note: The
s of high temperature, evidenced
be changed whenever the oil shows traces of dirt or the effect
by discoloration or strong odor.
ce (500 Hours).
Follow the instructions previously shown under Maintenan
Main Winch
winch and sand reel will minimize the
A regular program of preventive maintenance for the
trouble free service. All service intervals
need for emergency servicing and insure long life and
are specified for operating hours of the drill.
•
hundred (100) hours of operation, then
The gear oil should be changed after the first one
ever occurs first. The gear oil must be
every 1000 operating hours or six (6) months, which
le and safe operation of the brake
changed to remove wear particles that impede the reliab
change gear oil at these suggested
clutch and erode bearings, gears and seals. Failure to
slippage which could result in property
minimum intervals may contribute to intermittent brake
damage, severe personal injury or death.
nt temperature changes significantly
The gear oil should also be changed whenever the ambie
be more appropriate. Oil viscosity with
and an oil from a different temperature range would
operation. Make certain that the gear
regard to ambient temperature is critical to reliable brake
nt temperature. Failure to use
viscosity used in your winch is correct for your prevailing ambie
bute to brake slippage which
the proper type and viscosity of planetary gear oil may contri
death .
could result in property damage, severe personal injury or
ctions to change oil in the
Refer to Maintenance (100 Hours) for the procedure and instru
winch and sand reel.
Mounting Bolts
(6) months, whichever occurs first.
hours of operation, then every 1000 operating hours or six
Table 36: Winch Mounting Bolt Torque
Thread Condition Torque
Dry Thread 205 to 220 ft/lbs. (278 to 280 Nm)
Lubed Thread 158 to 170 ft/lbs. (214 to 230.5 Nm)
6-129
DRILLING SOLUTIONS

The following water injection pump maintenance
must be carried out as part of the 500 hour
routine maintenance schedule and every 1000
hours thereafter.
Refer to Maintenance (500 Hours) for the proce
dure and instructions to change oil in the
water injection pump.
Carousel
Carousel Gearbox
Change the carousel gearbox oil every 1000

operating hours. Follow the instructions shown
below.
CAROUSEL GEARBOX
CAROUSEL
FILL GEARBOX
PLUG
DRAIN
PLUG

Raise the derrick and pin it in the
vertical position.
2. Operate the carousel to warm the gearbox.
3. Lower the derrick to the horizontal position. Shut
off the engine.
6 pints (2.8 liters) under the drain
plug to collect the used oil.
5. Remove the fill plug and the drain plug from the
carousel gearbox and allow the
oil to drain.
6. Properly dispose of the used oil.
8. Refill the gearbox with clean gear oil to the
fill plug level (approximately 4 pints/
1.89 liters).
9. Clean and install the fill plug.
6-130
DRILLING SOLUTIONS
General Information
'11017cirl-r0
before you operate
or perform any maintenance, service or repair on the drill.
read and
If you are not experienced with the drill's controls and instruments,
the engine before
the drill. Do not perform
Safety should be the main concern for anyone working on or around
This includes an
tor and ear
approved hard hat, safety glasses, steel toe shoes/boots, gloves, respira
•
rotating components.
protection. Do not wear loose fitting clothing that can become caught on
warmed up.
1. Do not increase engine speed to high idle until the engine has been
ent.
2. Always chock the wheels if there is a possibility of uncontrolled movem
ing any
4. Always perform safety checks prior to starting, operating or perform
on to alert
5. Always sound the horn before moving the drill in either directi
personnel and allow sufficient time before putting the drill in motion .
s where there
6. Always use safe judgement when driving on unstable surface
there is
may be a risk of overturning or when loading onto a transporter where
e.
8. Never stop the drill on a slope or surface that is liable to collaps
e or cause a
9. Never stop the drill against a high wall that is liable to collaps
crushing risk.
levers and drill feed
10. Before starting engine, always check to see that the control
•
controls are at stop, neutral or off positio n.
6-131
DRILLING SOLUTIONS
Engine
Engine Valves
Refer to the actual manufacturer's manual for maintenance

instructions concerning valve
clearance, adjusters and injectors. This operation requires
a trained service engineer.
Compressor
Compressor Fire Prevention
A fiber gasket is installed between the outside cover of the

receiver tank and the metal tube
holding the separator element in place. This gasket prevents
oil from leaking around the metal
tube and down the hole.
When air and oil flow through the filter media, static electric
charges are created. If these
charges are allowed to build up, a spark similar to a lightning
flash will occur. This will set the
oil and the media on fire. The fire will burn from the inside of
the element through the standpipe
hose and will follow the air flow until it burns through the air
hose, This is NOT a fire caused
by the compressor flashing.
To prevent this from happening, several metal staples have
been installed THROUGH the
gasket so each side comes in contact with the metal. This
bridge serves to allow the static
charge to drain off outside the receiver tank and not cause
a static buildup.
,A CAUTION
When replacing the separator element, be sure there is at least
one staple that shows through
on both sides of the gasket and is not covered with glue.
OUTSIDE COVER
OUTSIDE COVER
0
GASKET
GASKET STAPLE 00
METAL COVER
0
METAL COVER p1 1O STAPLE CONNECTION ACTS AS SR OGE
ANO ALLOWS STATIC CHARGE TO DRAIN
OFF OUTSIDE RECEIVER TANK
6-132
DRILLING SOLUTIONS
Change Receiver Separator Element
Maintenance on the receiver separator element is on an "as required" basis. A change of the
separator element is required when there is excessive oil carryover with the compressed air.
Otherwise, change the separator element at 2000 hours.
1. Park the drill on stable, level surface and shut down engine. Allow time for the
drill to cool.
High pressure can cause severe injury or death. Do not attempt to remove
any plugs or open the drain valve before making sure all air pressure has
been relieved from the system. Completely relieve pressure before
opening the drain valve or removing the filler plug, fittings or removing
the receiver cover.
Hot oil or components can burn. Avoid contact with hot oil or
•
components.
2. Relieve all air pressure in receiver tank.
SEPARATOR
ELEMENT
VERTICAL
RECEIVER
TANK
• 3. Remove bolts from cover of the receiver tank, then remove the cover.
4. Pull the separator element from the tank.
DRILLING SOLUTIONS
6-133
5. Inspect the element for failure mode and then discard the used element in
6. Clean any old gasket material from receiver tank or cover before installing the
new element.
7. Remove the new element from box and insert the new element into the receiver
tank. Ensures the scavenge holes in the element are located properly.
8. There will be several holes at the bottom of the element.
9. Make sure there is a staple in the gasket on the element flange. Do not remove
the staple!
10. Install cover.
11. Start engine and compressor. Check for oil carryover or any leaks at operating
temperature.
Compressor Discharge Hose
The compressor discharge air hose between the compressor and the receiver tank should be
changed every two (2) compressor oil changes or once every 2000 hours, whicheve
r
occurs first,
This hose is subject to the highest temperatures in the compressor system and is in contact
with synthetic oil at all times. If the hose is not replaced periodically, the inner lining will begin
to break down. Lining material can clog the cooler and damage the compressor lubrication
pump.
6-134
DRILLING SOLUTIONS
General Information
before you operate

read and
If you are not experienced with the drill's controls and instruments,
the engine before
drill. Do not perform
This includes an
tor and ear
that can becom e caught on rotating components.
protection. Do not wear loose fitting clothing
warmed up.
1. Do not increase engine speed to high idle until the engine has been
movement.
2. Always chock the wheels if there is a possibility of uncontrolled
performing any
4. Always perform safety checks prior to starting, operating or
direction to alert
5. Always sound the horn before moving the drill in either
personnel and allow sufficient time before putting the drill in motion .
s where there
6. Always use safe judgement when driving on unstable surface
may be a risk of overturning or when loading onto a transpo rter where there is
a risk of overturning. Always use a spotter .

e.
8. Never stop the drill on a slope or surface that is liable to collaps
e or cause a
crushing risk.
and drill feed
10. Before starting engine, always check to see that the control levers
controls are at stop, neutral or off positio n.
6-135
DRILLING SOLUTIONS
Engine Coolant
The coolant system of any engine should be drain
ed and flushed out after 3000 hours or two
(2) years of service. Unless the coolant has a corro
sion preventive in it, rust and scale will
eventually clog up the system. Any effective comm
ercial flushing agent should be used at least
once or twice a year to ensure against buildup.
Clean the cooling system and flush the cooling syste
m before the recommended maintenance
interval if the following conditions exist:
1. The engine overheats frequently.

2. Foaming is observed.
3. Oil has entered the cooling system and the coola
nt is contaminated.
4. Fuel has entered the cooling system and the
coolant is contaminated.
NOTICE
Use of commercially available cooling system
cleaners may cause damage to cooling
system components. Therefore:
1. Caterpillar Engines - Use only cooling syste

m cleaners that are approved for
Caterpillar engines. Contact your nearest CAT
dealer or refer to your CAT
Operation and Maintenance manual for specifics.
2. Cummins Engines - Use only cooling syste
m cleaners that are approved for
Cummins engines. Contact your nearest Cum
mins dealer or refer to your
Cummins Operation and Maintenance manual for
specifics.
NOTE: Inspect the water pump and the wate
r temperature regulator after
the cooling system has been drained. This
is a good opportunity to
replace the water pump, the water temperatu
re regulator, thermostat and
the hoses if necessary.
This is a pressurized system. Hot coolant can

cause serious burns. To open the cooling
system filler cap, stop the engine and wait until
the cooling system components are
cool. Loosen the cooling system pressure cap
slowly in order to relieve the pressure.
Injury can occur when removing the radiator
cap. Steam or fluid escaping from the
radiator can burn. inhibitor contains alkali. Avoi
d contact with skin and eyes. Avoid all
contact with steam or escaping fluid.
6-136
DRILLING SOLUTIONS
Drain Cooling System
1. Move the drill to a stable. level surface.

2. Stop the engine and allow the engine to cool.
3. Place a container under the drain valve to collect used coolant.

pressure.
4. Loosen the cooling system filler cap slowly in order to relieve any
when drainin g the system to ensure
Remove the cooling system filler cap
proper draining.
container.
5. Open the drain valve and allow the radiator coolant to drain into the
drain plug from the water
At the same time, drain the engine block. Remove the
r's Servic e and
pump housing if required. Refer to the engine manufacture
Maintenance manuals for the recommended procedures.
NOTICE
Please
Engine coolant must be disposed of in a responsible manner.
ed dispo sal
consult the local environmental agency for recommend
• guidelines.
Flush Cooling System
1. Flush the cooling system with clean water in order to remove any
2. Refer to the engine manufacturer's Service and Maintenance
recommended flushing procedures
debris.
manuals for
NOTICE
sly risk
Any debris or contamination in the cooling system will seriou
g system must be
damage to the components being cooled. The coolin
free of debris and contamination.
3. Clean and install the drain plugs and/or close the drain valves.
Fill the Cooling System

manufacturer's
1. Refill the radiator with a 50-50 mixture of the engine
recommended antifreeze and quality water. Install the correct coolant filter (if
required).
manufacturer's
2. When refilling the cooling system, refer to the engine
•
Operation and Maintenance instruction manua l.
6-137
DRILLING SOLUTIONS
6-13 Torque Specifications
Standard Torque Values
General Information
A CAUTION
Use only the proper tools (inch or metric) on hardw
are. Other tools may
not fit properly. They may slip and cause injury.
Head Markings
Fasteners should be replaced with the same grade or a highe

r grade. If higher grade fasteners
are used, these should only be tightened to the strength
of the original grade fastener.
Grade 5 Capscrew Head Marking
I>
Grade 8 Capscrew Head Marking
Do not use these values if a different torque value or tighten

ing procedure is listed for a specific
application. Torque values listed are for general use only.
All values are suggested maximum
with dry plated hardware.
Make sure fastener threads are clean and you properly
start thread engagement. This will
prevent them from falling when tightening.
The following pages list the recommended tightening torque
s for the various size bolts used
by Drilling Solutions. Proper torque specifications should
be used at all times.
The head of grade five (5) is marked with three (3) short
lines. The head of a grade eight (8)
is marked with five (5) short lines.
In the following tables, DRY means "clean dry" threads
and LUBE means a "light film" of oil.
Excess oil in a threaded dead end hole can create a hydra
ulic lock giving a false torque
reading.
6-138
DRILLING SOLUTIONS
Recommended Torques in Foot Pounds (ft/lbs.)

This page lists the recommended tightening torques, in foot pounds (ft/lbs.), for the various
size bolts and nuts that are used. Proper torque specifications should be used at all times. The
head of a grade five (5) bolt is marked with three (3) short lines. The head of a grade eight (8)
bolt is marked with five (5) short lines. Dry means "clean dry threads" and LUBE means a "light
film" of oil. Excess oil in a threaded dead end hole can create a hydraulic lock giving false
torque readings.
Table 37: Recommended Torques in Ft/Lbs.
SAE Grade 5 SAE Grade 8
Size Tightening Torque Tightening Torque
Dry Lube Dry Lube
5/16 - 18 NC 16 - 17 12 - 13 23 - 25 17 - 18
5/16 - 24 NF 18 - 19 13 - 14 19 - 20
•
3/8 - 16 NC 28 - 30 21 - 23 42 - 45 33 - 35
3/8 - 24 NF 33 - 35 23 - 25 47 - 50 -
7/16 - 14 NC 47 - 50 33 - 35 65 - 70 51 - 55
7/16 - 20 NF 51 - 55 37 - 40 74 - 80 56 - 60
1/2 - 13 NC 70 - 75 51 - 55 102 - 110 74 - 80

1/2 - 20 NF 84 - 90 61 - 65 112 - 120 84 - 90
9/16 - 12 NC 102 - 110 74 - 80 140 - 150 102 - 110

9/16 - 18NF 112 - 120 84 - 90 158 - 170 121 -130
5/8 - 11 NC 140 - 150 102 - 110 205 - 220 158 - 170

5/8 - 18 NF 158 - 170 121 - 130 223 - 240 167 - 180
3/4 - 10 NC 242 - 260 186 - 200 353 - 380 260 - 280

3/4 - 16 NF 279 - 300 205 - 220 391 - 420 298 - 320
7/8 - 9 NC 400 - 430 298 - 320 558 - 600 428 - 460

7/8 - 14 NF 437 - 470 326 - 350 614 - 660 465 - 500
3/4 - 10 NC 242 - 260 186 - 200 353 - 380 260 - 280

3/4 - 16 NF 279 - 300 205 - 220 391 - 420 298 - 320
7/8 - 9 NC 400 - 430 298 - 320 558 - 600 428 - 460

7/8 - 14 NF 437 - 470 326 - 350 614 - 660 465 - 500
•
1 - 8 NC 595 -640 446 - 480 837 - 900 632 - 680
1 - 12 NF 651 - 700 493 - 530 930 - 1000 688 - 740
1-1/8 - 7 NC 744 - 800 558 - 600 1190 - 1280 893 - 960

1-1/8 0 12 NF 818 - 880 614 - 660 1339 - 1440 1004 - 1080
6-139
DRILLING SOLUTIONS
Dry Lube Dry Lube

1-1/4 - 6 NC 1042 - 1120 781 - 840 1693 - 1820 1255 - 1360
1-1/4 - 12 NF 1153 - 1240 856 - 920 1860 - 2000 1395 - 1500
1-3/8 - 6 NC 1358 - 1460 1023 - 1100 2213 - 2380 1655 - 1780
1-3/8 - 12 NF 1562 - 1680 1172 - 1260 2530 - 2720 1987 - 2040
1-1/2 - 6 NC 1804 - 1940 1358 - 1460 2939 - 3160 2195 - 2360
Recommended Torques in Nm
This page lists the recommended tightening torques, in newton-meters (Nm),

for the various
size bolts and nuts that are used. Proper torque specifications should be used
at all times. The
head of a grade five (5) bolt is marked with three (3) short lines. The head
of a grade eight (8)
bolt is marked with five (5) short lines. Dry means "clean dry threads" and LUBE
means a "light
film" of oil. Excess oil in a threaded dead end hole can create a hydraulic
lock giving false
torque readings.
Table 38: Recommended Torques in Nm
Dry Lube Dry Lube

5/16 - 18 NC 22 - 27 16 - 17 31 - 33 23 - 24
5/16 - 24 NF 24 - 26 17 - 19 26 - 27
3/8 - 16 NC 37 - 40 28 - 31 56 - 60 44 - 47
3/8 - 24 NF 44 - 47 31 - 33 63 - 67
7/16 - 14 NC 63 - 67 44-47 87 - 93 68 - 73
7/16 - 20 NF 68 - 73 49 - 53 97 - 107 75 - 80
1/2 - 13 NC 93 - 100 68 - 73 136 - 147 99 - 107
1/2 - 20 NF 112 - 120 81 - 87 149 - 160 112 - 120
9/16 - 12 NC 136 - 147 99 - 107 187 - 200 136 - 147
9/16 -18 NF 149 - 160 112 - 120 211 -227 161 -173
5/8 - 11 NC 187 - 200 136 - 147 273 - 293 281 - 227
5/8 - 18 NF 211 - 227 161 - 173 297 - 320 223 - 240
3/4 - 10 NC 323 - 347 248 - 267 471 - 507 347 - 373
3/4 - 16 NF 372 - 400 273 - 293 521 - 560 397 - 427
6-140
DRILLING SOLUTIONS
Dry Lube Dry Lube
7/8 - 9 NC 533 - 573 397 - 427 744 - 800 571 - 613

7/8 - 14 NF 583 - 627 435 - 467 819 - 880 620 - 667
1-8 NC 793 - 853 595 - 640 1116 - 1200 843 - 907

1-12 NF 868 - 933 657 - 707 1240 - 1333 917 - 987
1-1/8 - 7 NC 992 - 1067 774 - 800 1587 - 1707 1191 - 1280

1-1/8 - 12 NF 1090 - 1173 819 - 880 1785 - 1920 1339 - 1440
1-1/4 - 7 NC 1389 - 1493 1041 - 1120 2257 - 2427 1687 - 1813

1-1/4 - 12 NF 1537 - 1653 1141 - 1227 2480 - 2667 1860 - 2000
1-3/8 - 6 NC 1811 - 1947 1364 - 1467 2951 - 3173 2207 - 2373

1-3/8 - 12 NF 2083 - 2240 1563 - 1680 3373 - 3627 2529 - 2720
1-1/2 -6 NC 2405 - 2587 1811 - 1947 3917 - 4213 2927 - 3147
6-141
6-14 MAINTENANCE (25CM Swivel)
25 CM Swivel
Operation
The 25CM swivel is designed for use on the T3W. The two differen
t packing arrangements
allow this swivel to be used in all types of drilling applications. The
simple design, with
adjustable bearings, will provide long swivel life and easy field service
when required.
1. Before starting to drill, rotate the spindle/swivel slowly to get
the packing
unstuck from the washtube.
2. If drill has not been operated for an extended period of time, lubrica
te the
packing and bearings before rotating swivel.
3. If the drill has been used with mud or large amounts of water,
lubricate the
packing before the drill is shut down for an extended period of time
so that the
fluid does not penetrate the packing.
4. If the drill is started in extremely cold weather, allow the swivel
to rotate slowly
with air flowing through it. This will warm up the packing and allow
the bearing
grease to reach operating temperature before attempting to drill.
Routine Maintenance
The following services should be performed on a daily basis:
1. Clean external surfaces.

2. Visually inspect swivel for leakage, damage or wear. If
a problem is found, do
not use swivel until problem is corrected.
3. After the swivel has been running one hour, lubricate
bearings through the
grease zerk in the lower portion of the bearing housing, while the
spindle is
rotating. Pump grease until it exits the relief fitting in the upper portion
of the
bearing housing.
4. Lubricate the packing every three to four hours or when
packing begins to leak.
With the spindle rotating and pressure (air/mud pump) OFF,
lubricate packing
through the grease zerk in the Packing Box. If the unit becomes hard
to rotate
after greasing, or if packing becomes hot, relieve some of the grease
pressure
by depressing ball on the end of the grease zerk in the Packing Box.
5. Lubricate the trunnion pins through the grease fittings
provided in the end of the
trunnion pins.
6. Inspect the spindle for any movement while drilling. If
any movement is present,
refer to Bearing Adjustment.
6-142
DRILLING SOLUTIONS
GOOSENECK
3-1/2- NPT
THREAD
SWIVEL ASSEMBLY PACKING BOX
ZERK FITTING
YOKE ASSEMBLY PACKING BOX
-' 0
ITTI
0 0
0 0
BEARING
-FUNNION PIN HOUSING RELIEF
ZERK FITTING (2)
BEARING HOUSING
BEARING ZERK FITTING
ADJUSTING
NUT BEARING ADJUSTING
NUT SET SCREW
LOWER SUB
SET SCREW
LOWER SUB
3-1l2" IF LH PIN
6-143
DRILLING SOLUTIONS
ri
0-RING
LOWER SEAL
(UP FACES UP)
r. 11
- LOWER SEAL BOX
LOWER SEAL BOLTS

BEARING '~
ADJUSTING BEARING ADJUSTING NUT SET SORE
III
NUT LOWER SUB SET SCREW
SPINDLE THREAD SEAL
LOWER SUB
BEARINGS:
CONE=CPN 57438400
CUP = 57438414
6-144
DRILLING SOLUTIONS
-R Ni;
PACKING SOX
CAPSCRENS
GOOSENECK
Om%
SACKING --
BET (5) PACKING G...ANp
=IECES
CIF EASE FITTING
PAC K!NIG SE.A7 RING
CAPSCPE'vVS
•
_
GOOSENECK
CA.PSCREWS (41
r1
BEARING
LE - - ,
HOUSING
U=?EP
(UP FACES
DOWN)
-1/-3
25 CM SWIVEL PACKING
Packing Set Options for 25CM Swivel
There are two packing set options for the 25CM swivel:
(517-3447 kPa)
1. Standard packing set for operating pressures of 75-500 psi
•
which is CPN 57439341.
(2413-10,342 kpa)
2. Optional packing set for operating pressures 350-1500 psi
which is CPN 57409245.
6-145
DRILLING SOLUTIONS
Packing Replacement (Chevron, V-Ring)
Note: Before replacing leaking packing, lubricate the packing as describ

ed in Routine
Maintenance while spindle is rotating with the pressure off. This will normall
y stop leakage. If
this fails to stop leakage, packing should be replaced. Refer to the followin
g instructions when
replacing packing.
1. Unscrew and remove the four (4) washtube screws and lock washer
s.
2. Unscrew and remove the four (4) packing box screws and lock washer
s.
3. Slide (pry) the washtube (CPN 57409278) up into packing box assemb
ly.
4. Remove packing box assembly through window in Gooseneck.
5. Disassemble the packing box assembly. Clean and inspect all metal
parts for
wear and/or damage. Replace if necessary.
Disassembly of Packing Box Assembly
1. Pry washtube down, out of packing box.

2. Remove mud slinger (CPN 57409286) from washtube, if it is to be
replaced.
3. Remove packing gland (CPN 57409237) from packing box assemb
ly.
4. Remove the upper four (4) pieces of packing (CPN 57439341)
from packing
box assembly.
5. Remove lantern ring (CPN 57409262) from packing box assemb
ly.
6. Remove the last piece of packing set (CPN57439341) from
packing box
assembly.
7. Remove the packing seat ring (CPN 57409260) from packing
box assembly.
8. Remove 0-Ring (CPN 57438384) from upper face of packing
box assembly.
9. Remove 0-Ring (CPN 57438376) from upper face of spindle.
10. Clean 0-Ring grooves.
11. Clean packing box thoroughly.
12. Reverse above steps to install new packing and packing box assemb
ly.
Note: Lubricate packing assembly after installation and every
three to four hours of drilling
time to insure proper packing life.
Seal Replacement
.eplace Housing Seals every four (4) to six (6) months, when they begin
to leak grease, when
Jamage occurs and/or while performing a major overhaul. Refer to the
following instructions
when replacing seals.
6-146
DRILLING SOLUTIONS
Upper Housing Seal Replacement
1. Remove packing assembly as described in Packing Replacement.

2. Remove air line/mud line from gooseneck hose connection.
3. Unscrew and remove the four (4) gooseneck cap screws and lock washers.
4. Remove Gooseneck.
5. Remove old housing seal (CPN 57416620).
6. Clean all parts.
7. Replace new housing seal after cleaning area carefully. Lip of seal should point
down towards bearings.
8. Reverse procedure to reassemble.
Lower Housing Seal Replacement
1. Loosen lower sub locking screw.

2. Unscrew lower sub from swivel spindle. (Note: All left hand threads).
• 3. Unscrew and remove the six (6) lower seal box screws and lock washers.
4. Slide the lower seal box down and off of swivel spindle. Watch out for falling
grease.
5. Remove the old lower seal (CPN 57416620).
6. Clean all parts thoroughly.
7. Install new housing seal with lip of seal facing up towards bearings.
8. Reverse procedure to assemble.
Note: Lubricate bearings in bearing housing after replacing seals.
Bearing Adjustment
1/32"
Check for spindle movement (up & down) daily. Adjust when movement is greater than
bearing wear and/or bearing adjusting nut
(0.08 cm). Note: This spindle travel is caused by
becoming loose from drilling.
failure
A loose bearing adjusting nut will cause premature packing failure, premature bearing
to the following instructions when adjusting the
and cause general failure in the swivel. Refer
bearing adjusting nut.
Bearing Adjustment Nut
• 1. Loosen the two (2) bearing adjusting nut set screws.

2. Tighten bearing adjusting nut, using a pipe wrench. Remember, it is
thread.
DRILLING SOLUTIONS
left hand
6-147
a. Average torque should be about 125 ft/lbs (169.4 Nm) when the bearing
s
are loaded correctly.
b. If spindle becomes locked up after being adjusted, loosen adjusting nut until
spindle begins to rotate.
3. The bearing adjusting nut preloads the bearings and makes the spindle hard
to
turn. This is normal.
4. Tighten the bearing lock nut set screws.
The service kit, CPN 57410771, is sent with every new drill and it is the recomm
ended spare
parts requirement for one year's operation.
6-148
DRILLING SOLUTIONS
• 6-15 MAINTENANCE (40 RM Swivel)
40 RM Swivel
3- .*T FENP.;;X
BOLTS W,F.00KWAV-Ze, ;Cdr)":
(2) GOOSENECK
(3) 0-W3. PACKIN3 BOX

r" F3) 0-RING. KCMG BOx
(z) O-RN3. PAOKIFR.1 BOX
IS) PACtION3 SET. 6 PINGS
r- C7) PACKING BOX
ce) LANTERN RING
Et) PACX3443 ANLISTTNn (RA MO
(10) NLFT...MM1,44r
(11) 3ETECI‘Ei4004.4AE NEAR
(12) WASNIFIPE
(13) SCPEUS .AOLOCKWAC•4EFI3. (O1 =I
(14) S4443Ett RIFF3
(M) NO 3443 BEAL (QT( 2)
(16) O-RING. WAZHAPE
•
, -0C K BO LT AfrO sA."7
;13. :EAL. S-otEL.O
'6 61=E. =ETAME=
42343I-IEZ4. BEARING
(r) SPINCe.E. BEARINS
seApano. (ry.
t23) NOLOING. BEARNG W.7 TRAN30t4 FV440
Oil lir GREASE MING& (OW: 3)
(20) BET Se-PEWS. MTV: A)
06) 0-Rasa 'MMUS SEAL

3FINCLE THREAD
-CfNElz CONNEOTON IN - :14:C
•
3-147 IF .EFT MAD %to:OWED
6-149
DRILLING SOLUTIONS
Swivel Information
Table 39: Technical Data
Static Load Capacity 140,000 lbs. (63,504 kg)

Rotating Load Capacity (100 RPM) 71,000 lbs. (32,205.6 kg)
Pulldown Load Capacity 22,000 lbs. (9,979.2 kg)
Hose Connection 3 inch NPT Female
Lower Connection 3-1/2 inch IF LH Pin (mod.) 3 inch ID.
Fluid Passage Full 3 inch
Bearings Lubrication (NLG2 Grease) (5) Angular Ball
Packing Lubrication (NLG2 Grease) Chevron V-Ring
Standard (416) Chevron Working Pressure 50-500 PSI (3.45-24.5 BAR)
Optional (417) Chevron Working Pressure 125-1500 PSI (8.63-103.5 BAR)
Optional Rubber Ring 25-350 PSI (1.73-24.15 BAR)
Operation
The 4ORM swivel is designed for use on the T3W55K model

and the T3W7OK model.
1. Before starting to drill, rotate the spindle/swivel slowly
to get the packing
unstuck from the washtube.
2. If drill has not been operated for an extended period of
time, lubricate the
packing and bearings before rotating swivel.
3. If the drill is started in extremely cold weather, allow the
swivel to rotate slowly
with air flowing through it. This will warm up the packing and allow
the bearing
grease to reach operating temperature before attempting to drill.
Daily Maintenance
The following services should be performed on a daily basis:
1. Clean external surfaces.

2. Visually inspect swivel for leakage, damage or wear.
If a problem is found, do
not use swivel until the problem is corrected.
3. Inspect all bolts, nuts and threaded connections to insure
that they are tight and
in place. Do not use if any bolts or nuts are missing.
6-150
DRILLING SOLUTIONS
4. Lubricate the bearing case through the zerk fitting in the bearing case (upper
one). Bearings should be greased with bearing case warm (after being rotated
for about an hour) and the bearings rotating. Bearings should be lubricated until
the grease exits the upper housing seal.
5. Lubricate the packing through the zerk fitting located in the packing box. The
wash pipe should be rotating and the packing under no pressure loading while
packing is being greased. The packing should be lubricated after two (2) or
three (3) hours or every second drill rod (whichever comes first).
Note: If the unit becomes hard to rotate after lubricating the packing, the ball of
the zerk fitting should be depressed. This will relieve excess pressure from the
packing. Do not stand in front of the zerk fitting while depressing the ball
of the zerk fitting. Relieving pressurized grease could cause injury.
6. Lubricate the trunnion pins through the grease fittings provided in the end of the
trunnion pins.
Packing Adjustment
The 4ORM Swivel is supplied with adjustable packing. This adjustment is to be used only when
greasing the packing will no longer control leakage.
When Packing starts to leak, try to stop the leakage by greasing the packing. (See Daily
Maintenance / packing lubrication for instruction).
To Adjust Packing
1. Loosen the #10 jam nut located on the side of the gooseneck.
2. Loosen the #11 squarehead set screw located on the side of the gooseneck.
3. Tighten the #9 packing adjusting gland about a quarter of a turn. Note: This is
a left hand thread.
4. Check to see if leak stops.
5. Readjust if necessary.
6. Tighten the #11 squarehead set screw.
7. Tighten the #10 jam nut.
8. Lubricate the packing. Follow the instructions given in Daily Maintenance.
Packing Replacement
1. Stop rotation.
2. Stop the air flow of air and/or water.
3. Ensure the swivel is at a safe working height and the work area is clear.
4. Loosen the #10 jam nut located on the side of the gooseneck.
6-151
DRILLING SOLUTIONS
5. Loosen the #11 squarehead set screw located on the side of the
gooseneck.
Unscrew about three (3) or four (4) threads.
6. Remove the four #1 bolts with lock washers from the top of the #2
gooseneck.
7. Remove the four #13 screws with lock washers from the top
of the #12
washpipe.
8. Slide the packing assembly down towards the bearing case.
9. Remove the washpipe from the alignment of the bearing spindle
.
10. Remove the packing assembly.
11. Remove the #16 0-ring from the bearing spindle.
12. Clean the face of the bearing spindle and the upper face of the
gooseneck.
Remove the Packing Assembly
1. Drive the washpipe out of the packing assembly.

2. Unscrew the #9 packing adjusting gland. This is a left hand thread
.
3. Remove the first #6 packing ring.
4. Remove the #8 lantern ring.
5. Remove the remaining #6 packing rings (five pieces).
6. Remove the #9 packing gland.
7. Remove the two (2) 0-rings from the #9 packing gland.
8. Remove the #3 0-ring from the top of the #7 packing box.
9. Clean and inspect all parts. Never re-use packing and/o
r 0-rings. Replace
all worn or damaged items.
Assemble the Packing Assembly
1. Install #5 0-ring in the #9 packing gland.

2. Install the #9 packing gland into #7 packing box with the top
#3 0-ring groove
up.
3. Turn the #7 packing box over (#9 packing gland down)
and install the five (5)
#6 packing rings. Put a light coat of grease on each ring (male and
female end)
prior to installing.
4. Install the #8 lantern ring.
5. Install the remaining #6 packing ring.
6. Install the #9 packing adjusting gland and lightly tighten
(left hand thread).
7. Install the #12 washpipe through the packing assembly.
8. Turn over and install the #3 packing box 0-ring and #4
packing gland 0-ring.
6-152
DRILLING SOLUTIONS
9. Install the #16 washpipe 0-ring.

10. Install the four #1 packing box bolts w/lock washers in the top of the #2
gooseneck and just start the threads in the #7 packing box.
11. Slide (drive) the #12 washpipe down onto the #21 bearing spindle and start the
four #13 bolts with washers.
12. Tighten the four #1 bolts with washers.
13. Tighten the four #13 bolts with washers.
14. Lubricate the packing through the zerk fitting in the #7 packing box.
15. Adjust the #9 packing adjusting gland. This is a left hand thread.
16. Pressure test and re-adjust if necessary to stop leakage.
17. Tighten the #11 square head setscrew and the #10 jam nut.
Major Repair Disassembly

in a safe work area.
Major repair should only be done with the swivel removed from the drill and
1. Loosen the #10 jam nut on the side of the #2 gooseneck.
• 2. Loosen the #11 square head set screw on the side of the #2 gooseneck.
3. Remove the four (4) #1 bolts with washers.
4. Remove the four (4) #13 bolts with washers.
5. Remove the packing assembly.
6. Remove the #17 housing lock bolt and nut.
7. Unscrew the #2 gooseneck from the #23 bearing housing. This is a left hand
thread.
8. Remove the #19 retainer wire from the #23 bearing housing.
. The #23
9. Slide the #23 bearing housing off the #22 bearings and remove
bearing housing should slide in a downward motion towards the 3-1/2" IF LH
pin tool joint.
10. Remove the four (4) #25 set screws from the lower connection.
loose. Do
11. Secure the #28 lower connection and break the #21 bearing spindle
not unscrew more than two (2) to three (3) threads.
unscrewing
12. Stand this assembly up (washpipe face on flat surface) and finish
the #28 lower connection. Remove the lower connection.
13. Remove the #27 spindle thread seal from the #28 lower connection.
•
bearing
14. Remove the #26 thread seal 0-ring, the five #22 bearings and #20
shield from the #21 bearing spindle.
.
15. Remove the two (2) #15 housing seals from the #23 bearing housing
6-153
DRILLING SOLUTIONS
16. Remove the #15 housing seal and the #18 shield seal from the
#2 gooseneck.
17. Dis-assemble the packing assembly (See Packing Replacement
).
18. Clean and inspect all the removed parts. Replace all worn and/or
damaged
parts. Never re-use packing, housing seals and/or 0-rings.
Should you have any problems or require additional information,
contact your local Atlas
Copco Drilling Solutions Distributor or Dealer.
6-154
DRILLING SOLUTIONS
•
Section 7 - Troubleshooting
7-1
T3W Instruction Manual Section 7 - Systems/Troubleshooting
7-1 INTRODUCTION
General Information
drill. Do not perform
Always wear correct safety gear while working on or around the drill.
This includes an
tor and ear
protection. Do not wear loose fitting clothing that can become caught on rotating
components.
Troubleshooting Information
Improper operation and maintenance is the most frequent cause of drill
failures and problems.
In the event of a failure, it is recommended that you read through this
manual. Problems will
be related to defects occurring in the following areas: electrical, operato
r observed problems,
pneumatic, mechanical/hydraulic and mechanical/Engine.
When carrying out troubleshooting procedures, it is important to

strictly
observe the safety precautions and guidelines in Section 2
of this
manual.
Electrical
These are problems related to the electrical systems which control the
engine, hydraulically
operated controls and the compressor controls. Refer to 7-2 Electric
al System for further
information on the electrical systems used on this drill.
Five (5) circuit breakers protect the drill's electrical circuits. The circuit
breakers are mounted
between the current producer, batteries or alternator and the devices
they are protecting. In
the event of an overload of a circuit, it is necessary to press in the tripped
circuit breaker.
NOTE: If there is a recurrence, call for service assistance to
correct the
cause of the overload in the circuit.
Operator Observed Problems

During operation, the operator may observe some problems which may
be defined in 7-3
Operator Observed Problems Trouble Shooting Chart.
The trouble shooting chart is limited to machine failure control operati
onal problems which will
guide the operator to rectify the cause of the failure.
7-2
DRILLING SOLUTIONS
• Section 7 - Systems/Troubleshooting T3W Instruction Manual
Pneumatics
During operations, the operator may observe some problems which may be defined in 7-4
Compressor.
Troubleshooting and repairs of defects in the mechanical functioning of the compressor
systems requires specialist knowledge. All compressor related problems should be referred to
your local service support for assistance and are not considered part of operator maintenance
covered in this manual. If you are unable to determine the cause of the problem, contact your
local Atlas Copco Drilling Solutions service office.
Mechanical Hydraulic Components

Troubleshooting and repairs of defects in the mechanical functioning of the hydraulic systems
requires specialist knowledge. All mechanical problems should be referred to your local
service support for assistance and are not considered part of operator maintenance covered
in this manual. If you are unable to determine the cause of the problem, contact your local
Drilling Solutions service office.
Mechanical Engine
• Troubleshooting and repairs of defects in the mechanical functioning of the engine systems
requires specialist knowledge. All engine problems should be referred to your local service
support for assistance and are not considered part of operator maintenance covered in this
manual. If you are unable to determine the cause of the problem or are unable to find a solution
when following a troubleshooting chart, contact your local Atlas Copco Drilling Solutions
service office
7-3
7-2 ELECTRICAL
General Information
Read and understand Section 2 - Safety Precautions and Guidelines before

you operate
and
Unexpected drill motion or moving parts can cut or crush. Shut down the engine
before
Safety should be the main concern for anyone working on or around the drill. Do not
perform
Always wear correct safety gear while working on or around the drill. This includes
an
approved hard hat, safety glasses, steel toed shoes/boots, gloves, respirator and
ear
protection. Do not wear loose fitting clothing that can become caught on rotating
components.
1. Do not increase engine speed to high idle until the engine has been warmed
up.
4. Always perform safety checks prior to starting, operating or perform
ing
maintenance when troubleshooting the drill
5. Always sound the horn before moving the drill in either direction to
alert
6. Always use safe judgement when driving on unstable surfaces where
there
e or cause a
crushing risk.
10. Before starting engine, always check to see that the control levers
and drill feed
7-4
DRILLING SOLUTIONS
• Section 7 - Systems/Troubleshooting
Electrical System Information
relation to the operator's control panel that is described in Section 4 -

The following information is provided to give an understanding of the electrical system

Operatin
there are wiring schematics shown at the end of this section which relate to the
g
and the
Controls
informat
. Note
ion
provided here.
the
The T3W Waterwell drill is an EPA compliant drill. As the EPA sets new standards to keep
with
environment clean, the T3W30K, T3W40K, T3W55K and T3W7OK drills are equipped
Caterpillar C15 tier 3 engines as standard deck engines.
Engine
,
The Cat C15 electronic engines have the following characteristics: direct fuel injection
after cooled
electronic unit injection that is mechanically actuated, turbocharged and air-to-air
(ATAAC).
g,
The electronic engine control system provides the following functions: electronic governin
automatic air to fuel ratio control, torque rise shaping, injection timing control and system
•
diagnostics.
The engines have built-in diagnostics in order to ensure that all of the components are
the
functioning and operating properly. In the event of a system component deviation from
that
programmed limits, the operator will be alerted to the condition by a DIAGNOSTIC lamp
is mounted on the control panel. There are three types of diagnost ic codes: ACTIVE , LOGGED
Module).
and EVENT. These codes are logged and stored in the ECM (Electronic Control
Electrical System Components

The electrical systems consists of five (5) circuits. These circuits are the engine and
compressor starting circuit, drill and operating lights circuit, drill functions circuit, engine
monitoring circuit and the electronic air regulation circuit.
EMERGENCY OIL PRESSURE
FUEL
CIRCUIT TACHOMETER ENGINE GAUGE
BREAKERS SHUTDOWN GAUGE
DISCHARGE
TEMP
GAUGE
WATER
TEMP
GAUGE
COMPRESSOR
ON/OFF -
SWITCH POWERVIEW
DIAGNOSTICS
VIEWER
DIAGNOSTIC START
'BUTTON
•
_ ON•LOCK
KEY SWITCH
ECM
LIGHTS
FILTER
BYPASS
7-5
DRILLING SOLUTIONS
The electrical system has two 12 volt batteries, connected in series, that
provide 24 volt Direct
Current (DC) to the system. The batteries use a machine ground to comple
te the circuit. The
battery and starter ground cable are size 2/0. They are protected by two
sections of fusible
links, one attached to the starter motor and the other attached to the alternat
or. Current flows
to the hot or (+) wire for the engine controls, the hot or (+) wire for the drill
lighting system and
to the engine ECM. Refer to the appropriate electrical schematics for wiring
details.
When the engine is started, battery current is supplied to the starter motor
through the starter
solenoid (S2) contacts when they are closed. To close the contacts, the
Key Switch must be
turned to the "ON" position and the Starter Button depressed. [This activate
s the (S1) coil
which, in turn, closes contact (S1). Coil (S2) is then powered and, in turn,
activates (S2)
contact. This is what actually makes contact with the motor starter. Note:
Relay S2 is built into
the starter itself.]
Note: Reference the wiring schematics at the end of this section (7.2 Electric
al System) which
relate to the information provided here.
Before the engine can start, the Emergency Stop button must be pulled
out or disengaged.
This allows current to flow through the Relay and the Emergency Stop
Button to the Fuel
Solenoid. This solenoid allows the flow of fuel into the engine. If power
is cut off to the Fuel
Solenoid, engine fuel flow will cease and the engine will stop. This is why
it is called an
"Energize To Run" system.
NOTICE
Do not operate the starter motor for more than 30 seconds at a time.
Let the starter
motor cool for at least 2 minutes before attempting to start again.
Overheating, caused
by excessive cranking, will seriously damage the starter motor.
Components
Batteries
The electric system uses two 8D type batteries rated at 12 volts each.
These are connected
in series to provide 24 VDC. They should be checked every 50 operatin
g hours as part of
routine maintenance. Refer to Section 6.6 Maintenance at 50 Hours
or Weekly.
P-
0 0
/ 5 .ef P
Cl
7-6
DRILLING SOLUTIONS
Fusible Links
The three (3) Fusible Links used on T3W drills are blue and are 9 inches (23cm) long. There
or
is a ring connector on one end of each link. Fasten one (each) fusible link end ring connect
ring connect or to the alternat or. The other
to each starter and fasten the third fusible link end
wire
end of each fusible link is connected to the main hot wire #1 by a wire nut. The main hot
(#1) is a red, 8 gauge wire.
NOTICE
Fusible Links must be in place to operate the drill. If a short circuit destroys a fusible
link, it MUST be replaced before the drill goes back in service.
Alternator
current
The alternator is a 24V, 100 amp model. It is used to charge the batteries and provide
recomm ends a schedul ed inspecti on
to the electrical system and the night lights. Caterpillar
of the alternator for loose connections and proper battery charging .
•
Key Switch
on it
The Key Switch controls current to all the electric circuits on the drill. When it is turned
Compre ssor starting circuit, and power
supplies power through Wire #7 to the Engine and
s the
through Wire #6 to the Drill and Operating Lights circuit. The key switch also energize
the end of this section
ECM (Electronic Control Module). Refer to the Electric Schematics at
for further information.
Circuit Breakers
the drill's
A bank of five (5) circuit breakers, located on the operator's control panel, protect
the current produce r, batteries or
electrical circuits. The circuit breakers are mounted between
an overload of a circuit, it is
alternator and the devices they are protecting. In the event of
necessary to press in the tripped circuit breaker.
NOTICE
of the overload
If there is a recurrence, call for service assistance to correct the cause
in the circuit.
Table 1: Circuit Breakers
Breaker 1 15 Amp Engine and Compressor Starting Circuit

Drill and Operating Lights
•
Breaker 2 15 Amp
Breaker 3 15 Amp Drill Functions Circuit
Breaker 4 15 Amp Engine Monitoring System (EMS) Circuit
Breaker 5 15 Amp Electronic Air Regulation System (EARS) Circuit
7-7
DRILLING SOLUTIONS
Push Buttons
The push button switch, located on the control console, enables the operato
r to start the
engine when the key switch is "ON". This push button switch is spring
loaded to disconnect
power when it is released.
Relays
A starter relay is connected between the starter button and the starter
motor that energizes
the starter solenoid switch. The starter relay actually engages the starter
motor. There are two
parts to any relay; a coil and at least one set of contacts (points). The
coil physically changes
the condition of the contacts from normally open to closed or vice versa.
There can be several
sets of contacts for one coil.
Relays are used in several circuits on the drills and the schematics do
not always show how
they interact with each other.
A relay consists of a coil connected to one or more sets of contacts. When
the coil is energized,
the solenoid pulls the other contacts downward. In some cases, this disconn
ects a circuit while
in others it makes a new circuit. For example, the shutdown relay R1
has a coil marked R1.
This coil is connected physically to R1A, a normally closed contact. RIB
is a normally open
contact, connected physically, that becomes energized when R1 is energiz
ed. Even though
the schematic shows the elements in different places, they are actuall
y made up of a single
device.
NORMAL
OPERATION
All shutdown devices are in the open mode during normal running conditi
ons and are
connected to the R1 Relay coil.
ir 111.1111,111•1•08/01=ROM
Power
R1A
(3,
No Power
FV
i -561
Fuel Valve
1161
Ground
• 1•11111..=•=61=1.1•11.1•11.1=11.1•1 114
/1/
7-8
DRILLING SOLUTIONS
Section 7 - Systems/Troubleshooting T3W Instruction Manual
device
Should an abnormal condition occur in any of these circuits, the appropriate monitoring
d, it moves
will close and cause R1 relay coil to become energized. When R1 coil is energize
the flow
the R1A contacts from a normally closed position to an open position. This interrupts
the engine. It also cuts off current to the red light in the
to the Fuel Solenoid and shuts down
Emergency Stop Button.
oil
If the engine was at high idle (1800 RPM) when the shutdown occurred, the high pressure
switch may shut the engine down.
RI B HOLDS
POWER OFF
try to
If the oil pressure remained higher than 10 psi, but lower than 27 psi, the engine would
When current is interrupt ed to the Fuel
restart at low idle. For this reason we added R1B.
Solenoid, it must remain off until the engine stops. To insure this happens, RIB supplies
current to R1 coil continuously to keep it from cycling.
Tachometer
ter is
The tachometer shows the RPM of the engine while the engine is running. The tachome
Since engine speed controls pump speed, it
calibrated in RPM x 100 with a range of 0 to 30.
is important to maintain certain RPM speeds when performing various functions .
Emergency Engine Shutdown

stops
Pushing the emergency engine shutdown switch shuts off power to the fuel valve which
fuel flow and shuts the engine down. Turning the key switch does the same thing. All engines
fuel.
are "energized to run", which means the fuel system must be energized in order to pump
Engine Electronics
Engine
The C15 Engine has a comprehensive, programmable Engine Monitoring System. The
of the
Control Module (ECM) has the ability to monitor the engine operating conditions. If any
te
engine parameters extend outside an allowable range, the ECM will initiate an immedia
action.
and
The following actions are available for engine monitoring control: WARNING, DERATE
and/or
SHUTDOWN. These engine monitoring modes have the ability to limit engine speed
the engine power.
7-9
DRILLING SOLUTIONS
Many of the parameters that are monitored by the ECM can be programmed
for the engine
monitoring functions. The following parameters can be monitored as a part
of the Engine
Monitoring System: Operating Altitude, Engine Coolant Level. Engine Coolan
t Temperature,
Engine Oil Pressure, Engine Speed, Fuel Temperature, Intake Manifold Air
Temperature and
System Voltage.
The Engine Monitoring package can vary for different engine models and
different engine
applications. However, the monitoring system and the engine monitoring control
will be similar
for all engines.
Note: Many of the engine control systems and display modules that are availab
le for
Caterpillar Engines will work in unison with the Engine Monitoring System
. Together, the two
controls will provide the engine monitoring function for the specific engine
application.
Gauges and Indicators

Your engine may not have the same gauges or all of the gauges that are describ
ed. For more
information about the gauge package, refer to the parts book information
for your drill.
Gauges provide indications of engine performance. Ensure that the gauges
are in good
working order. Determine the normal operating range by observing the gauges
over a period
of time.
Noticeable changes in gauge readings indicate a potential problem with a
gauge or with the
engine. Problems may also be indicated by gauge readings that change even
if the readings
are within specifications. Determine and correct the cause of any significa
nt change in the
readings. Consult your Atlas Copco distributor or Cat dealer for assistance.
EMERGENCY
TACHOMETER ENGINE FUEL OIL PRESSURE
SHUTDOWN GAUGE GAUGE
DISCHARGE
TEMP
0 INTERSIAGE GAUGE
OR MIESSUJM-
PRESSURE
4 0
WATER
S 0
NESSUS' WHERNITEN FUEL LEVEL TEMP
GAUGE
COMMIESSEM
DISCHARGE WATER
Mort ITMPERATURE IIMPFNATIIRE
2
POWERVIEW
nommamc DIAGNOSTICS
0 VIEWER
LIGHTS
01AG/4051'1C
FEED PRESSURE Fl TEl

Ce
El ASS ETHER START ON LE
THROTTLE
ECM
FILTER
BYPASS
7-10
DRILLING SOLUTIONS
Tachometer
This gauge indicates engine speed (rpm). When the throttle control is moved to the full throttle
position without load, the engine is running at high idle. The engine is running at the full load
rpm when the throttle is at the full throttle position with maximum rated load.
NOTICE
Engine overspeed may cause serious damage. Keep the tachometer indicator in the
green operating range.
Note: The high idle rpm and the full load rpm are stamped on the Information Plate.
Emergency Engine Shutdown
The Emergency Engine Shutdown has a red light that comes on when the fuel system is
energized. If the light goes out, it normally means that the engine fuel system is not operating.
Pushing the Emergency Engine Shutdown shuts off power to the fuel valve which stops fuel
flow and shuts the engine down. Turning off the key switch does the same thing. All engines
are "energized to run", which means the fuel system must be energized in order to pump fuel.
• Fuel Gauge
The fuel level gauge monitors the level of fuel in the fuel tank for the deck engine. The fuel
level gauge is electronically operated. The fuel gauge is shown in increments of EMPTY, 1/4,
1/2, 3/4 AND FULL. The fuel gauge only registers when the key switch is ON.
Oil Pressure Gauge
The oil pressure should be greatest after a cold engine is started. The pressure will decrease
as the engine warms up. The pressure will increase when the engine rpm is increased. The
pressure will stabilize when the engine rpm is stable.
A lower oil pressure is normal at low idle. If the load is stable and the gauge reading changes,
perform the following procedure:
1. Remove the load.

2. Reduce engine speed to low idle.
3. Check and maintain the oil level.
NOTICE
There is pressure monitoring system on the engine that will shut down
•
the engine immediately in the event that the oil pressure drops below 10
psi on LOW idle or less than 27 psi on HIGH idle; otherwise the engine
could be severely damaged. Check the oil level according to the
instructions provided in the Maintenance Instructions. Refer to engine
diagnostics section for checking engine problems.

Compressor Discharge Temperature Gauge
While compressing air, heat is formed. Oil is pumped into the airend to cool this air. The
discharge temperature gage is a Murphy switchgage consisting of a gauge on the operator's
control panel that shows the temperature of the oil and air leaving the air end. Normal
operating temperatures are 180°F-220°F (82°C-104°C). This gauge also contains a switch
that will stop the engine if the oil temperature in the compressor exceeds 248F° (120°C).
Water Temperature Gauge
The Engine Water Temperature Gauge shows the temperature of the engine coolant system
in both F and C scales. Normal operating temperature is from 150°-208°F (65°-98°C). The
system will shut down if the temperature exceeds 210°F (99°C).
PowerView Diagnostic Viewer
The PowerView system is comprised of the PowerView and MLink PowerView Gauges. It is a
multifunction tool that enables the operator to view many different engine parameters and
engine service codes. It includes a graphical backlit LCD screen and has excellent contrast
and viewing from all angles. Back lighting can be controlled via menu or external dimmer
potentiometer. The display can show a single parameter or a quadrant display showing 4
parameters simultaneously. Diagnostic capabilities include fault codes with text translation for
the most common fault conditions. Enhanced alarm indication with ultra bright alarm and
shutdown LEDs (amber & red).
Filter Bypass Indicator Light
The Filter Bypass Indicator Light indicates oil is bypassing the return filter elements located in
the hydraulic reservoir. This indicates that it is time to change the return filter elements.
ECM Indicator Light
The ECM (Engine Control Module) Indicator Light signals fault codes of the engine protection
system, plus battery voltage above or below normal.
Cat Monitoring System

The Monitoring System is designed to alert the operator to an immediate problem with any of
the engine systems that are monitored. The Monitoring System is also designed to alert the
operator to an impending problem with any of the engine systems that are monitored.
NOTICE
The Engine Monitoring System is not a guarantee against catastrophic failures.

Programmed delays and derate schedules are designed to minimize false alarms and
provide time for the operator to stop the engine.
7-12
DRILLING SOLUTIONS
"Warning / Derate / Shutdown"
A WARNING
If the Shutdown mode has been selected and the warning indicator activates, engine
shutdown may take as little as 20 seconds from the time the warning indicator is
activated. Depending on the application, special precautions should be taken to avoid
personal injury.
Sensors and Electrical Components
Coolant Temperature Sensor
The engine coolant temperature sensor monitors the temperature of the engine coolant. The
coolant temperature signal is sent to the Electronic Control Module (ECM) for engine
monitoring and for improved engine control. The signal is used by the ECM for all of the
following engine functions: engine timing control, engine operating mode and engine
protection.
The ECM is capable of adjusting the engine timing relative to the engine operating
temperature. The concept of dynamic timing provides the engine with the ability to control
exhaust emissions. Timing control also aids in white smoke cleanup during cold engine
operation.
The ECM also uses the signal from the engine coolant temperature sensor to determine the
mode of operation for the engine. Several aspects of engine operation are affected by the
engine operating mode: acceleration ramp rates, engine timing and fuel injector timing.
Coolant Temperature Protection
Excessive engine coolant temperature is an undesirable operating condition. Serious damage

to the engine can result if the coolant level is too low or too high and the engine is allowed to
overheat. If the engine coolant temperature increases to excessive levels, the engine
monitoring system will initiate actions that will protect the engine from damage.
Coolant Level Sensor
The coolant level sensor is an optional sensor. This sensor monitors the engine coolant in the
cooling system expansion tank. The coolant level sensor signal is sent to the ECM for the
purpose of engine monitoring.
Engine Oil Pressure Sensor
The engine oil pressure sensor provides an oil pressure signal to the Electronic Control
Module (ECM) for the purpose of engine monitoring. The electronic signal is compared to an
Oil Pressure Map that is stored in EC Memory. The Oil Pressure Map is derived from a direct
relationship between engine speed and the oil pressure that is expected at that speed.

The engine monitoring system records a low engine oil pressure condition in ECM memory if
the sensor value is not within the proper range. The monitoring system then initiates protective
measures.
Low engine oil pressure is an undesirable operating condition.

When a low oil pressure condition exists in the engine, there is a possibility of damage to major
engine components. Low oil pressure protection is a safety feature that will take the necessary
measures in order to initiate an engine shutdown in the event of a low oil pressure condition.
Fuel Temperature Sensor
The fuel temperature sensor monitors the inlet fuel temperature. The Electronic Control
Module (ECM) utilizes the signal from the fuel temperature sensor to provide fuel temperature
compensation for the engine fuel control system. Fuel temperature compensation provides the
following benefits:
1. Rated engine horsepower regardless of fuel temperature.

2. Highly accurate fuel rates and fuel consumption rates.
3. Optimum fuel economy.
Changes in the temperature of the fuel affects the power output of the engine. The ECM
adjusts the engine fuel rate according to the temperature of the fuel. This feature allows full
engine power to be realized by the operator at any fuel temperature.
High Fuel Temperature is an undesirable operating condition.

Fuel temperature will also affect the calculation of fuel consumption rate that is performed by
the ECM. The ECM utilizes the fuel temperature signal to provide an adjusted value for these
calculations.
Fuel Pressure Sensor
The fuel pressure sensor monitors filtered fuel pressure. Although fuel pressures that are
outside the normal operating range may adversely affect engine performance, there should
not be any noticeable reduction in the engine horsepower. Abnormal fuel pressure will not
cause an engine shutdown. A low filtered fuel pressure may indicate that the low pressure fuel
system requires maintenance.
The fuel pressure sensor measures the fuel pressure after the fuel has been filtered. The
sensor connector for the fuel pressure sending unit is located on the machine side of the
machine connector. For more information, refer to the actual manufacturer Troubleshooting
Guide for this engine.
For more information on fuel system maintenance, refer to the maintenance section in the
actual manufacturer Operation and Maintenance Manual.

Air Inlet Temperature Sensor
AWARNING
Excessive inlet air temperature is an undesirable operating condition.
The air inlet temperature sensor detects the temperature of the air that is passing through the
inlet manifold. A signal is sent to the Electronic Control Module (ECM) for interpretation.
The ECM uses the information from the inlet air temperature sensor in order to accurately
control the emissions levels of the engine. As the inlet air temperature changes, the fuel
injection timing is advanced. This is done in order to maintain the exhaust emission standards.
Atmospheric Pressure Sensor
The atmospheric pressure sensor measures the pressure in the crankcase. This sensor
assumes that crankcase pressure is a representation of atmospheric pressure. A signal is sent
to the Electronic Control Module (ECM).
The ECM utilizes the value that is read by the atmospheric pressure sensor for the following
functions:
1. Reference source for pressure sensor calibrations

2. Calculating the operating altitude
3. Calculating boost pressure
4. Checking for air inlet restriction
When the ECM is powered, all of the pressure. sensors that are used for engine monitoring
receive an automatic calibration. The ECM uses the value that is received from the
atmospheric pressure sensor to calculate the pressure offset value.
The ECM also utilizes atmospheric pressure to determine the active engine derate during high
elevation operation. The engine monitoring system compares the current atmospheric
pressure value to the programmed derate set point. The engine is derated by limiting the fuel
delivery at a rate of approximately 3 percent for each 1000 ft. (304 m) of elevation.
Actual boost pressure is calculated by the ECM. The difference between the turbocharger
outlet pressure and the atmospheric pressure is equal to the actual boost pressure. Boost
pressure is used for calculating fuel system adjustments.
Turbocharger Outlet Pressure Sensor
The turbocharger outlet pressure sensor measures the pressure of the turbocharged after
cooled air from a port in the air inlet manifold. The sensor provides a signal to the Electronic
Control Module (ECM) that is used to calculate turbocharger boost pressure. The ECM derives
boost pressure by taking the difference between the turbocharger outlet pressure and the
atmospheric pressure.

Engine boost and actual engine speed are used by the ECM to govern the fuel air ratio control
and the fuel rack limiting functions. During a change in speed or a change in load, the ECM
adjusts the fuel injector delivery and the engine timing in order to provide maximum engine
response while minimizing the transient smoke levels.
Engine Monitoring and Protection
Pre Tier 11 Engines: The system operation that is described above outlines the importance of
a valid signal from the turbocharger outlet pressure sensor. If this signal becomes suspect,
erratic operation of the engine could result. The ECM will compensate by applying a default
signal to all control functions that utilize the signal. The ECM will use the default signal while
the diagnostic code remains in the ACTIVE state. The diagnostic condition will be displayed
for the operator and the engine will continue to operate.
Speed Timing Sensor
If primary speed timing sensor cannot sense engine speed, the ECM "Diagnostic" lamp will
indicate a diagnostic fault code. The diagnostic fault code will be logged into the memory of
the Electronic Control Module (ECM).
If primary speed timing sensor cannot sense engine speed, the automatic default will use
secondary speed timing sensor. The secondary speed timing sensor will be used until the
primary speed timing sensor is replaced. The engine will shut down if both speed timing
sensors fail.
Failure of the Speed Timing Sensor
If any of the following conditions are present, a failure of the speed timing sensor may have
occurred:
1. The speed timing sensor output has opened.

2. The speed timing sensor is shorted to ground.
3. The speed timing sensor is shorted to supply.
4. The speed timing sensor is missing pulses.
5. The speed timing sensor has extra pulses.
Intermittent failure causes erratic engine control. The electronic control system will detect a
failure of the primary speed timing sensor. The operator will be warned through the ECM
"Diagnostic" lamp and PowerView display screen.
Engine Speed Governing
The engine speed governor monitors the throttle position and actual engine speed (rpm) in
order to help control the following items: engine speed, response, torque output and smoke
limiting. The engine speed governor also helps to maintain constant engine speed.The engine
speed is controlled by the governing of the fuel injection duration of the electronic unit
injectors. Throttle input is used to calculate the desired engine speed.

Engine Diagnostics
Self Diagnosis
The electronic control module has some self diagnostic ability. When an electron
ic problem
with an input or an output is detected, a diagnostic code is generated. This indicate
s the
specific problem with the circuitry.
Diagnostic codes are also generated when an abnormal engine operating conditio
n is
detected. For example, a diagnostic code will be generated if the low oil pressur
e alarm is
activated. In this case, the diagnostic code indicates the symptom of a problem
. This type of
diagnostic code is called an event. An event is triggered by the detection of
an abnormal
engine operating condition.
A diagnostic code which represents a problem that currently exists is called an
active code.
A diagnostic code that is stored in memory is called a logged code. Always
service active
codes prior to servicing logged codes. Logged codes may include the followin
g categories:
1. Intermittent problems
2. Recorded events
3. Performance history
Logged codes may not indicate that a repair is needed. The problems may have
been repaired
since the logging of the code. Logged codes may be helpful to troubleshoot intermitt
ent
problems.
ECM "Diagnostic" Lamp
The ECM "Diagnostic" lamp is used to indicate the existence of an active fault
by flashing
codes. The ECM "Diagnostic" lamp flashes simultaneously with the PowerView display
screen
flashes.
When the ignition switch is first turned on, the ECM "Diagnostic" lamp will go through
the
following procedure:
1. The ECM "Diagnostic" lamp will come on and the ECM "Diagnostic" lamp will
remain on for five seconds. This checks the operation of the lamp.
2. The ECM "Diagnostic" lamp will turn off.
3. The ECM "Diagnostic" lamp will come on again and the ECM "Diagnostic" lamp
will flash codes for any active diagnostic codes. Not all diagnostic codes have
a unique flash code.
4. The ECM "Diagnostic" lamp will turn off for five seconds.
5. The ECM "Diagnostic" lamp repeats all active diagnostic codes.
A fault diagnostic code will remain active until the problem is repaired. The electron
ic control
module will continue flashing the flash code at five second intervals until the problem
is
repaired.
DRILLING SOLUTIONS
7-17
Diagnostic Flash Code Retrieval

codes,
Problems with the electronic control system are reported via these types of codes: flash
SPN/FMI codes, diagnostic codes and special event codes.
Table 2: Cross Reference for Diagnostic Codes
Diagnostic
Flash SPN(*1)/ Code or
Description of Code
Code FMI Code Event
Code
N/A 1387-15 E443 (*2) High Auxiliary Pressure Warning
1387-16 High Auxiliary Pressure Derate
1387-00 High Auxiliary Pressure Shutdown
0441-15 E445 (*2) High Auxiliary Temperature Warning
0441-16 High Auxiliary Temperature Derate
0441-00 High Auxiliary Temperature Shutdown
626-05 545-05 Ether Start Relay open/short to +batt
2417-05 Ether Injection Control Solenoid open/

short to +batt
626-06 545-06 Ether Start Relay short to ground
2417-06 Ether Injection Control Solenoid short to

ground
1835-03 1835-03 Auxiliary Pressure Sensor open/short to

+batt
1835-04 1835-04 Auxiliary Pressure Sensor short to ground
1836-03 1836-03 Auxiliary Temperature Sensor open/short

to +batt
1836-04 1836-04 Auxiliary Temperature Sensor short to

ground
111-02 111-02 Engine Coolant Level Sensor Loss of

Signal
13 174-03 173-03 Fuel Temperature open/short to +batt
174-04 174-04 Fuel Temperature short to ground
21 678-03 41-03 8 Volt DC Supply short to +batt
678-04 41-04 8 Volt DC Supply short to ground

Flash
Code
SPN(*1)/
FMI Code
Diagnostic
Code or
Event
Code
Description of Code
21 620-03 262-03 5 Volt Sensor DC Power Supply short to

+batt
1079-03
620-04 262-04 5 Volt Sensor DC Power Supply short to
ground
1079-04
24 100-03 100-03 Engine Oil Pressure open/short to +batt
100-04 100-04 Engine Oil Pressure short to ground
100-10 100-10 Engine Oil Pressure abnormal rate of
change
25 102-03 102-03 Boost Pressure Sensor short to +batt
•
102-04 102-04 Boost Pressure Sensor short to ground
102-10 102-10 Boost Pressure Sensor abnormal rate of
change
26 108-03 274-03 Atmospheric Pressure open/short to +batt
108-04 274-04 Atmospheric Pressure short to ground
27 110-03 110-03 Engine Coolant Temperature open/short
to +batt
110-04 110-04 Engine Coolant Temperature short to
ground
28 91-13 91-13 Throttle Position calibration required
32 91-08 91-08 Throttle Position signal abnormal
34 190-08 190-08 Engine Speed signal abnormal
723-08 342-08 Secondary Engine Speed abnormal
35 190-15 E362(*2) Engine Overspeed Warning
190-00 Engine Overspeed Shutdown
37 94-03 94-03 Fuel Pressure open/short to +batt
•
94-04 94-04 Fuel Pressure short to ground
38 105-03 172-03 Intake Manifold Air Temp open/short to
+batt
105-04 172-04 Intake Manifold Air Temp short to ground

Diagnostic
Flash SPN(*1)/ Code or
Description of Code
Code FMI Code Event
Code
42 637-13 261-13 Engine Timing calibration required
46 100-17 E360(*2) Low Engine Oil Pressure Warning
100-18 Low Engine Oil Pressure Derate
100-01 Low Engine Oil Pressure Shutdown

51 168-00 168-00 System Voltage high
168-01 168-01 System Voltage low
168-02 168-02 System Voltage intermittent/erratic
56 630-02 268-02 Check Program Parameters
58 639-09 247-09 J1939 Data Link communications

61 110-15 E361(*2) High Engine Coolant Temp Warning
110-16 High Engine Coolant Temp Derate
110-00 High Engine Coolant Temp Shutdown
62 111-17 E2143(*2) Low Engine Coolant Level Warning
111-18 Low Engine Coolant Level Derate
111-01 Low Engine Coolant Level Shutdown
63 94-15 E096 High Fuel Pressure Warning
64 1636-15 E539(*2) High Inlet Air Temperature Warning
1636-00 High Inlet Air Temperature Shutdown
65 174-15 E363(*2) High Fuel Temperature Warning
174-16 High Fuel Temperature Derate
174-00 High Fuel Temperature Shutdown
71 651-05 001-05 Injector Cylinder 1 open circuit
651-06 001-06 Injector Cylinder 1 short
651-11 001-11 Injector Cylinder #1 fault

Flash
Code
SPN(*1)/
FMI Code
Diagnostic
Code or
Event
Code
Description of Code

•
(*1) Suspect Parameter Number

(*2) Caterpillar Electronic Technician (ET) will display the number 1, 2, or 3 after the event
code to designate a warning, a derate or a shutdown.

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Description
The PowerView has been developed to meet the needs for instrumentation and control on
electronically controlled engines communicating using the SAE J1939 Controller Area
Network (CAN).

POWERVIEVV
The PowerView is a multifunctional tool that enables operators to view many different engine
parameters and service codes. The PowerView includes a graphical backlit LCD screen. The
display can show either a single parameter or a quadrant display showing four parameters
simultaneously. Diagnostic capabilities include fault codes with text translation for the most
common fault conditions. The PowerView has four buttons using self-calibrating charge
transfer activation technology, which eliminates the concern for pushbutton wear and failure.
The enhanced alarm indication has ultra bright alarm and shutdown LRDs (amber & red). It
has a wide temperature range of -40°F to +185°F (-40°C to +85°C), display viewing -40°F to
+167°F (-40°C to +75°C), and increased environmental sealing to +/- 5 PSI (±35kPa).
•
Other components in the system are microprocessor PowerView Gages for displaying critical
engine data broadcast by an electronic engine Engine Control Unit (ECU): engine RPM, oil
pressure, coolant temperature, system voltage, etc. and a combination audible alarm and
relay unit for warning and shutdown annunciation.
Faceplate Features and Keypad Functions
AMBER - - RED SHUTDOWN

WARNING LIGHT DERATE KEY
DISPLAY -- - BEZEL
MENU KEY -- -- ENTER KEY
/
LEFT ARROW KEY (SCROLL UP) RIGHT ARROW KEY (SCROLL DOWN)
The keypad on the PowerView is a capacitive touch sensing system. There are no mechanical
switches to wear or stick. It operates in extreme temperatures; with gloves, through ice, snow,
mud, grease, etc., and it allows complete sealing of the front of the PowerView. The "key is
touched" feedback is provided by the flashing screen. The keys on the keypad perform the
following:
•
Menu Key - The menu key is touched to either enter or exit the menu screens.
Left Arrow Key - The left arrow key is touched to scroll through the screen either moving the
parameter selection toward the left or upward.

Right Arrow Key - The right arrow key is touched to scroll through the screen either moving
the parameter selection toward the right or downward.
Enter Key - The enter key, also known as Enter Button is touched to select the parameter that
is highlighted on the screen.
Mechanical Installation
Typical Quick Connect Installation

Last PVA Gage or
PVAA Audible Alarm To optional
To PVAA external device
Audible Alarm
Terminating
Resistor PVJR Relay N.O.
POWERVIEW Relay N.C.
PV100 OR Ext. Sonalert
Relay Comm.
Optional PVW-A wire harness

(includes terminating resistor)
•
Next PVA Gage
Wire
Harness
PVW-J
TO DRILL
HARNESS
WIRING
Wire Harness PVW-P Wire Harness PVW-J
Electrical Installation
PowerView Unit Back View

Deutch DTO6-6S Style Connections
Plug A Plug B
PIN 1 CAN LO RN 4 CAM IINLD

POI S Nome
PIN 2 CAN NI V PottNNionielec
-C
PIN I V. PIN 6 GaND
Recommended Connectors:
Body: Deustch DT06-6S
Wedge Lock: W6S
Terminals: 0462-201-16141
Sealing Plug: 114017

PowerView Operation
1. When power is first applied to the PowerView, the "Logo" is displayed.

2. The "Wait to Start" message will be displayed for engines with a pre-startup
sequence. Once the "Wait to Start" message is no longer displayed the
operator may start the engine. Note: Displays only when SAE J1939 message
is supported by engine manufacturer.
3. Once the engine has started the single engine parameter is displayed.
Main Menu Navigation
0 1500
1800 RPM
ENG RPM
3000
COOL TEMP
r1
1. Starting at the single or four engine parameter display, touch "Menu".
1
.
!
98%
.0Y) •.....
4.2
I.. ..0..
11000 RPM
57 PSI
CG
•
(
2. The first seven items of the "Main Menu" will be displayed. Touching the "Arrow
Buttons" will scroll through the menu selection.
GO TO 1-UP DISPLAY
LANGUAGES
STORED COOES
ENGINE CONF
SETUP I-UP DISPLAY
SETUP 4.UP DISPLAY
SELECT UNITS
3. Touching the right arrow button will scroll down to reveal the last items of "Main
Menu" screen highlighting the next item down.
ADJUST BACKLIGHT
ADJUST CONTRAST
UTILITIES
7-25
4. Use the "Arrow Buttons" to scroll to the desired menu item or touch "Menu
Button" to exit the Main menu and return to the engine parameter display.
CO TO1-UP DISP ',A

LANGUAGES 98%
4:1161*
1000 RPM
ENO NY
STONED CODES
ENGINE CONE
SETUP /-UP DISPLAY
SETUP WP DISPLAY 14.2 I 57 PSI
1111•01,11 1:14
SELECT MRS fa,
Co 0
Engine Configuration Data
1. Starting at the single or the four engine parameter display touch the "Menu
button".
11.11116111111 1 1 98% 1000 RP M

1300 3000 1.0.••••• I MI WU
1800 RPM 14.2 I 57 PSI

ENG RPM COOL TEMP
2. The main menu will pop up on the display. Use the "Arrow Buttons" to scroll
through the menu until the "Engine Configuration" is highlighted.
GO TO 4-UP DISPLAY
. I .0.1
STORED FAULT CODES
ADJUST BACKLIGHT
ADJUST CONTRAST
SELECT UNITS
SETUP 1-UP DISPLAY
00
3. Once the "Engine Configuration" menu has been highlighted touch the "Select
Button" to view the engine configuration data.
GO TO 4-UP DISPLAY
ENGINE CONFIGURATION
STORED FAULT CODES
ADJUST BACKLIGHT
ADJUST CONTRAST
SELECT UNITS
SETUP 1-UP DISPLAY

4. Use the "Arrow Buttons" to scroll through the engine configuration data.
ENGINE CONFG DATA
90
%TORQUE RPM&IDLE
J
5. Touch the "Menu Button" to return to the main menu.
GO TO 4-UP DISPLAY
3:2g
OTORED
ADJUST FAULT CODED
BACKUGHT
ADJUST CONTRAST
SELECT UNITS
SETUP 1-UP DISPLAY
6. Touch the "Menu Button" to exit the Main menu and return to the engine
parameter display.
t•I1/12
ENGINE 4":111
CONFIGURATION
STORED
ADJUST FAULT CODES
SACKIJGHT
ADJUST CONTRAST
SELECT1-UP
UNITSDISPLAY
SETUP
Stored Fault Codes
1. Starting at the single or the four engine parameter display touch the "Menu
button".
Ii1111111111111111111110111111111111111
1800 RPM
MPG RPM MRS OIL
•
through the menu until the Stored Fault Codes is highlighted.
GO TO 4-UP DISPLAY
4214111141L11111P:41Ca:MMIll
ADJUST BACKLIGHT
ADJUST CONTRACT
SELECT uNrre
SETUP 1-UP DISPLAY
3. Once the "Stored Fault Codes" menu item has been highlighted touch the
"Enter Button" to view the "Stored Fault Codes" (when applicable, consult
engine manufacturer for the SAE J1939 supported parameters).
REQUESTING
FAULT CODES
Co
4. If the word "MORE" appears above the "Arrow Buttons" there are more stored
fault codes that may be viewed. Use the "Arrow Buttons" to scroll to the next
"Stored Diagnostic Code".
lox SHUTDOWN
WARNING
SPN110 FMI10
HIGH COOLANT TEMP
4 YORE P HIDE
5. When the arrow appears to the right of the word -MORE" continue to scroll to
the right to see more 'Stored Diagnostic Codes". If the arrow shifts to the left
side of the word "MORE" the end of the stored codes has been reached. Press
the left "Arrow Button" to review the stored codes.

• 6. Touch the "Menu Button" to return to the main menu.
1—O0 TO 4-UP DISPLAY

I ENGINE CONFIGURATION
STORED FAULT CODES
ADJUST BACKLIGHT
ADJUST CONTRAST
SELECT UNITS
SETUP 1•UP DISPLAY
Cry Co
7. Touch the "Menu Button" to exit the Main menu and return to the engine
parameter display.
Faults and Warnings
Auxiliary Gauge Fault
1. During normal operation the single or four parameter screen will be displayed.
• a 1S00
1800 RPM
ENG RPM COOL TEMP
3000
98%
1.400.111,61
14.2
tat toLt
1
1000 RPM
57 PSI
I1N Mit
2. The PVA Series auxiliary gauges can be attached to the PowerView. These
auxiliary gauges communicate with the Modbus master PVA Series gage via a
daisy-chained RS-485 port. If at any time -during system initialization or normal
operation an auxiliary gauge should fail, the single or four parameter screen will
be replaced with the "MLink Gauge Fault" message. The screen title "MLink
Gage Fault" will flash.

3. To acknowledge and "Hide" the fault and return to the single or four parameter
display touch the "Select Button".
ENGINE OIL PRESSURE

GAGE NOT RESPONDING
co
4. The display will return to the single or four parameter screen.
1111111111111111111111111111111111111111 98% 0 RPM

1800 RPM
MPG RPM HRS OIL 14.2 I 57 PSI
Pi MO
IPS RAS
0 Indicates Auxiliary Gage Fault
Indicates Fault Warning
0 Indicates Derate or Shutdown Condition Fault
5. Touching the "Select Button" will re-display the hidden fault. Touching the
"Select Button" once again will hide the fault and return the screen to the single
or four parameter display. Note: The fault can only be cleared by powering the
system down, removing or replacing the auxiliary gauge.
Active Fault Codes
1111111111111111111111111111111111111111 0 RPM
1800 RPM
MPG RPM HRS OIL
14.2 I 5.7.PSI
(Ye 00 Oc) off

2. When the PowerView receives a fault code from an engine control unit the
single or four parameter screen will be replaced with the "Active Fault Codes"
message. The screen title will flash between the two messages "Active Fault
Codes" and "Warning".
orx ACTIVE FAULT CODES
SPN110 FM10
HIGH COOLANT TEMP
41 MORE 11.' HIM
3. If the word "MORE" appears above the "Arrow Buttons" there are more active
fault codes that may be viewed. Use the "Arrow Buttons" to scroll to the next
"Active Fault Code".
ACTIVE FAULT CODES

SPN110 FI1110
HIGH COOLANT TEMP
.4 MO I. MIpE
4. When the arrow appears to the right of the word "MORE", continue to scroll to
the right to see more "Active Fault Codes". If the arrow shifts to the left side of
the word "MORE", the end of the active codes has been reached. Touch the left
"Arrow Button" to review the active fault codes.

5. To acknowledge and "Hide" the fault and return to the single or four parameter
display touch the "Select Button".
or x ACTIVE FAULT CODES

SPN110 FM10
HIGH COOLANT TEMP
MORE HIDE
OC)
6. The display will return to the single or four parameter display, but the display
will contain the flashing "Active Fault" warning icon.
IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII
1800 RPM
MPG RPM HRS OIL
7. Touching the "Select Button" will re-display the hidden fault.
ri—or x ACTIVE FAULT CODES

SPN110 FM10
HIGH COOLANT TEMP
MORE NIDE
L
8. Touching the "Select Button" once again will hide the fault and return the screen
to the single or four parameter display. Note: Ignoring active fault codes could
result in severe engine damage.
GO TO 4-UP DISPLAY
STORED FAULT CODES
AD-UST BACKLIGHT.
AL1-UST CONTRAST
SELECT UNITS
SETUP I-UP DISPLAY

Shutdown Codes
IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIUI 98% O RPM

1.1111121111•11
1800 RPM
MPG RPM HRS OIL 1
1.(2. I 57
1,PSI
2. When the PowerView receives a severe fault code from an engine control unit
the single or four parameter screen will be replaced with the "Shutdown"
message. The screen title will flash the message "Shutdown!".
3. To acknowledge and "Hide" the fault and return to the single or the four
parameter display, touch the "Select Button".
co
4. The display will return to the single or four parameter display, but the display
will contain the flashing "Shut Down" icon.
IIIUIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII
,98:4 O RPM
1800 RPM 1
57 PSI
•
MPG RPM HRS CO 14.2
Mt 4.1. Olt afiliS

5. Touching the "Select Button" will re-display the hidden fault.
SHUTDOWN
SPN110 FM1O
HIGH COOLANT TFM
YORE MOE
L
6. Touching the "Select Button" once again will hide the fault and return the screen
to the single or four parameter display. Note: Ignoring the Shut Down message
could lead to severe engine damage.
immumuminummiiim 98% 0 RPM

1800 RPM
MPG RPM FIRS OIL 14.2 I 57 PSI
CIL NM
c» /)
Go
Back Light Adjustment
#ve4
1. Starting at the single or four engine parameter display touch the "Menu Button".
GO T04 UP DISPLAY
TION 98% 0 liPM
STORED FAULT CODES
ADJUST BACRUGINT
ADJUST CONTRAST
SELECT UNITS 14.2 51
,PSI
SETUP 1-UP DISPLAY
00
2. The main menu will pop up on the display. Use tie "Arrow Buttons" to scroll
through the menu until the "Adjust Backlight" is highlighted.
GO TO 4-UP DISPLAY
OTORED FAULT CODES
ADJUST BACK I IGHT
ADJUG T CONTRAST
SELECT UNITO
SETUP 1-UP DISPLAY

3. Once the "Adjust Backlight" menu has been highlighted, touch the "Select
Button" to activate the "Adjust Backlight" function.
GO TO 4-UP DISPLAY
STORED FAULT CODES
ADJUST OACKUGHT
ADJUST CONTRACT
SELECT UNITS
SETUP 1-UP DISPLAY
4. Use the "Arrow Buttons" to select the desired backlight intensity.
ADJUST BACKLIGHT
.
)11111011000000113.
..."'"""111111p.
OC__)1_01
GO TO 4-UP DISPLAY
STORED FAULT CODES
: ADJUST BACKLIGHT
ADJUST CONTRAST
I SELECT UNITS
LZETUP 1-UP DISPLAY
6. Touch the "Menu Button" to exit the main menu and return to the engine
parameter display.
GO TO 4-UP DISPLAY
ENGINE CONFIGURATION *fo' 1 0 RPM
STORED FAULT COOES
ADJUST SACICUGHT
ADJUST CONTRAST
SELECT UNITS 14.2
UAT b-.1-1
I 57 PSI
SETUP 7-UP DISPLAY

Contrast Adjustment
1. Starting at the single or four engine parameter display, touch the "Menu
Button".
1111111111111111111111111111111111111Ill
98% 0 RPM
g1,0 0.0.V
1800 RPM
MPG RPM HRS OIL 14.2, I 5,7„PSI
win
through the menu until "Adjust Contrast" is highlighted.
GO TO 4 UP DISPLAY
STORED FAULT CODES
ADJUST BACKLIGHT
ADJUST CONTRAST
SELECT UNITS
SETUP 1-UP DISPLAY
3. Once the "Adjust Contrast" menu item has been highlighted, touch the "Select
Button" to activate the "Adjust Contrast" function.
00 TO 4-UP DISPLAY
OTORED FAULT CODES
ADJUST BACKLIGHT
•DJUST CONTRAST
SELECT UNITS
SETUP 1-UP DISPLAY
4. Use the "Arrow Buttons" to select the desired backlight intensity.
ADJUST CONTRACT
imloonion

•
GO TO 4-UP DISPLAY
STORED FAULT CODES
ADJUST BACKLIGHT
ADJUST CONTRAST
SELECT UNITS
SETUP I-UP DISPLAY
6. Touch the "Menu Button" to exit the main menu and return to the engine
parameter display.
111111111111111111111111111111111E11
98% I 0 RPM
1800 RPM
MPG RPM HRS OIL 14.2. IF: 57 PSI
j MT Tr1.T .iKD
Y 0
• Select Units
1. Starting at the single or four engine parameter display, touch the "Menu
Button".
1111111111111111111111111111111111111111
98% 0 RPM
1800 RPM
1.2 57 PSI
MPG RPM MRS OIL ma4w 04.104111
through the menu until the "Select Units" is highlighted.
00 TO 4-UP DISPLAY
ENGINE CONFIOURATION
CTORED FAULT CODES
ADJUST BACKLIOHT
ADJUST CONTRACT
SELECT LIMITS
SETUP 140 DISPLAY
DRILLING SOLUTIONS
7-37
4. Three options are available for modification of the 1-Up display.
a. Use Defaults - This option contains a set of engine parameters: Engine

Hours, Engine RPM, System Voltage,% Engine Load a Current RPM,
Coolant Temperature, Oil Pressure, Etc. The OEM factory default has all
available parameters available for display.
b. Custom Setup - This option contains a list of engine parameters. Engine
parameters from this list can be selected to replace any or all the default
parameters. This option can be used to limit the number of parameters
available for scrolling in the 1-Up Display.
c. Automatic Scan - Selecting the scan function will cause the 1-Up Display
to scroll through the selected set of parameters one at a time, momentarily
pausing at each.
5. Use Defaults - To select "Use Defaults" use the arrow buttons to scroll to and
highlight "Use Defaults" in the menu display.
6. Touch the "Select Button" to activate the "Use Defaults" function. This action
will reset the unit to the OEM factory default with all parameters available for
scrolling from the 1-Up Display.
ONE UP
DEFAULTS
SELECTED
7. Custom Setup - To perform a custom setup of the 1-Up Display. use the arrow
buttons to scroll to and highlight "Custom Setup" on the display. Two methods
may be used:
a. Build a list by individually selecting parameters.

b. "Select All Parameters" then de-select those parameters not desired.

ETIM
CUSTOM SETUP
AUTOMATIC SCAN OFF
MIN
8. Touching the "Select Button" will display a list of engine parameters.
PERCENT LOAD AT CURRENT RPM 3

ENGINE OIL PRESSURE 2
numtw
the Orlig or Iircatanc;
mr in; 1:0131114Off,
• 9. Use the "Arrow Buttons" to scroll to and highlight the "Clear All Parameters"
from the menu. Note: Highlighted parameters were previously selected.
10. Press the "Select Button" to clear previously selected parameters.
ENGINE SPEED 1
ENOME OiL PPE=URE 2

11. Use the "Arrow Buttons" to scroll to and highlight the desired parameter. Press
the "Select Button" to select the parameter for inclusion in the 1-Up Display.
ENGINE OPEED 1
ENGINE OIL. PREGGURE 2
12. Continue to scroll through and select the additional parameters for the custom
1-Up Display.
13. Automatic Scan - Selecting the scan function will cause the 1-Up Display to
scroll through the selected set of parameters one at a time. Use the "Arrow
Buttons" to scroll to the "Automatic Scan" function.
14. Touching the "Select Button" toggles the "Automatic Scan" function on.
LIOE DEFAULTC
CLIC:TOM OETUP
AUTOMATIC SCAN ON
15. Touching the "Select Button" again toggles the "Automatic Scan" function off.

16. Once the "Use Defaults", "Custom Setup" and "Automatic Scan" functions have
been set, touch the "Menu Button" to return to the main menu.
GO TO 4-UP DISPLAY
STORED FAULT CODES
ADJUST BACKLIGHT
ADJUST CONTRAST
SELECT UNITS
SETUP 1-UP DISPLAY
17. Touch the "Menu Button" to exit the main menu and return to engine parameter
display.
GO TO 4-UP DISPLAY
ENGNE CONFGURATION
STORED FAULT CODES
ADJUST BACKLIGHT
ADJUST CONTRAST
SELECT UNITS
SETUP 1-UP DISPLAY
4-Up Display Setup
1. From the single or four engine parameter display, touch the "Menu Button".
1111111111111111111111111111111111111111 I 0 RPM
9
1800 RPM
2 4,2, I 57 PSI
MPG RPM HRS OIL .
(",:;\
.12
through the menu until "Setup 4-Up Display" is highlighted.
I ADJUST BACKLIGHT
ADJUST CONTRAST
SELECT UNITS
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
UTILITIES

3. Once the "Setup 4-Up Display" menu item has been highlighted, touch the
"Select Button" to activate the "Setup 4-Up Display" menu.
ADJUST BACKLIGHT
ADJUST CONTRACT
SELECT UNIT
SETUP 1-UP DI;PLAY
SETUP 4-UP DISPLAY
UTILITIES
4. Use the "Arrow Buttons" to select one of the four engine parameter display
locations.
5. Pressing the "Select Button" will bring up a list of engine parameters.
rElTiOltiE ;PEED 1
•ERCENT LOAD AT CURRENT RPU 3
ENGINE OIL PREOCURE 2
6. Use the "Arrow Buttons" to scroll through and highlight the desired engine
parameter.
ENGINE SPEED 1
ENGINE OIL PRECCURE 2

• 7. Pressing the "Select Button" will place the selected parameter in the pre-
selected 4-Up Display Location.
98%
LOAD@RPM
OR PM
ENG RPM
57 PSI _
CUSTOM OIL PREC
8. Use the "Arrow Buttons" to select the next parameter display location.
OR PM
98%
ENG RPM
LOAM:It RPM
14.2 57 nu
CUSTOM OIL PREC
O O
• 9. Press the "Select Button" to view the engine parameter list.
ENGINE SPEED 1
10. Use the "Arrow Buttons" to scroll to and highlight the desired parameter.
ENGINE SPEED 1
•
7-45
DRILLING SOLUTIONS
11. Pressing the "Select Button" will place the selected parameter in the pre-
selected 4-Up Display Location.
98% ORPM
LOAN/RPM ENG RPM
14.2
57 PSI
CUOTOM OK PRES
(o)
12. Repeat the parameter selection process until all spaces are filled. Note: The
parameters in any of the four display locations may be edited and saved without
affecting the other display locations.
13. Press the "Menu Button" to return to the main menu.
98% 0RPM
LOADNPM ENG RPM
14.2
57 PSI
CLIGTOM OIL PRES
14. Press the "Menu Button" to exit the Main menu and return to engine parameter
display.
AD.:UST BACKLIGHT
AC..11IST CC NTRAST
:;ELECT UNI-S
SETUP 1-:./P DISPLAY
SETUP 4-UP DISPLAY
MODBUS COMM
CLEAR ALL GAGES
7-46
DRILLING SOLUTIONS
Utilities
This section is for use with PowerView PVA Gages. The UTILITIES Section below should
be used when working with a FW Murphy Technical Support.
1. Starting at the single or four engine parameter display, press the "Menu
Button".
I1111111111111111111111111111111111111111
1800 RPM
MPG RPM HRS OIL
2. The main menu will be displayed. Use the "Arrow Buttons" to scroll through the
•
menu until the "Utilities" is highlighted.
ADJUOT 'BACKLIGHT
ADJUOT CONTRACT
ELECT UNITO
LETUP 1.UP DICPLAY
LETUP 4-UP DICPLAY
=IIIMM.11111
3. Once the "Utilities" menu item has been highlighted, touch the "Select Button"
to activate the "Utilities" functions. When "Gage Data" is, selected the
PowerView will communicate with the analog gages at a fixed rate of 38.4 k
Baud, 8 data bits, no parity check, .2 stop bits, half duplex.
GA0E8 DATA 110

REMOVE ALL GAGES
COFTWARE VERCION
f /mil t'S\.

4. Press the "Select button" to enter the "Gages Data" display.
'ca. GAGE DATA

ENGINE OIL PRESSURE
ADDRESS: 20
SOFTWARE REVISION N XXX
ERRORS:
5. Use the "Arrow Buttons" to scroll through the items or touch "Menu" to return to
the main menu.
6. Press "Select" to return to the "Utilities" menu.
r90200111111=EIM
.. II
EMCNIT ALL ClAGE
SOFTWARE VERSION
7. Use the "Arrow buttons" to scroll to "Remove All Gages". Then press "Select"
to highlight and enter the menu.
CLEARING ALL GAGES

PLEASE WAIT
ec,
8. After clearing all gages is done, the display automatically returns to the
"Utilities" menu. Scroll to "Software Version" and then press "Select" and the
software version display will flash for a few seconds showing the version used.
9. Press the "Menu Button" to exit the "Utilities" menu and return to the engine
parameter display.

Table 3: J1939 Parameters
SAE
J1939 Description PGN Parameter Display Value
Section
5.3.6 Elec Eng Cont #2 - EEC2 61443 Accelerator Pedal Position Throttle
Percent Load at Current RPM Load@RPM
5.3.7 Elec Eng Cont #1 - EEC1 61444 Actual engine (%) torque Eng Torque
Engine Speed Eng RPM
5.3.19 Engine hours, Revolutions 65253 Total Engine Hours Eng Hrs
5.3.23 Fuel Consumption 65257 Trip Fuel Trip Fuel
Total Fuel Used FuelUsed
5.3.28 Engine Temperature 65262 Engine-Coolant Temp Cool Temp
Fuel Temperature Fuel Temp
Engine Oil Temperature Oil Temp
Engine Intercooler Temp Inte Temp
5.3.29 Engine Fluid Level/Pressure 65263 Fuel Delivery Pressure Fuel Pres
Engine Oil Level Oil Lvl
Engine Oil Pressure Oil Pres
Coolant Pressure Cool Pres
Coolant Level Cool Lvl
5.3.32 Fuel Economy 65266 Fuel Rate Fuel Rate
Instantaneous Fuel Economy Fuel Econ
Average Fuel Economy Avg Econ
5.3.35 Ambient Conditions 65269 Barometric Pressure Baro Pres
Air Inlet Temperature Air In Temp
5.3.36 Inlet/Exhaust Conditions 65270 Boost Pressure Bst Pres
Intake Manifold Temp Mani Tmp
Aie Filter Differential Press. AirDifPr
Exhaust Gas Temperature Exh Temp
5.3.37 Vehicle Electrical Power 65271 Electrical Potential (Voltage) Sys Volt
Battery Pot. Voltage (Switched) Bat Volt

5.3.46 Engine Fluid Level/Press #2 65243 Injector Metering Rail 1 Pres Inj Pres1
Injector Metering Rail 2 Pres Inj Pres2
5.3.58 Fan Drive 65213 Fan Spd
7-49
DRILLING SOLUTIONS
SAE
J1939 Description PGN Parameter Display Value
Section
5.3.111 Auxiliary Temperatures 65164 Auxiliary Temperature Aux Temp

Auxiliary Pressure Aux Pres
Diagnostic Messages ' 65226 DM1 - Active Diagnostic SrvcCode
65227 DM2-Previously Act Diag Codes StorCode
65228 DM3 - Diagnostic Clear
J1939 N/A Machine Hours (PowerView N/A Machine Hours Mach Hrs
Calculated)
5.3.17 Engine Conf. 65251 Engine Configuration Eng Conf

Source: SAEJ1939-71 Surface Vehicle Recommended Practice
Electric Ladder
The electric ladder schematic is a logical way to show how the current flows
in the various
parts of the electrical circuits on a drill. The schematic is broken into six (6)
parts that are
different and serve different purposes.
The first part is the Power Supply. These are the Batteries that supply
all the power to the
system. They are indicated by the two battery symbols.
Battery I il 1.1 id 1111 1

The second part is the Fusible Link that protects against massive
short circuit and fire. It is
always located in the main wiring just beyond the batteries. It is located beyond
the batteries
and between the alternator and the batteries so any high flow of electricity
is prohibited or
stopped from getting to the batteries and causing a fire. Remember that electric
ity flows out of
the batteries but back from the alternator to the batteries. Fuse links are blue
colored and are
9 inches (23 cm) long. They have a ring connector on one end and use a
wire nut to connect
to the main hot wire.
Fusible Link
7-50
DRILLING SOLUTIONS
The Third part is the Key Switch and the Circuit Breakers that protect each separate circuit
and control the power to the whole system.
0 0
Circuit Breaker
Key Switch
The fourth part is the Main Power Wire or Wires. These are the positive or plus (+) wires
that carry the current to each area. They are usually larger in size than the others so they can
carry more current without getting hot.
Main Power Wire
The fifth part is the switch or controller that allows current or disconnects current from the
operating system. These may be push button switches or remotely controlled switches that
cause a change in the system.
Switch
0
The sixth part is the actual Solenoid, Relay, Light or other device that is activated by
supplying power to it or removing power from it.
f0
Fuel
Solenoid Light
The last part is the Return or Ground Wire,that makes a complete circuit and allows the
system to be a system. These wires don't always seem significant but without a good ground
wire the system will not function.
/ / 1/
Ground

Schematics
TA v NAE4.7 0000N0
1
FUSIBLE 1,RA Sg 05 STARTER 74010R1
26540110360
A
SI Oo 57A0TE5 SOLENOID
0
START RELAri
TusoliT I1NK 52 OS STARTER KOT0R2
2456199360 R2
S2
350 0 5 STARTER SOLENOID
START. RELAY 2 fisStseE L1.S OS ALTERNATOR

K=3
02 ORSASSRIA0
TO ER01NE SCR
C81 STARS BUTTON

KEY SwiTCH IS ANws 07 RI
0 04 67 017 OS
OtO SEW OELAT1
265484g/8 CIRCUIT BREAKER 2,52 , 65$32 26 1111 40
2657011406S
12
01 0 IS NELAT2
C112 2659906466
IS Amp. NIGHT L1017 2057142262
oa IB 22 91997 L IGHT ss NOW LIGHT
C1RCu1T MAKE*
uglY i7
26511111401 117614I ((687
2651064055 0 NIGHT LIONT
OS (NIGHT L1651
w ont LgoN7 OS MIOST L1614T
NIONT LIONT 110 NIONT LIONT

CB3
2 SPEED MEAD
0, IS ANN,
2657179608 0 2 SPEED BEAD IOPTIONALI
C1RCViT BREAKER Se 051 RE6E4 ON
v
2457004055 266782808e
DRILL TEED
2 0
PULL MIN VALVE
5 OS
HULL BACK VALVE
2657016484
OS
I6OLAT1041 VALVE PuLLOAC4
2
Agg 1501ATIO6 VALVE PULL DONN
ROTATION
PUMP
OS ROTA7106 Pow.
CONTROLLER COortOstlo
2457818476 .50 I , 1x 19 - SO ROTATION POMP
0
4 SS RoTATI04 POW CLOCKWISE
1 7S ROTATION POOP COUNTERCLOCKWISE
91 $00-EXTEND oS
JIB EXTEND
,2 03 JO RETRACT
DUAL JIB
•SI 11 502-RETRA,?,
CONTROLLER
24.51U6642
1,3 503.$11116 OOT
ti
0 JIB MINS 00T
le 0 JIB SWING II
SO4.01.1466 IN
DUAL JIB
CONTROLLER 4L
t
HELPER SIDE ...2.
2657616602
OS Pp HST01613
OS
OTIAKIE EILEEN BYPASS
SALL VALVE
2657436170
SAITCN N
COS 7650137207 1 OS P DRILL TOPTgONALI
06 •
1 5 MPs
I a 1 OS vEOf SALL VALVETOPTIONALT
0 T , OIAL
INJECTION LDSt
a_c3 SO .24v "
imPu
/ONO INJECTION TOPTgENTALg
.12V 0117
5 A''' 7657119404 F_DO goeiCATOR
0
061TO FLOW INDICATOR (OPTIONAL/
F ON 'lb
SwolcH 2657297637
00 ONO Instil iopi.oNALT
6.10010

7-3 OPERATOR OBSERVED PROBLEMS
General Information
rA WARNING
Read and understand Section 2 - Safety Precautions and Guidelines before you operate
If you are not experienced with the drill's controls and instruments, read and
Unexpected drill motion or moving parts can cut or crush. Shut down the engine before
approved hard hat, safety glasses, steel toed shoes/boots, gloves, respirator and ear
•
protection. Do not wear loose fitting clothing that can become caught on rotating components.
1. Do not increase engine speed to high idle until the engine has been warmed up.
4. Always perform safety checks prior to starting, operating or performing any
crushing risk.
•

During operations, the operator may observe some problems which may be defined in the
following Operator Observed Problems Troubleshooting Chart.
The troubleshooting chart is limited to machine control operational problems which will guide
the operator to rectify the cause of the failure.
Table 4: Trouble Shooting Chart
Problem Cause Correction
Engine will not start. Circuit Breaker Tripped. Reset Circuit Breaker.
(Starter does not rotate).
Emergency Stop Switch Check Emergency Stop
requires resetting. Switch and reset if required
Batteries Discharged. Check Batteries. Recharge
if required.
Fusible link to starter motor Call for service to correct
fused. fault.
Starter Relay fault.
Starter Switch defective.
Starter Solenoid or Starter
defective.
Compressor Switchgage Replace Switchgage.
defective.
Shutdown Relay defective. Replace Relay.
Empty Fuel Tank. Fill Fuel Tank.
Battery cable connections Clean and tighten
loose or disconnected. terminals.
Defective Wiring. Check with test lamp.
Engine difficult to start. Compressor Butterfly Inlet Close Butterfly Inlet Valve
Engine has poor and Valve open while starting. when starting.
irregular performance.
Low Battery power. Check Battery.
Batteries discharged. Charge Batteries if
necessary.
Battery Cable connections Clean and tighten terminal
loose or corroded causing connections.Cover
starter to turn too slowly. connections with acid free
grease.

The Third part is the Key Switch and the Circuit Breakers that protect each separate circuit
and control the power to the whole system.
O 0
Circuit Breaker
Key Switch
The fourth part is the Main Power Wire or Wires. These are the positive or plus (+) wires
that carry the current to each area. They are usually larger in size than the others so they can
carry more current without getting hot.
Main Power Wire
•
The fifth part is the switch or controller that allows current or disconnects current from the
operating system. These may be push button switches or remotely controlled switches that
cause a change in the system.
Switch
The sixth part is the actual Solenoid, Relay, Light or other device that is activated by
supplying power to it or removing power from it.
Fuel
Solenoid Light
The last part is the Return or Ground Wirefriat makes a complete circuit and allows the
system to be a system. These wires don't always seem significant but without a good ground
wire the system will not function.
Ground
7-51
Remember that all power flows from the batteries to the main power line, usually through the
ammeter. You will notice several diodes in the circuits. The symbol is an arrow with a bar
across the end. These act the same as check valves in a hydraulic circuit. They allow current
to flow in one direction but not backwards.
24 Volt battery power means that both 12 volt batteries add together to produce 24 volts.
Batteries in series produce whatever their voltages add up to. Thus, two 12 volt batteries will
produce 24 volts.

•
Electrical Symbols
1111141111 rim A o o
CIRCUIT
BATTERY FUSE LINK AMMETER KEY SWITCH BREAKER
—0--Z15- 0 0
°To
PRESSURE BYPASS EMERGENCY
GROUND SWITCH PUSH BUTTON BUTTON STOP
R1 II
*N 0 SECTION
1•4,
**N C SECTION
0_
TEMPERATURE
COIL (RELAY) of RELAY of RELAY LIMIT SWITCH SWITCrl
,
,
•
FLOAT SWITCH ENCLOSURE MOTOR ALTERNATOR FUEL SOLENOID
\
/
/(1)
LIGHT SWITCH RESISTOR DIODE SHUNT
* N 0 = Normally Open
** N C = Normally Closed

Schematics
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7-3 OPERATOR OBSERVED PROBLEMS
General Information
•
protection. Do not wear loose fitting clothing that can become caught on rotating components.
crushing risk.
•

During operations, the operator may observe some problems which may be defined in the
following Operator Observed Problems Troubleshooting Chart.
The troubleshooting chart is limited to machine control operational problems which will guide
the operator to rectify the cause of the failure.
Table 4: Trouble Shooting Chart
Engine will not start. Circuit Breaker Tripped. Reset Circuit Breaker.
(Starter does not rotate).
Emergency Stop Switch Check Emergency Stop
requires resetting. Switch and reset if required
Batteries Discharged. Check Batteries. Recharge
if required.
Fusible link to starter motor Call for service to correct
fused. fault.
Starter Relay fault.
Starter Switch defective.
Starter Solenoid or Starter
defective.
Compressor Switchgage Replace Switchgage.
defective.
Shutdown Relay defective. Replace Relay.
Empty Fuel Tank. Fill Fuel Tank.
Battery cable connections Clean and tighten
loose or disconnected. terminals.
Defective Wiring. Check with test lamp.
Engine difficult to start. Compressor Butterfly Inlet Close Butterfly Inlet Valve
Engine has poor and Valve open while starting. when starting.
irregular performance.
Low Battery power. Check Battery.
Batteries discharged. Charge Batteries if
necessary.
Battery Cable connections Clean and tighten terminal
loose or corroded causing connections.Cover
starter to turn too slowly. connections with acid free
grease.

Problem
(continued): Engine
Cause
Using too high viscosity

Correction
Use appropriate oil grade

difficult to start. Engine oils in low ambient in winter.
has poor and irregular temperature.
performance.
Fuel Line blockage due to Change fuel filters. Bleed
wax separation in winter. fuel system. Check for fuel
leaks and loose
connections.
Incorrect Valve Clearances Call for service to adjust.
Defective Fuel Injectors. Call for specialist service.
Defective Turbo Charger.
Blocked Air Cleaner Clean or replace element.
Element.
•
Loose or badly adjusted Call for specialist service to
engine speed control make adjustments.
linkage.
Engine Shuts Down. Engine Fault. Check Engine Diagnostics.
Engine making Engine oil level too high. Drain engine oil to correct
excessive fumes. level on the dipstick.
Blocked air cleaner Clean or replace element.
element.
Low compression due to Call for specialist service.
poor condition of valves or
incorrect valve clearances.
Engine Overheats. STOP Excessive dirt on cooling Clean cooling fins on
engine immediately. system blocking air flow. radiator and oil coolers.
Engine coolant loss. Low
coolant level in engine.
Defective injector nozzles.
Incorrect fuel pump
calibration.
Cooling system fan not Clean cooling fins on
rotating or rotating at radiator and oil coolers.
reduced RPM.

Low engine oil pressure. Low engine oil will activate See Actual Manufacturer's
engine diagnostic ECM Operation Manual for
system. correct engine diagnostics.
Battery State - Ammeter Speed of alternator too low. Check drive belt tension.
indicates low or negative
Not changing due to Call for service to correct
value.
defective alternator or defects.
regulator.
General defects on Circuit Breaker open. Reset respective circuit

electrical equipment. breaker.
Defective parts or wiring. Call for service to correct

defects.

7-4 COMPRESSOR
General Information
Unexpected drill motion or moving parts can cut or crush. Shut down the engine
before
Safety should be the main concern for anyone working on or around the drill. Do not
perform
•
protection. Do not wear loose fitting clothing that can become caught on rotating compone
nts.
crushing risk.
DRILLING SOLUTIONS
7-59
Compressor Fire Prevention

A fiber gasket is installed between the outside cover of the receiver and the metal tube holding
the separator element in place. This gasket prevents oil from leaking around the metal tube
and down the hole.
When air and oil flow through the filter media, static electric charges are created. If these
charges are allowed to build up, a spark similar to a lightning flash will occur. This will set the
oil and the media on fire. The fire will burn from the inside of the element through the standpipe
hose and will follow the air flow until it burns through the air hose. This is not a fire caused by
the compressor flashing.
To prevent this from happening, several metal staples have been installed through the gasket
so each side comes in contact with the metal. This bridge serves to allow the static charge to
drain off outside the receiver tank and not cause a static buildup.
CAUTION
When replacing the separator element, be sure there is a least one staple that shows
through on both sides of the gasket and is not covered with glue.
OUTSIDE COVER
OUTSIDE COVER
0
GASKET
STAPLE
GASKET
METAL COVER
STAPLE CONNECTION ACTS AS BRIDGE

METAL COVER AND ALLOWS STATIC CHARGE TO DRAIN
OFF OUTSIDE RECEIVER TANK
Pneumatic System Information

All air compressors used on T3W Series drills are of the oil flooded asymmetrical rotary screw
design. Tapered roller bearings are used to handle thrust and radial loads.
Standard equipment for the air compressor includes a separate three stage inlet air cleaner
and full instrumentation and controls. The lubrication system includes an oil cooler, bypass
valve, oil filter, oil pump and a combination receiver and oil separator tank. A safety shutdown
system is also provided for high discharge air temperature.
Electronic Air Regulation: Variable air pressure and volume control allow you to increase
or decrease both pressure and volume as needed, giving you more control when drilling a
hole.

A compressor is considered high pressure if the discharge pressure is

greater. All T3W high pressure compressors have discharge pressu
bar). They are designated HR2.5 which describes the rotor sizes. The
250 psi (17.25 bar) or

res of 350 psi (24.15
rotors: 226mm x 2/127.5mm. The size of the rotors and their speed determ
of the air end. There are two sizes: 900 cfm and 1070 cfm.
HR2.5 has two sets of
ine the inlet volume
There are three (3) systems on a rotary screw compressor. Each system
is critical to the
operation of the air end and the systems are all interrelated. These system
s are:
1. Lubrication System
2. Separation System
3. Regulation System
Lubrication System
The equipment used in the lubrication section includes the receiver tank,
temperature bypass
valve, oil cooler, strainer, filters, oil pump, relief valve, discharge check
valve and special oil.
•
Receiver Separator Tank
The receiver tank contains the compressed air and lubricating oil for the
compressor. The oil
is removed from the air by centrifugal force, gravity, velocity-and filt-r6tiO
n-2-The receiver tank
has an oil level sight glass that shows the oil level at all times. The oil
level must be visible in
the sight glass whether the drill is running or shut down.
OIL
OIL
LEVEL
SIGHT FILL
GAUGE
DRAIN VALVE
7-61
Oil Pump
It
The oil pump is a gear type pump, driven from the rear of one of the compressor rotors.
It is speed sensitive and pumps at rated volume
operates whenever the compressor is turning.
only when the compressor is at full RPM.
OUT
PUMP__ FLOW
SHAFT
STRAINE -.1•••••10•04
!N
from
It acts as a normal pump when the oil is cold but becomes a restriction to maintain oil flow
and tempera ture. This
the receiver tank when the compressor is operating at normal pressure
prevents all the oil from being forced out of the receiver tank at once and flooding the
the same
compressor rotors. There is no shaft seal in this pump since it is being lubricated by
oil it is pumping.
Strainer
A 40 mesh (150 micron) strainer is mounted just before the inlet to the oil pump as shown
parts of
above. It protects the pump and catches any foreign debris such as hose pieces and
the thermostat that could damage the pump. The metal strainer should be removed, cleaned
and reinstalled every 500 hours.
Compressor Oil Cooler

four
The cooling package on the T3W with a Tier 3 engine is a side by side configuration with
core
cores; the radiator cooler core, the hydraulic oil cooler core, the engine charge air cooler
and the compressor oil cooler core.
CAC RAD HOC CCC
The compressor oil cooler is a single pass unit. Hot oil enters from the bottom of the cooler
carried
and cool oil exits out from the top. This prevents any air bubbles that may have been
along with the oil from being trapped in the top and creating a vapor barrier.

Temperature Bypass Valve
The temperature by[pass valve, also called the mixing valve, contains a
thermostat that stops
oil flow in one direction when it is cold and allows oil to flow from another direction
when it
reaches operating temperature.
PORT C
/
PORT B
Temperature
Bypass
Valve
PORT A.
When the temperature is below 140°F (63°C), oil flows from port "B" to port "A", thus
bypassing
the cooler altogether. When the temperature increases to 160°F (71°C), the thermos
tat is
completely opened and all the oil flows from port "C" to "A" and shuts off all flow
to "B". At
temperatures in between 140°F (63°C) and 160°F (71°C), some oil flows through
port "B" to
"A" and some oil flows through the cooler and from "C" to "A". Under normal operatio
n, some
oil is flowing through both "B" and "C". The normal discharge temperature of the
oil leaving the
air end should be between 180°F (83°C) and 220°F (104°C).
Relief Valve / Check Valve
RELIEF VALVE
RELIEF
VALVE__ CHECK
VALVE
TEMP
BYPASS
VALVE
A 75psi (5.17 bar) relief valve is connected between the inlet and outlet of the oil
cooler. If the
cooler becomes plugged and the inlet pressure becomes 75 psi (5.17 bar) higher
than the
outlet pressure, the relief valve opens and allows oil to bypass the cooler. When
the differential
pressure is reduced below 75 psi (5.17 bar), the valve will close and normal flow
resumes. This
allows the oil cooler system to function properly.
DRILLING SOLUTIONS
7-63
Oil Filter
10M FILTER
FILTER LOCATION MAY VARY

DEPENDING ON WHICH AIR
END IS USED
HP COMPRESSOR
OIL FILTERS
Two 10 micron filters are installed at the outlet of the pump before the oil reaches the
compressor bearings. They catch any contaminants that may have been picked up in the
circuit and prevent them from plugging the orifices at the inlets to the bearings.
Discharge Check Valve
The Discharge Check Valve is located at the outlet of the compressor and prevents any oil or
air, under pressure, from backing up into the compressor housing. While the compressor is
running, oil and air are being forced out of the compressor housing and this keeps the
discharge check valve open. When the compressor is stopped, nothing is coming from the
compressor side, but pressure is built up in the receiver. This would pressurize the compressor
housing if the discharge check valve were not there.
The previous picture shows the discharge check valve being held open. It has a single spring.
The hinge must be mounted on top to prevent the valve from staying open when the drill is
shut down. Notice the white nylon ring that forms a tight seal to prevent back flow when the
drill is stopped.

Compressor Oil
The very high pressure created in high pressure air ends requires a special
compatible with certain types of 0-rings. Therefore, use "Viton" type
fittings and filters. The oil is also not compatible with other oils and
other oil. These high pressure compressors use XHP605 oil.
oil. This oil is not

0-rings in the air end
should never be mixed with
Be sure to change the filters
every 500 hours.
Lubrication System Operation
Oil is injected into the air end under pressure. The oil serves three purpos
es:
1. It cools the air end bearings and rotors.
2. It lubricates the moving parts.
3. It seals the clearances between the male and female rotors, and
between the
rotors and the housings and end plates.
The Discharge Check Valve prevents air pressure and oil from returnin
g and entering the
compressor when the drill is stopped.
•
The Receiver-Separator Tank serves two purposes:
1. It stores compressed air for future use

2. It separates the oil from the air
Oil is forced from the receiver by air pressure flowing through the piping
towards the oil cooler.
The oil has three paths it can follow at this point.
PORT C
Temperature
PORT B
Bypass
11111/51.21W4002,41- - - 1=117111 Valve
PORT A.
1. When the oil is cold, the temperature bypass valve allows oil to bypass
the
cooler and go directly to the oil pump ("B" to "A").
2. As the oil warms up to 140°F (63°C), the thermostat in the mixing valve starts
to open and some oil flows up through the cooler. Most of the oil still
flows
•
through the bypass ("B" to "A" and some "C" to "A").
3. When the oil temperature reaches 160°F (71°C), the valve is closed comple
tely
and all oil flows through the cooler ("C to "A"). The valve stays partially open
during normal operation and the discharge temperature of the
oil stays
between 140°F (63°C) and 160°F (71°C).
DRILLING SOLUTIONS
7-65
cooler builds up to
If the oil cooler becomes plugged and the differential pressure across the
It still flows from
75 psi (5.17 bar), the relief valve opens and allows oil to bypass the cooler.
("C" to "A") in the temperature bypass valve.
mesh (150:) screen
When the oil exits the temperature bypass valve, it passes through a 40
g at low pressure,
into the inlet of the oil pump. When the oil is cold or the receiver is operatin
the
the pump performs as a regular pump by forcing oil into the compressor. But as
acts to prevent excess oil from getting into the
temperature and pressure increase, the pump
compressor and flooding it.
that keeps
Before the oil reaches the pump, it passes through a 40 mesh,150 micron strainer
larger debris from reaching the pump.
through
After the oil passes the pump and before it gets to the compressor bearings, it passes
through a metal manifol d that sends oil to all areas
two (2) 10 micron filters and then flows
line. The balance of the oil goes into the
of the compressor. Each bearing has its own supply
low pressure area of the rotors.
compressor and
A 425 psi (29.33 bar) relief valve is located between the oil pump and the
bearing that prevents damage to the system in case of a high pressure surge during cold starts
and/or blockage in the bearing lines. When the temperature of the oil warms up, the relief valve
will close.
Separation System
When the
Lubricating oil is forced through the air end to cool, seal and lubricate the rotors.
must be separat ed from the air going down
oil is pumped into the receiver separator tank, it
the hole. This is accomplished in three steps.
s
1. The air/oil mixture enters the receiver through the inlet pipe and splashe
against the inner walls. This forces the majority of oil to fall to the bottom of the
tank and remain there.
STEP I
ary% CF OIL PEVOVED FROM
MIXTURE IN TANK
TOP VIEW
OIL
FLOW
"DE VIEW

2. When the down stream air line is opened and air flows down the hole, some of
the remaining oil is carried along with it into the filter area. A metal canister
prevents oil from flowing through the filter directly. The air/oil mix enters the
outer edge of the element and moves toward the center. As the oil travels
through the element, it is slowed down by friction and gravity pulls it downward.
Most of the oil drops out of the bottom of the element and falls into the reservoir.
DISCHARGE AREA
I-
ELEMENT
SHELL OF
ELEMENT
=:;7 AIR
4111.1 OIL
OIL LEVEL
• STEP 2
0.9% OF OIL REMOVED FROM
MIXTURE IN TANK
STEP 3
0.1% OF OIL REMOVE: FROM
OIL'AIR MIXTURE IN TANK
3. The final step in the separation process is removing any remaining oil from the
element so it is not carried over into the down hole air stream. When enough
excess oil is carried into the center of the element, a series of holes in the end
of the filter element allow the oil to fill an area between the flange and the
element. The scavenger line is connected between the flange and the inlet of
the compressor. Since there is a differential pressure between the receiver tank
and the low pressure area of the compressor, oil and air are forced through the
scavenger line into the inlet area of the air end, thus removing the last of the oil
carryover. A 0.94" orifice in the line prevents excessive amounts of air loss.
It is important to note when changing separator elements that the element be installed
correctly. The word "TOP" should always be on top to insure that the drain holes are at the
bottom. This prevents excessive buildup in the scavenger area.
OIL END VIEW OF

SEPARATOR ELEMENT
• E ',1EN
DRAIN HOLES
Another item to watch when changing elements is to be sure that the staples in the gaskets
are left there to prevent a static electric charge from building up and causing a fire.

Electronic Air Regulation System (EARS)

The following information is general for all Atlas Copco Drilling Solutions drills using Electronic
Air and Fan Regulation System. Due to differences in drill models, there will be differences in
components used. As an example, a TH60 model drill utilizes a single truck engine and
therefore would use a shaft speed sensor and an engagement sensor not used on other drill
models. Also, an engine oil pressure switch is required for some installations that do not have
J1939 equipped engines. You and the service technician must refer to the parts book
specific to your drill for parts and schematics specific to your drill.
Minimum
Inlet Pressure Pressure
Butterfly Senss7r! Holding
Valve with
L_ Valve Vent Valve
Actuator —1 (Blowdown
Ball Valve)
with
Vacuum Actuator
Sensor
Separator
Compressor 0
Tank o0
Silencer
op
c
The Electronic Air Regulation System consists of fourteen (14) general components. Some of
the components are only required on some of the applications.
1. Flow Sensor
Flow
Sensor
The Flow Sensor, mounted below the butterfly valve, detects the volume of air
the compressor is producing and sends this data to the MC2 electronic
controller. This sensor is actually a vacuum sensor.

2. Proportional Butterfly Valve and Actuator on compressor inlet

ACTUATOR
PROPORTIONAL
BUTTERFLY VALVE
The Proportional Butterfly Valve and Actuator is controlled by the MC2

electronic controller. It regulates the air flow into the compressor from the
t closed (no air enters the compressor) to fully open position. The actuator
includes a visual position indicator. The indicator is horizontal when the valve
is closed and vertical when the valve is full open.
3. Pressure Sensor on the receiver tank
•
PRESSURE SENSOR
The Pressure Sensor, located on the receiver, detects the pressure in the
receiver tank and sends this data to the MC2 electronic controller.

4. Proportional Vent Valve and Actuator on the receiver tank
PROPORTIONAL ACTUATOR
VENT VALVE
The Proportional Vent Valve and Actuator is controlled by the MC2 electronic
controller. It can release air from the receiver tank. The air is vented to
atmosphere through an air silencer. The proportional vent valve was previously
called the blowdown valve.
5. MC2 Electronic Controller
MC2
Electronic
Controller
The MC2 electronic controller monitors air flow, air pressure, engine data and
operator inputs. It controls the actuators so that the compressor produces the
flow or pressure requested by the operator. It also detects several fault
conditions and alerts the operator by flashing an error code with the diagnostic
light. The MC2 controller is initially powered up with the key switch and then
latches its power on so that it can perform a shutdown sequence after the key
switch is shut off. System will stay energized for 10 seconds after the receiver
pressure drops to 5 psi.

6. Flow Control Knob on operator's console
Max Pressure
Compressor Control Knob

On/Off switch
Diagnostic
Light
Flow
Control knob
The Flow Control Knob is a variable voltage input into the electronic controller
(.5 VDC to 4.5 VDC). When the compressor on/off switch is in the on position
it regulates the flow into the compressor between the minimum flow (required
to prevent damage to the compressor) and maximum flow. (Full open position
on the butterfly valve).
7. Maximum Air Pressure Control Knob
The Maximum Air Pressure Control Knob is a variable voltage input into the
electronic controller (.5VDC to 4.5VDC). When the compressor on/off switch is
on it regulates the maximum pressure in the receiver tank between the
minimum holding tank pressure and the maximum working pressure of the
compressor system.
8. Compressor On/Off Switch
The Compressor on/off switch energizes the flow and pressure control
commands. When the switch is in the on position the Flow and Pressure control
knobs are active and their combined inputs to the MC2 controller regulate the
desired compressor output. When the switch is in the off position the flow is set
to the minimum flow required to prevent damage to the compressor (similar to
anti rumble) and the Maximum pressure is set to the minimum holding tank
pressure. (By default in the off position, the air flow and maximum pressure
settings are set to the minimum.)
9. Diagnostic Light
The RED Diagnostic Light is normally off but will flash out an error code if the
MC2 electronic controller detects an error. (See error detection and error codes
section). If this light is flashing turn off the engine.

10. Hardware Interface Board
Electrical Noise
Operator
Conditioning Circuit Suppression Circuits
Power Control
Relay
CiagnoVic
The hardware interface board is a DIN rail mounted circuit board with terminal
strips down each side. It is not intended for exposure to wash down. This board
contains circuits to perform the following functions.
a. Power control relay that allows the MC2 electronic controller to latch on the
supply voltage to the EAR system. This allows the system to complete the
receiver tank bleed down after the key switch has been turned off.
b. Diagnostic port allows a lap top computer equipped with the correct
software to monitor the system via a USB port.
c. A 20-amp fuse protects the system in the event of a wiring short.
d. Operator Conditioning Circuit provides regulated power to the sensors and
operator inputs. It also allows the MC2 controller to detect hardware faults.
e. Electrical Noise Suppression Circuits prevent electrical noise from being
generated by the electric motors in the valve actuators.
11. Interconnect System

•
The Interconnect System includes harness split out boxes and cable sets that
connect the various components. Several variations of the Interconnect
System are required to accommodate the wide range of drills the system can
be installed on.
12. Oil Pressure Switch
An Engine Oil Pressure Switch is required for some installations that do not
have J1939 equipped engines. This switch should close when a hot engine is
turning 75% of the idle speed.
13. Shaft Speed Sensor (TH60 Model Drills Only)
In order to control the compressor, the system needs to know if the compressor
is turning and more importantly if it is in the process of shutting down. On direct
coupled drills this is accomplished by monitoring the key switch and the J1939
engine bus. On drills without J1939 or not direct coupled configurations, the
system can be configured to use an additional input from a sensor to make the
determination.
A frequency reading input designed to receive a signal from a magnetic or other
type sensor is required for some installations to determine the speed
associated with compressor rotation or to check for correct transmission gear
•
selection.
14. Engagement Sensor (TH60 Model Drills Only)
Engagement Sensors are used on some installations to detect if various
compressor drive line components are engaged. Used on some drill
configurations that utilize a single truck engine, the system is capable of
monitoring the engine speed and the transmission tail shaft speed to determine
if the operator has selected the correct gear for PTO operation. If the wrong
gear is selected the error code is flashed and the compressor is commanded
to make minimum air.

Electronic Air Regulation Operation
Pressure Sensor
Actuator Proportional Butterfly
Proportional
Vent Valve
Start Up Operation
At start up the controller will command the butterfly valve to the closed position preventing air
entry into the compressor and will open the vent valve to vent any trapped air in the system
and the receiver to atmosphere. This allows the engine to start with the least possible load.
After the engine speed reaches the minimum RPM (lo idle), there is a factory set delay time to
allow the engine to stabilize after which the MC2 controller regulates the compressor to which
ever input is applicable (On/Off, Flow or Pressure command).
Shut Down Operation
When the MC2 controller detects the key is in the off position, it closes the Butterfly valve and
bleeds down the pressure in the system and the receiver tank through the vent valve to
atmosphere. Because the system is ramping down the receiver pressure, normal system
efficiencies and internal leakage allow the pressure to drop fast enough during the early stages
of the shut down sequence without the assistance of the controller to open the vent valve. This
results in what appears to be a delay in venting the tank, however the pressure is dropping at
the correct rate.

Flow Regulation
Electronic Air Regulation

System Operation
Flow Override
• Flow Sensor
•
Controller
Pressure Sensor
Maximum
Pressure
Command
Note: Local environmental and atmospheric conditions will ultimately

determine the maximum output of the compressor. EG. altitude, ambient
temperature and condition of inlet filters.
The MC2 electronic controller continuously regulates the required airflow into the compressor
using commands from two sources.
1. The Flow control knob. (Manual input)

2. The (Maximum) Air Pressure control knob. (Manual input)
Maximum Pressure Regulation

The MC2 electronic controller has two methods to control the maximum pressure in the
receiver.
1. It overrides the Flow knob command signal.

2. It opens the vent valve to let air out of the receiver tank.
Method I - When the maximum pressure commanded by the (maximum) air pressure
control knob is achieved the MC2 electronic controller enters the pressure control mode. It
overrides the flow knob input and reduces the flow to lower the pressure in the receiver. The
MC2 electronic controller then regulates the flow up or down to maintain the maximum
pressure and will not command more flow than is requested by the flow control knob. If the
pressure drops to a level where the commanded flow should be increased, the MC2 electronic
controller exits the pressure control mode and returns control to the flow command.
DRILLING SOLUTIONS
7-75
Method 2- The controller is constantly regulating the receiver tank pressure using a command
that is 20 PSI above the maximum pressure command. If the pressure is below the command
value the vent valve is moved to the closed position. If the pressure is above the command
value the vent valve is opened (vented). For most conditions the pressure is below the
command value and results in the vent valve being closed.
The vent valve regulation system controls the pressure when the compressor on/off switch is
in the off position.
Emergency Venting
If the maximum system pressure is exceeded the MC2 electronic controller commands the
butterfly valve to close and opens the vent valve. This allows quick system reaction to
overcome pressure spikes.
Compressor Turning
In order to control the compressor correctly, the system needs to know if the compressor is
actually turning and, more importantly, if it is in the process of shutting down. On direct coupled
drills this is accomplished by monitoring the key switch and the J1939 engine bus. For other
non-direct configurations and for drills without a J1939 bus, the system can be configured to
use two additional inputs to make the determination. The first additional input is a frequency
reading input designed to receive a shaft speed from a magnetic or other type pickup. The
second is an On/Off type input that can be configured to function as an engine speed at
minimum indicator, or an indication a compressor drive chain component is engaged.
Gear Selection Error Detection
On drill configurations that utilize a single truck engine, the system is capable of monitoring
the engine speed and the transmission tail shaft speed to determine if the operator has
selected the correct gear for PTO operation. If the wrong gear is selected, the error code is
flashed and the compressor is commanded to make more air.
Temperature Regulation
The temperature regulation is setup to monitor various system temperatures and adjust the
cooling fan speed to prevent any of the four monitored temperatures from exceeding their
individual set points. The four temperatures being monitored are as follows:
1. Engine Coolant
2. Hydraulic Oil Cooler
3. Compressor Oil Cooler
4. Charge Air Manifold

Electronic Air Regulation Troubleshooting
Self Diagnostics
POWER
ON
o
DIAGNOSTIC
The MC2 Controller is energized
The system can detect various types of problems and flash out a code for the operato
r or
technician. The Diagnostic light is an indication that the controller is detecting an
error and the
engine should not be run. The system can detect 11 error/fault conditio
ns. The diagnostic
light will flash out the number of the fault (one flash indicates error/fault one,
etc.) The first flash
in the sequence is longer than the following flashes and allows identification of flash
•
one. The
time between each flash is constant (error/fault code 1 appears as a slowly
flashing light). If
the system has more than one error, there is a built in priority where error code
one is the
highest priority, error code two is next, etc.
Error Codes and Priorities
1. Flow is below minimum for 15 seconds and the Flow sensor is not indicatin
g an
electrical fault. This is the highest priority and most critical error. Operation of
the compressor below minimum flow will result in damage to the compressor.
2. Flow sensor is indicating an electrical fault. (It is indicating an out of range
signal).
3. Pressure sensor is indicating an electrical fault. (It is indicating an out of range
signal).
4. Flow knob is indicating an electrical fault. (It is indicating an out of range signal)
5. Pressure knob is indicating an electrical fault. (It is indicating an out of range
signal)
6. Electronic Controller is not receiving engine data information (J1939).
7. The regulated 5 volt supply from controller is too high or low, indicating a short
in the wiring.
8. The J1939 and Speed Sensors do not agree. This can indicate a sensor error
•
or an incorrectly selected gear (drills that utilize a single truck engine). If this
error is present the system will limit flow to the minimum.
9. The COC temperature sensor is indicating an electrical fault. (It is indicating an
out of range signal).
DRILLING SOLUTIONS
7-77
al fault. (It is
10. The Hydraulic temperature sensor is indicating an electric
indicating an out of range signal).
11. One of the four (4) temperatures is too high.
Standard Test Conditions

rs and sensors
1. EAR/EFR system is fully assembled with all connectors, actuato
easily
connected and tight. The system has a limited number of parts that can
be given a quick examination. This can save a lot of time.
2. The engine is not running.
3. The engine ignition (Key Switch) is ON.
to that mode.
4. Drills with the capability to select a drill mode should be pre-set
5. Drills that have an in/out box should have the box disengaged.
6. Receiver tank discharged.
7. Compressor on/off switch set to off position.
8. Flow or volume knob set to minimum (fully counter clockwise).
9. Maximum air pressure knob set to minimum (fully counter clockwise).
10. The throttle valve should be open (if equipped).

•
I 7E
INTERFACE BOARD 2657861335
I8E
n 4_
• [ 201 I RED
4.4.4
C. •
CD
TO MCI PIN 134 202 2 BLACK
TO MCI PIN 12
TO MCI PIN 4 1 34
35
TO MCI PIN 27 COM'RESSOR ONrOFF
R16 36
Ye, • 37 SWITCH
TO MCI PIN 38 IK vc▪
203
I
TO NCI PIN 10 39
4 'Yvk 204
TO MCI PIN 42 4 OcK
NH,
140
41 205
TO MCI PIN 29 4
42 206 B
TO MC11 PIN 214
207 A
43 210
44
45 208 C
400
O
•
209 B
46
47 21 1 3 2
10 0 N <
TO MCI PIN 34 43 ci
(-I
212 C J
C
TO NCI PIN 7 2—
4" 0
0C
4
213 0
TO MCII PIN 35 2+
49 216
50 214
;£6P 6IL ,;0 2

O 51
215
2 0
13
4 0
14 217
TO MCI PIN 2 4111-,----
- ge a 218
0 0
0
15 -40
TO MCI PIN 17 56
• 51
6
2
17 219
O,A Ih SB
TO NCI PIN 16 14 _4. 59 220

-0 60
a 221
o
0
O
To NCI 9 222
PIN 3
•
DRILLING SOLUTIONS
7-79
• • •
DRILLING SOLUTIONS
Section 7 - Systems/Trou leshooting
BLOWDOWN VALVE
b
ACTUATOR 2651817512
---> CURNLH1 FLOW COMPRESSOR
FOR CW DIRECTION FAN SPEED DISCHARGE HYDRAULIC
-,11131r- TEMPERATU RE TEMPERATURE BATTERY BATTERY SWITCH
KEY
0 2657866220 IGR)
•265786622
PLUS (PR) (KY)
SIGNALGND SIGNALGND 02 05 07
V
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4 15AT 0 0 AD RI3w 0
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W .1.02K N M
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0 N N M
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-
Z Z
Z Z
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a a as CL
V y -
V
I
V
I WY
(7)
O 0 0 0 0 0 0
I-
0 0 0 h h
2 2 I-
CO
MC l1
2 -
FROM I7F BOARD PIN 14
3 -4UFROM 1 F BOARD P IN 19
4 —.4
FROM IF BOARD PIN 20
5 -.4 FROM I F.' BOARD P IN 23
6 -411 FROM IF BOARD P IN -31
7 -- FROM IF BOARD PIN I I
8 —.4 FROM'IF
BOARD PIN 24
g -41 FROM IF BOARD PIN 30
10 F R Om, IF .BOARD PIN 6
II
12 -- FROM IF BOARD PIN 2
13 -FROM IF BOARD PIN I
14 —.4
I S FROM IF BOARD PIN 33
16 _Ai FROM 1 F BOARD PIN 18
17 FROM IF BOARD PIN 15
20 —41
21 —4 FROM IF BOARD PIN 9
22 FROM 1 F BOARD PIN 25.

7-81
DRILLING SOLUTIONS
MC11 (continued)
25 --4
26 —41
27 —4 FROM IF BOARD PIN 4
28 _4 FROM IF BOARD PIN 32
29 —44 FROM 1 F BOARD P I N 8
30 —1
31
--41
32 —41
33
34 FROM I F BOARD P IN I 0
35 —4I FROM I F BOARD P I N 1 2
36
37
—1
38 FROM 1 F BOARD PIN 5
39 —1
40

7-82
DRILLING SOLUTIONS
Error Code Meaning and Diagnostic Information

the possible faults that could
The following is a listing of the diagnostic error codes along with
cause the error.
DC (2 PSIA) and
1. Code 1- The vacuum sensor input has been below 1.05 Volts
le non-rotating
above 0.5 Volts DC 0 PSIA) for more than 30 seconds. Possib
compressor causes include:
a. Damaged vacuum sensor.

b. Low vacuum sensor supply voltage.
c. Partial short in vacuum sensor output signal wiring.
d. Damaged controller.
Additional causes in a rotating compressor:
ed low for too
a. The butterfly valve is not opening and the vacuum has remain
long.
Interface board terminals for vacuum sensor:
a. Terminal 46 - Vacuum Sensor Supply (20-30 Volts DC).

b. Terminal 47 - Vacuum Sensor Ground.
c. Terminal 48 - Vacuum Sensor Signal.
. It goes off the
The sensor supply voltage originates on the interface board
interface board at terminals 46, 49, 71,69.
25 Volts DC. Possible
2. Code 2 - The vacuum sensor input ,has been below 0.
causes include:
a. Damaged vacuum sensor.

b. Disconnected or damaged vacuum sensor wiring.
c. Low vacuum sensor supply voltage.
d. Shorted Vacuum sensor wiring.
e. Damaged controller.
a. Terminal 46 - Vacuum Sensor Supply (20-30 Volts DC).

b. Terminal 47 - Vacuum Sensor Ground.
c. Terminal 48 - Vacuum Sensor Signal.
. It goes off the
7-83
DRILLING SOLUTIONS
3. Code 3 - The vacuum sensor input has been below

0.25 Volts or greater than
4.75 Volts DC. Possible causes include:
a. Damaged pressure sensor.

b. Disconnected or damaged vacuum sensor wiring.
c. Low vacuum sensor supply voltage.
d. Shorted vacuum sensor wiring.
a. Terminal 49 - Pressure Sensor Supply (20-30 Volts

DC).
b. Terminal 50 - Pressure Sensor Ground.
c. Terminal 51 - Pressure Sensor Signal (0.48-0.51
Volts DC).
at terminals 46, 49,
71, 69.
4. Code 4 - The flow potentiometer input is below 0.25
Volts DC or greater than
5.75 Volts DC. Possible causes include:
a. Damaged Flow potentiometer.

b. Disconnected or damaged flow potentiometer wiring
.
c. Low flow potentiometer supply voltage.
d. Shorted flow potentiometer wiring.
Interface board terminals for flow potentiometer:
a. Terminal 40 - Flow Potentiometer Supply (4.6 Volts

DC).
b. Terminal 41 - Flow Potentiometer Return (0.4 Volts
DC).
c. Terminal 42 - Flow Potentiometer Signal (counter clockw
ise 0.4 Volts DC,
clockwise 4.6 Volts DC).
Interface board terminals for the plus supply and
ground used by the
potentiometer circuits:
a. Terminal 7 - Plus supply from the controller (5 Volts DC).

b. Terminal 8 - Ground from controller (ground).
7-84
DRILLING SOLUTIONS
•
is below 0.25 Volts DC

5. Code 5 - The maximum pressure potentiometer input
or greater than 5.75 Volts DC. Possible causes include:
a. Damaged maximum pressure potentiometer.

ter wiring.
b. Disconnected or damaged maximum pressure potentiome
c. Low maximum pressure potentiometer supply voltage.
d. Shorted maximum pressure potentiometer wiring.
ter:
Interface board terminals for Maximum Pressure potentiome
DC).
a. Terminal 43 - Maximum Pressure Pot Supply (4.6 Volts
DC).
b. Terminal 44 - Maximum Pressure Pot Ground (0.4 Volts
ter clockwise 0.4 Volts
c. Terminal 45 - Maximum Pressure Pot Signal (coun
DC, clockwise 4.6 Volts DC).
ground used by the
Interface board terminals for the plus supply and
potentiometer circuits:
•
DC).
a. Terminal 7 - Plus supply from the controller (5 Volts
b. Terminal 8 - Ground from controller (ground).
from the engine (J1939).
6. Code 6 - The controller is not receiving the data
Possible causes include:
a. Wiring problem in J1939 circuit.

b. Damaged PowerView disrupting communications.
c. Damaged Engine ECM.
d. Damaged controller.
Interface board terminals for J1939 Data from drill:
a. Terminal 34 - Data Low (2-3 Volts DC).

b. Terminal 35 - Data High (2-3 Volts DC).
provides to the interface
7. Code 7 - The regulated 5 volt supply the controller
voltage should be
board is below 4.8 Volts DC or above 5.2 Volts DC. (This
interfa ce board ). Possible causes
measured from the ground on Pin 8 of the
include:
and interface board.
a. Short on interface board or wiring between controller
b. Damaged controller.
7-85
DRILLING SOLUTIONS
Interface board terminals for the plus 5 volt supply and

ground.
a. Terminal 7 - Plus supply from the controller (5 Volts
DC).
b. Terminal 8 - Ground from controller (ground)
8. Code 8 (TH60 drills) - The engine speed as repor
ted by the J1939 data link
and the shaft speed sensor do not agree when the drill
mode is selected. This
voltage should be measured from the ground on Pin
8 of the interface board.
Possible non-rotating compressor causes include:
a. Damaged controller.
b. Wiring shorted to fan drive PWM output or some
other device that outputs
a modulated voltage.
The tail shaft is not turning at the correct speed for the
reported engine speed.
Possible causes include:
a. A transmission or other drive line component is

in the wrong gear.
b. A drive line disengagement component such
as a clutch is not engaged.
Additional causes in a rotating compressor:
a. Damaged speed sensor.

b. Disconnected or damaged speed sensor wiring
.
c. Damaged controller.
Interface board terminals for Shaft Speed Sensor:
a. Terminal 72 - Shaft Speed Sensor Output signa

l. Zero Volts DC on a non
running drill and approximately )00( Volts DC running
at idle.
b. Terminal 38 - Shaft Speed Sensor Ground.
The speed sensor is a conventional two wire magnetic
pickup. The resistance of
the coil is approximately 2.5k ohms.
9. Code 9 - The Compressor Oil Cooler (COC) temp
erature sensor input is below
0.25 Volts DC or greater than 4.75 Volts DC. Possible
causes include:
a. Damaged COC temperature sensor.
b. Disconnected or damaged COC temperature senso
r wiring.
c. Low COC temperature sensor supply voltage.
d. Shorted COC temperature sensor wiring.
7-86
DRILLING SOLUTIONS
Interface board terminals for COC temperature sensor:
a. Terminal 71 - COC Temperature Sensor Supply (20-30 Volts DC).

b. Terminal 75 - COC Temperature Sensor Ground.
c. Terminal 74 - COC Temperature Sensor Signal.
goes off the
The sensor supply voltage originates on the interface board. It
interface board at terminals 46, 49, 71, 69.
0.25 Volts DC or
10. Code 10 - The hydraulic temperature sensor input is below
greater than 4.75 Volts DC. Possible causes include :
a. Damaged hydraulic temperature sensor.

b. Disconnected or damaged hydraulic temperature sensor wiring.
c. Low hydraulic temperature sensor supply voltage.
d. Shorted hydraulic temperature sensor wiring.
Interface board terminals for hydraulic temperature sensor:
Volts DC).
a. Terminal 69 - Hydraulic Temperature Sensor Supply (20-30
b. Terminal 73 - Hydraulic Temperature Sensor Ground.
c. Terminal 70 - Hydraulic Temperature Sensor Signal.
goes off the
The sensor supply voltage originates on the interface board. It
by the Electronic Fan
11. Code 11 - One of the four temperatures monitored
Regulation (EFR) systems has exceeded its maxim um temperature. Possible
causes include:
a. One of the temperatures is too hot.

b. Damaged hydraulic temperature sensor.
c. Damaged COC temperature sensor.
d. Damaged coolant sensor on the ECM system.
e. Damaged air intake sensor on the ECM system.
Blown Fuse Check List

off.
1. Turn off the KEY input and verify the power to the controller is
a. Terminal 32 = Zero Volts

b. Terminal 78 = Ground
7-87
DRILLING SOLUTIONS
2. Use a multi-meter to measure resistance between Term

inal 32 and Terminal
78. The resistance should not be less than 20 ohms.
3. If the resistance is less than 20 ohms, there is a short in
the system. Check the
resistance of every terminal to ground (Terminal 78) and
eliminate the short.
Terminals 8, 17, 33, N, 38, 47, 50, 53, 58, 64, 73 and 75
are also ground and
will always read zero ohms.
Actuator Diagnostics Table
The actuator is composed of the following components:
1. 24 volt DC motor.
2. Integrated gear box with life time lubrication.
3. Two cam operated limit switches.
4. Thermostat and heater.
Clockwise rotation always closes the valve and counter
clockwise rotation always opens the
valve. The actuator has six (6) wires:
1. Clock Wise Supply

2. Counter Clock Wise Ground
3. Clock Wise Ground
4. Counter Clock Wise Supply
5. Heater Ground
6. Heater Supply
Actuator Test Box
To connect the actuator test box, simply uncouple existin

g cable connector plug and connect
the test box cables in series with the two uncoupled plugs
. This is used to rotate the actuator
either clock wise or counter clock wise direction. It is best
to use this device to check the
actuator for full range operation and smoothness. The box
is powered from the actuator heater
circuit so the power to the system and key switch must
be active. When the test box is
installed, the EAR system no longer has control of the
actuator.
CAUTION
Extreme caution should be exercised if the compresso

r or engine must be run while the
test box is installed.
Closing the butterfly valve while the compressor is
turning can result in expensive
damage to the compressor. Insure minimum pressure
is maintained for sufficient anti-
rumble.
7-88
DRILLING SOLUTIONS
•
CAUTION
essor is making high

Opening the receiver tank vent valve too quickly while the compr
volumes of air can result in damage to the separator elements.
Actuator Test Using an Actuator Test Box

7CTCR
CONNt-
Actuator Test Box

FAST: SLOW
Switch
CCW OFF / CW
Switch
•
CONNECTOR
ACTUATOR
Instructions:
is lined up with the
1. Make sure the white line on the actuator indicator knob
or knob).
scribed mark on the actuator. (This requires removing the indicat
be tested.
2. Install the actuator test box in series with the actuator to
3. Set the speed switch to fast.
nd the actuator and
4. Use the clock wise and counter clock wise switch to comma
observe the actuator response.
5. Set the speed switch to slow.
the actuator and
6. Use the clock wise and counter clock wise switch to command
observe the actuator operation at slow speed.
Results:
by the switch.
1. The butterfly valve should move in the direction-commanded
the long edge of the
2. The actuator should have free travel from horizontal with
d at the end
actuator to perpendicular to the same edge. The actuator is stoppe
•
can be heard as a faint click. The actuator
of travel by internal limit switches that
should not load up and stop.
clock wise and
3. The actuator should stop in the horizontal position after moving
in perpendicular position after moving counter clock wise.
7-89
DRILLING SOLUTIONS
4. The actuator should move smoothly with a steady buzzi

ng sound. There should
not be any spots where the actuator loads up and slows
down.
If there appears to be a problem with the actuator, possi
ble causes include:
1. If the actuator operates backwards of the indications
on the tester, there are
two possible causes.
a. The heater circuit is wired backwards (diagnose and

repair). This problem
does not affect operation of the system. It should, howe
ver, be corrected.
Use the schematic and connector pin diagrams to diagn
ose and correct.
b. The test box is wired incorrectly. Use the tester schem
atic and connector
pin diagrams to diagnose and correct.
2. If the actuator does not travel the full operating distan
ce, there are several
possible causes.
a. The limit switch or limit switch cams have come loose

. It will be necessary
to diagnose and repair. Remove the cover and correct the
problem.
b. Something inside the valve is stopping the actua
tor. It will be necessary to
remove the actuator from the valve to isolate this cause
. Then diagnose
and repair the problem.
c. The actuator has broken internal gears or other mech
anical problems. It will
be necessary to remove the actuator from the valve to
isolate this cause.
Then diagnose and repair the problem.
3. If the actuator does not stop in the horizontal position
after moving clock wise
and in the perpendicular position after moving counter
clock wise, the internal
cams will need to be adjusted.
Potentiometer Testing using a mult- meter
Instructions:
1. Rotate the shaft to a position approximately half way

between the mechanical
stops.
2. Measure the resistance between the three wires/termin
als until the pair with the
greatest resistance is found.
a. The resistance should correspond with the resistance

marke d on the pot.
b. The resistance between either one of these wires
and the third wire should
be approximately half the resistance marked on the pot.
3. This pair of wires/terminals are the two ends of the resist
ive element.
4. The third wire/terminal is the wiper.
5. Rotate the shaft fully in one direction and measure the
resistance as the shaft
is rotated slowly in the other direction.
7-90
DRILLING SOLUTIONS
a. The resistance should change from approximately the

resistance of the pot
to near zero ohms. (Depending on the direction you rotated, the
action
could be reversed.)
b. The resistance should change smoothly with no
places where the
resistance changes or appears to be unstable.
c. The resistance should be stable when side loading is applie
d to the shaft
(provided the shaft is not rotated).
Summed On/Off Inputs Decode Table
The interface board sums (adds together) the three on/off inputs to
create a single voltage that
the controller decodes to determine the status of the three inputs.
The three on/off inputs are:
Key Switch, Compressor On/Off Switch and the Auxiliary On/Off
Switch. The following table
can be used to determine if a specific input will be decoded an ON
or OFF.
Table 5: Decode Table
Voltage Range Key Compressor Auxiliary

on Terminal 5 Switch On/Off Switch On/Off
0.000 - 0.557 OFF OFF OFF
0.558 - 1.323 ON OFF OFF
1.324 - 1.391 OFF OFF OFF
1.392 - 1.917 OFF OFF ON
1.918 - 1.964 OFF OFF OFF
1.965 - 2.321 ON OFF ON
2.322 - 2.351 OFF OFF OFF
2.352 - 2.623 OFF ON OFF
2.624 - 2.652 OFF OFF OFF
2.653 - 2.891 ON ON OFF
2.892 - 2.914 OFF OFF OFF
2.915 - 3.104 OFF ON ON
3.103 - 3.123 OFF OFF OFF
3.124 - 3.293 ON ON ON
3.293 - BATTERY OFF OFF OFF
DRILLING SOLUTIONS
7-91
Actuator Diagnostics
The system cannot detect if an actuator is connected, adjusted or functioning correctly.

Adjustment and functionality can be checked by operating the system and visually observing
the response. These steps can also be used to demonstrate normal operation of the system.
Follow these steps:
1. Setup the drill so air can be blown safely out of the drill steel (throttle valve
open). Wear safety glasses and hearing protection equipment.
2. With the compressor switch in the off position and both the maximum pressure
control and flow control knobs rotated counter-clockwise, start the engine and
engage all required drive components. After a short delay the receiver tank
pressure should climb to just below the minimum pressure valve setting and
stabilize. The interstage pressure, if applicable, will be very low and the vent
valve will be slightly open and venting the minimum air. The butterfly valve will
be slightly open to maintain minimum air flow (his may not be apparent). Any
significant deviation of the pressure indicates a problem with the vent valve
(previously called blowdown valve) or vent valve actuator. Any significant
deviation in air volume (above or below minimum air) indicates a problem with
the butterfly valve or actuator. If the butterfly fly valve is stuck or failed in the
open position it may be impossible to start the engine. This condition is easy to
detect because the receiver will begin to pressurize during the cranking cycle.
3. Increase the throttle to full engine RPM, rotate the pressure and volume control
knobs fully clockwise and switch the compressor to the on position. This will
allow full system air volume to blow out of the bit. Receiver tank pressure will
build to overcome the minimum pressure valve setting. The butterfly should be
fully open and the system blowing maximum volume of air. If the butterfly valve
is not fully open and does not deliver the maximum required air flow, this would
indicate that the proportional actuator requires adjustment.
4. While watching the pressure, slowly close the throttle valve to force the
pressure to rise in the receiver tank. Increase the pressure to approximately
70% of full pressure. Correct operation of the volume control can now be tested
by adjusting the volume control knob counter clockwise and observing a
decrease in the receiver tank pressure. Note that there can be a significant
amount of rotation on the maximum flow knob where no change in the flow is
observed. This is because the flow knob can command full flow which is only
achievable at sea level with clean filters. If the flow will not adjust this indicates
a problem with the butterfly valve actuator or valve.
5. While watching the pressure gauge, continue to very slowly close the throttle
valve to cause the pressure to increase in the receiver tank. As the pressure
reaches and exceeds the maximum pressure the system will begin to override
the flow control knob and lower the commanded flow. The pressure should
maintain close to maximum pressure as the throttle valve is slowly closed.

6. Continue to very slowly close the throttle valve.
pressure and the vent valve will begin to open and regulate the
20 PSI (1.38 bar) above the maximum pressure. If the pressure
this indicates a problem with the vent valve actuator or valve.
Once the flow is reduced to

minimum flow, the pressure will rise to 20 PSI (1.38 bar) above
the maximum
receiver tank to
raises too high,
Control Logic
Flow
,
Command Butterfly Valves Butterfly Valve
From 1 I Contro Logic—' Actuator Flow
Operator
I Feed Back —
Flow Sensor
I
Flow Override For
Pressure Control
aximum
•
Pressure I
Command Vent Valve
Control Logic Vent Valve Pressure
From
Operator Feed Back I Pressure Sensor
Compressor Related Problems

Trouble shooting and repairs of defects in the mechanical functio
ning of the compressor
systems requires specialist knowledge. All compressor related
problems should be referred to
your local service support for assistance and are not considered
part of operator maintenance
covered in this manual. If you are unable to determine the cause
of the problem, contact your
local Drilling Solutions service office.
Table 6: Compressor Related Problems

Drill Shuts Down After A High discharge Check for low oil level
Short Running Time temperature
Check for obstructions in
oil cooler
Check fan speed
•
Compressor Turned On, Butterfly valve stuck in
But Does Not Produce closed position
Compressed Air
DRILLING SOLUTIONS
7-93
Cause Correction
Problem
Oil carryover through Check for high oil level in

Excessive Oil
discharge air hose separator
Consumption
Check for plugged orifice in
scavenger line
Clogged air inlet filter Clean or replace filter

Compressor Makes Air
elements
But Volume Is Low
Broken butterfly valve Replace valve
Excessive Foaming Of Foam and air release XHP605 replaces XHP505

Compressor Fluid characteristics of oil are as the standard factory fill
insufficient to remedy the for XHP compressors
Excessive OH Carryover symptoms (problem). above 300 psi (20.7 bar)
Into Service Air Products previously used
were Mobil 626 and
Oil Or Foam Out Of The
Blowdown Valve During XHP505.
Shutdown

Electronic Fan Regulation System

• The EFR (Electronic Fan Regulation) system is implemented in combin

(Electronic Air Regulation) system. Many of the components of the EAR
with the EFR system.
ation with the EAR
Depending on the configuration, the electronic controller monitors the

different systems on the machine.
system are shared
temperature from
1. Compressor Temperature
2. Hydraulic Temperature
3. Engine Coolant Temperature
4. Engine Intake Manifold Temperature
The controller increases the fan speed if any of the temperatures exceed
the built in
temperature set-point for that particular system. On machines with engine
s cooled by the
same fan circuit as the compressor, the EFR is configured to read the
engine coolant and
intake manifold air temperatures from the J1939 communication bus.
7-95
m required to keep the

The controller is always working to reduce the fan speed to the minimu
hottest system below the determined temperature set-poin t.
Additional System Components
of the air/oil mix after

The compressor discharge temperature sensor detects the temperature
er.
it exits the compressor and sends this information to the electronic controll
ic oil in the return

The hydraulic temperature sensor detects the temperature of the hydraul
manifold and sends this information to the electronic controller.
s the fan speed

The fan speed control valve is controlled by the electronic controller. It regulate
from controller
over a fixed range. The valve reduces the fan speed as the current signal
increases. The fan speed defaults to maximum in the event of a EFR failure.

7-5 HYDRAULIC SYSTEM
Hydraulic System Introduction

Power to drive the hydraulic systems is supplied by a diesel engine
with a drive shaft

connection to a hydraulic pump drive, which in turn drives from three
‘(3) to five (5) hydraulic
pumps, depending on the drill configuration. The hydraulic'pumps
convert the mechanical
rotary energy from the engine to hydraulic energy which can be used
by the various motors
and cylinders to perform the necessary drilling tasks. The result is
a simple and flexible drilling
system.
Note: The drawing below shows the configuration for a 55K/70
K model with a mud pump.
•
ROTATION
The hydraulic system consists of several circuits. Each circuit include

s one or more pumps
which supply pressurized streams of fluid to hydraulic cylinders and
motors.
1. The Rotation Pump is used to supply oil to the rotary head rotatio
n motors in
the Rotation Circuit.
2. The Main Pump is used to supply oil to the Main Manifold.
3. The Auxiliary Pump is used on T3W models with 55K/70K pulldown
and is
used to supply additional oil to the Main Manifold.
4. The Fan Pump supplies oil to the Cooler Fan Package Circuit.
5. The Mud Pump Drive Pump supplies oil to power the Mud Pump Circui
t.
•
The Main Manifold is used to supply oil to the main valve, 10-spool valve,
2-spool valve (30K/
40K models), 3-spool valve (55K/70K models), regen valves, remote
valve, jib boom and jib
arm, main and auxiliary winches, and the hot oil shuttle manifold.
DRILLING SOLUTIONS
7-97
7-6 HYDRAULIC SYMBOLS
Fluid Power Symbols

tic
Understanding and recognizing fluid power symbols is skill used in reading schema
tics used to describe
drawings for trouble shooting. It will-also aid in understanding the schema
the hydraulic systems used on Drilling Solutions drills.
are used to
Symbols on schematics are pictographs (pictures of what the object does) and
language
represent the component. The following symbols are an international fluid power
designed by the American National Standard Institute.
Fluid
Valve Conditioner
(1 (47 Gauge
Pump Motor
of these three
You will remember fluid power symbols more easily if you learn the significance
shapes:
1. Circle = Pump, Motor or Gauge

2. Square = Valve of some sort
3. Diamond = Fluid Container
Line Symbols
as a line.
Hydraulic lines, tubes and hoses that carry fluid between components are drawn
As a Working Line
As a Pilot Line
1111111
As a Drain Line
1. The Working Line is an unbroken line which connects symbols in the hydraulic
diagram together.
2. The Pilot Line denotes pilot pressure.
3. The Drain Line denotes system drainage.
at the
Connections for lines are shown below. Pay attention to the presence of a "dot"
intersection of lines. If there is no "dot" and the lines cross, the lines do not connec t. If the
lines intersect but one line ends, then even without a "dot" the lines do connec t.

Crossing Line Symbols
Let's examine the crossing line symbols. These are fluid or lines
They are independent and separate of each other.
Lines No t Lines Not

that cross but do not join.
I Lines Not
Connected Connected I Connected
Joining Line Symbol
The symbols for joining lines is shown in below. They show us

that fluid paths areconnected.
Lines Lines ,
Connected i Connected
Flexiblia Line
•
Pay attention to the presence of a "dot" at the intersection of lines.
If lines intersect but one line
ends, then even without a "dot" the lines do connect.
Flexible Line Symbol
The symbol for a flexible line or hose is also shown above. The
curve in the line illustrates the
flexible hose and the two heavy "dots" represent terminal points
.
Arrow Symbols
The arrow symbol appears in the working line.. The arrow shows
the direction of flow of the
fluid.
Oil Flows„ Oil Flows

in One Direction in Both Directions
Reservoir or Tank Symbols
Reservoirs and tanks are used to contain fluids, provide coolin

g, separate air and oil, and
provide pressure to the pump if the reservoir is pressurized.
•
The tank and reservoir symbols are shown next. They appear
on hydraulic diagrams as the
vented tank or pressurized tank. It is important to note that even
though these symbols may
appear in many different places on a hydraulic diagram, there
is usually only one centralized
reservoir tank.
DRILLING SOLUTIONS
7-99
I)
Vented Pressurized Pressurized Pressurized

Reservoir Reservoir Reservoir Reservoir
I I
Vented Reservoir Vented Reservoir
I I-E-1
Vented Reservoir
Oil Return Above Oil Return Below Suction Line Attached
Oil Leyel Oil Level To Bottom
return lines as above.

Reservoir symbols can also show the point of connection for suction and
Fluid Container Symbols

ioners" are filters,
The condition of the oil is changed from one state to another. Typical "condit
ls for fluid conditioners
heaters and coolers which can contain drains of various sorts. Symbo
represents an oil
are shown below. The symbol with a dotted line drawn from top to bottom
nts an oil cooler.
filter. The same symbol with arrows at the top and bottom of it represe
Temperature
Fitter or
Cooler Heater Control Unit
Strainer
-4•-
Manual Drain Auto Drain Manual Drain Auto Drain

Separator Separator Filter Separator Filter Separator
lt
1 F
Accumulator Symbols
are installed in parallel
Hydraulic accumulators act as shock 415-SUrbers for the system. They
re (keep pressure
with the pump and do several things. They dampen out oscillations in pressu
are drawn as ovals with
constant) and provide flow when components move and activate. The
tes the oil from the
a line in the center which represents the diaphragm or piston that separa
loaded type and on
spring or gas. On the left is the gas loaded type, in the center is the spring
the right is the weighted type.
Pneumatic Spring
(Gas Filled) Loaded Weighted
Accumulator Accumulator Accumulator
DRILLING SOLUTIONS
7-100
Restrictor Symbols
Sometimes it's necessary to slow down flow or to create a pressu

re drop at some point in the
system.
Fixed Restrictor Adjustable Restrictor
Adjustable Adjustable
Restrictor Restrictor
Pressure Pressure &
Compensated Tern peratu re
Compensated
Restrictors are drawn to represent a pinch in the line, and can

either be fixed or variable and
can be controlled by other systems as well, such as being tempe
rature,or pressure controlled.
Hydraulic Cylinders
Hydraulic cylinders convert fluid power to linear mechanical power

. Fluid under pressure
pushes against the ends of the piston to move it in order to move
some other mechanism.
Cylinders are drawn as rectangles with lines in the center to repres
ent the piston, and lines
through the ends to represent the rod. Fluid ports are shown
on the'outer ends of the
cylinder barrel.
PORT ROD
PISTON
BARREL
-
TYPICAL HYDRAULIC CYLINDER
A single-acting cylinder has only one port so that fluid under pressu
re only enters one end
and pushes only in one direction. The cylinder reverses by openin
g a valve to let gravity or a
spring return the piston to the other end.
DRILLING SOLUTIONS
7-101
rized fluid will enter both ends and

A double-acting cylinder has ports at each end so pressu
push against the piston in both directions.
DOUBI E -ACTING CY-INDER

SINGLE -ACTINGCYLINDER
DIFFERENTIALCYLINDER
DOUBLE ROD-END CYL.NDER
SINGLE ROD END WITH A SINGLE ROD END WITH ADJUSTABLE

CUSHION ON ROD END ONLY
='XED CUSHION AT BOTH ENDS
Activating Device Symbol

manually by hand with a
There are a variety of ways to- actuate control valves. These include
external pilot pressure, using
lever, by foot with a pedal, with an electric solenoid (coil), using
of the above.
a spring, using internal pilot pressure or using any combination
•
LEVER PEDAL SOLENOID
CONTROLLED CONTROLLEC CONTROLLED
PILOT PRESSURE
INFINITELY VARIABLE CONTROLLED
(NOT JUST ON AND OFF)
le3t 1 1 AL1
11
EiEt TT x 321
kiWik 1 1 TT
SOLENOID OPERATED WITH
SOLENOID OPERATED WITH
INTERNAL PILOT PRESSURE INTERNAL PILOT PRESSURE
AND SPRING CENTERING
DRILLING SOLUTIONS
7-102
•
There are ten basic arrangements that will appear from time to time
on hydraulic diagrams.
These symbols show how a pump, motor or valve is actuated. They
are shown below.
I=E 43:C
SPRING MANUAL - 41E
PUSH BUTTON LEVER PEDAL
WEE
PRESSURE INTERNAL DETENT
SOLENOID COMPENSATED SERVO
PILOT
Miscellaneous Symbols
Miscellaneous symbols are shown below. ,
-0+0-
QUICK DISCONNECTS
-OH 1-0-
QUICK DISCONNECTS SPRING
(CONNECTED) (DISCONNECTED)
• PRESSURE
SWITCH
INIMM11•111111X
RACHETING DETENT
ON VALVE
MANUAL SHUTOFF
VALVE
TEST POINT
FOR GAUGE TEMPERATURE PRESSURE
INDICATOR INDICATOR
I
_ • _!_
Pump and Motor
It is important to note that the only difference in the pump and motor
symbols is the direction
of the energy triangle. Remember that in the pump symbol the energy
triangle is pointed
outward toward the working line. In the motor symbol the energy
triangle is pointed in toward
the center of the circle, away from the working line.
•
PUMP MOTOR
DRILLING SOLUTIONS
7-103
Pump Symbols
The triangle
Pumps are drawn as circles with triangles pointing outward from the center.
be viewed as an arrow. A
represents the direction that fluid flows out of the pump and should
indicate a
single arrow shows a one-direction (unidirectional) pump, while two arrows
body indicate s the
reversible (bidirectional) pump. A diagonal arrow cutting across the pump
le on the side
pump displacement (output flow and volume) can be adjusted. A small rectang
the pump output is compen sated (adjusted
of the pump with a small arrow insidejndicates that
or controlled) by a pressure signal from-a pilot line.
FIXED VARIABLE VARIABLE

FIXED
MENT
DISPLACEMENT DISPLACEMENT DISPLACEMENT DISPLACE
PRESSURE
UNIDIRECTIONAL REVERSIBLE
COMPENSATED
attachments to the
Pumps are also drawn to indicate how their output can be controlled. The
The lever and pedal look like a lever and
pumps look like the components they represent.
of the pump, either with or without
pedal. The drive shaft is shown as a pair of lines on the side
as stacks, which indicate
an arrow showing the direction of rotation. Pumps can also be drawn
that all pumps are driven by the same driveshaft.
,L0 LEVER PEDAL PUMP WITH

DRIVE SHAFT
DRIVE SHAFT
SHOWING
CONTROLLED CONTROLLED DIRECTION
PUMP STACK
Hydraulic Motor symbols

circle. Hydraulic
Motors are drawn as circles with triangles pointing in toward the center of the
differences, pumps
motors are actually hydraulic pumps that work in reverse. Except for a few
would for pump
and motors are identical. Use the same rules to interpret motor symbols as you
symbols.
BI -DIRECTIONAL MOTOR WITH

NON-REVERSIBLE REVERSIBLE DRIVE SHAFT
MOTOR MOTOR PRESSURE
COMPENSATED

Instrument Symbols
There are three types of instrument symbols which you should know. The pressure gauge
symbol is shown on the left side below. The temperature gauge is shown in the center and the
flow meter symbol is shown at the right.
TEMPERATURE
PRESSURE FLOW METER
Valves
Hydraulic pressure is controlled through the use of valves that open.and close at different
times to allow fluid to be bypassed from points of higkpressure to p"oiijits of low pressure. The
basic valve symbol is a square (box) which represent& the valve body or spool. An arrow in
the center represents the path oil takes through the valve.
Pressure control valves are typically pilot operated - that is, the valve is moved automatically
by hydraulic pressure and not by a person. Pilot oil pressure is resisted by a spring, which can
•
often be adjusted. The higher the spring tension, the more fluid pressure required to move the
valve.
To visualize the operation of this type of valve, imagine that the entire square will move away
from the pilot line and towards the spring. If the valve is normally open, fluid flow will be cut off
by the pilot line. If the valve is normally closed, the pilot line will cause oil to start flowing.
Valves can either be ON/OFF valves with no flow in the middle, Orinfinitely variable, which
means flow will gradually increase or decrease as pilot pressure increases and/or decreases.
INLET INLET
SPRING SPRING
PILOT LiNE •
OUTLET
NORMALLY OPEN VALVE NORMALLY CLOSED VALVE
Pressure Relief Valve
A pressure relief valve is a normally closed valve that senses the high pressure at its inlet. As
the pressure at the inlet increases, the pressure in The pilot line begins to push against the
valve body (spool). As the valve body moves, the ports begin to line up and fluid will begin
flowing through the relief valve. The relief valve typically dumps back into the reservoir. Most
relief valves are infinitely variable.
PRESSURE RELIEF VALVE
7-105
Sequence Valve
A sequence valve is a normally closed valve that opens once the inlet pressure reaches a pre-
set point. This type of valve is designed to allow different components to act "sequentially",
meaning one after the other. Once the primary actuator reaches the limit of its travel, fluid
pressure in the feed line will rise. This rising pressure opens the sequence valve which allows
fluid to flow through it to the secondary cylinder.
TO PRIMARY CYLINDER
TO SECONDARY CYLINDER
SEQUENCE VALVE
Pressure Reducing Valve.
A pressure reducing valve is a borrnally open valve that senses the outlet pressure going to
an actuator. As the pressure in the outlet increases, pilot pressure increases which gradually
closes the reducing valv. As the'valve closes, oil from the high pressure side of the valve is
directed back to the reservoir which dumps pressure at the outlet.
PRESSURE REDUCING VALVE PRESSURE REDUCING VALVE
Directional Control Valves
The direction that fluid flows in a line can be controlled by using valves which allow flow in only
one direction. These valves are typically referred to as "check valves" because they "check"
the flow if it tries to reverse. These valves can have simple check balls or can have machined
poppet type valves. They can also be more complex pilot operated valves that have spools.
In the case of a ball check valve, the allowed flow is opposite the arrow, or towards the ball. If
the valve has no spring, the valve offers resistance to flow only in the "closed" direction; in the
"open" direction the valve moves with any movement of fluid and does not have a pressure
setting.
If the check valve has a spring it will oppose flow in the "open" direction up to the point where
hydraulic pressure overcomes spring tension. Check valves can also be pilot operated.
NO FLOW C> CI FREE FLOW

BYPASS VALVE PILOT OPERATED
ONE WAY VALVE (SPRING WADED BYPASS VALVE
(CHECK VALVE) CHECK VALVE)

Another method of drawing check valves (directional valves) is using composite symbols as in
the previous sequence. This method contains a blocked path and a free path. The dashed
lines represent pilot pressure lines. As pressure increases on the blocked side of the valve,
the pilot line moves the valve to reduce or cut off supply, depending upon whether the valve
is normally open or closed.
The spring keeps the valve in the normal position. If pressure builds up on the flow side of the
valve, the pilot line pressurizes and moves the valve into the open position, compressing the
spring in the process, and allowing oil to flow. If the flow attempts to reverse, the other pilot
line pressurizes and adds to spring pressure to close the valve, cutting off flow.
These valves are commonly referred to as flow dividers or flow control valves. This type of
valve can be a pressure relief valve or pressure,reducing valve depending upon location of
pilot source and spring setting.
FREE FLOW
NO FLOW
•
ONE WAY VALVE
SHOWN CLOSED PILOT PRESSURE FROM
RIGHT PUSHES VALVE
UPWARD TO ALLOW FLOW
Two Position Flow Control Valve
Two position flow control valves typically,are used to make the flow reverse to an actuator in
a simple system, although other arrangements are possible. The valve spool slides long-ways
to allow one or the other valve position to direct flow. Because these valves have no center
position they must be used with a pressure relief valve that opens to dump system pressure
when the actuator bottoms out.
Note that the direction of oil flow does not change on the pump side of the valve. The direction
changes only after the valve changes the flow to redirect pressure to the retracted side of the
cylinder.
Three Position Flow Control Valves
• Flow control valves are drawn as composite symbols using Squares to represent the valve
spool. To visualize the operation of these valves it's necessary to imagine them moving long-
ways with the spool sliding to move the different flow arrows into a position to allow oil to flow
through them.

CLOSED CENTER VALVE & SYSTEM

OPEN CENTER VALVE & SYSTEM WITH PRESSURE RELIEF VALVE
The centers of the valves determine what type of system is in use. An open center system
uses valves that allow oil to flow through them at all times (out of the pump and back into the
reservoir) when no actuators are in use: This system does not require a pressure relief valve.
A closed center system uses valves that block flow through them when no actuators are in
use, thereby "liquid locking" the system. In this type of system a pressure relief valve is
mandatory to prevent the system from destroying itself when the valves are in the center.
Valve Symbols
The next area to cover is valve symbols. Begin with some of the basic symbols shown below.
Boxes = Positions
1 2 3
Most valves are depicted by using a box aS a symbol. Pressure and flow control valves usually
use one box. Directional control valves use two or more boxes. The number of boxes indicates
the number of valve positions. Notice that the box symbols shown below have lines drawn to
them. These are referred to as "ports". At the left is a two port valve, commonly called a 2-way
valve. In the center is three port, or 3-way valve. On the right is a four port or 4-way valve.
2 Port 3 Port Port
11
2 Way 3 Way Way
Three Position "4-Way" Valve
Let us examine the most common of all control valves, which is the "4-way" valve below.

This control valve directs fluid or oil flow to a forward position, a neutral position or a reverse
position. The previous picture shows the fluid or oil flow path when the valve is in neutral
position. In neutral, oil flows from the pump into the valve and back to the reservoir.
Arrows
Arrows in the adjoining squares show the fluid flow path when the valve is "shifted to the other
positions.
x
A
El
Forward Position
With the forward position activated, the fluid or oil flows from the pump through the valve and
•
onto the left side of the cylinder. Return oil from the cylinder is released through the valve and
back to the tank.
40-
ir
Neutral Position
With the valve in the neutral position, fluid or oil is allowed to flow from the pump through the
valve body and back to the tank. Refer to picture below.

Reverse Position
With the reverse position activated, fluid or oil flows from the pump through the valve and into
the right side of the cylinder. Return oil from the left side of the cylinder is released back
through the valve and returned to the tank.
Valve Centers
Let's look at valve centers now. There are four main center valve configuration symbols:
1. Closed Port - Closed Center

2. Closed Port - Opened Center
3. Open Port - Closed Center
4. Open Port - Open Center
Closed Port Closed Pot Open Port Open Port
11
T T-
Closed Center Open Center Closed Center Open Center
Series Parallel Valves
Now that we have seen our directional control valves at work, let's see how we bank two or
more valves together. As shown below, one pump is supplying oil to two valves for control of
two different actuators. The valves are connected together by a parallel passage which allows
simultaneous operation of both functions.
I
TV
Series
Parallel
111
T T
•
Reverse Position

When the bottom valve is shifted to the reverse position, oil is still available for the other
spool
through the parallel passage. This is called a series parallel valve.
Pilot Operated Lock Check Valve
The pilot line symbol indicates a pilot operated lock check valve. This valve will allow
reverse
flow when pilot pressure is present.
Pilot Line r
Bypass Valve
The check valve symbol is also used to show a bypass valve. In this application, the
ball is
held seated by spring pressure and the valve opens when pressure drop across the filter
becomes too great.
IFilter with
I Bypass
Overcenter Valve
The overcenter valve shown below throttles return oil to prevent a runaway condition
on a
heavily loaded cylinder or motor. If the cylinder should try to collapse faster than the pump
is
supplying oil, the pilot pressure will drop and the overcenter valve will throttle the exhaust
oil
leaving the cylinder.
Overcenter
Valve
L Fror'n
: Directional
rDirectional—
Valve
Valve
DRILLING SOLUTIONS
7-111
Review
the
Let's review. A typical hydraulic diagram (schematic) is shown below. Can you name all
components?
1.
2.
3.
4.
5.
6.
7.
8.
9.
6
5
NI
• T T
J
(a 43

7-7 HYDRAULIC CIRCUITS
General Information
If you are not experienced with the drill's controls and instruments, you must read and
approved hard hat, safety glasses, steel toed boots/shoes, gloves, respirator and ear
protection. Do not wear loose fitting clothing that Can become caught on rotating components.
Do not wear oil stained or damaged garments:_.
1. Do not increase engine speed to..high idie.c.infil theeengine has been warmed up.
2. Always chock the wheels if there is'i'pbsSibility of uncontrolled movement.
4. Always perform safety checks prior tostarting'and using the drill.,
personnel and allow sufficient time before putting the drill in motion., 4
a risk of overturning. Always use a spotter.:
crushing risk.
10. Before starting engine, always check to see that the control levers and the drill
feed controls are at stop, neutral or off position.
•

Rotation Circuit
The primary components of the rotation circuit are the rotation pump, charge pump, rotation
motors, hot oil shuttle manifold, torque limit control (option), rotation pressure gauge, 3750 psi
relief valve, 6000 psi relief valve, diverter valve and controls. This system utilizes a closed loop
system. The controls for the components are shown below.
Rotation Pump
The rotation pump is a closed-loop hydrostatic transmission piston type package pump. The
rotation pump symbol is shown in the schematic below. The circles with the two power
triangles, pointing outward, show that the pump is bi-directional. The arrow through the middle
at an angle means the pump has a variable flow control. The entire pump is depicted as a
"package".
VA V Vs S - 04
F 4500 VALVE RELIEF
PSI 6000 PSI
-08
OTAT IOW
o '06
rSUCTION
35-44
RVO
rtil" •
KG
00
Oil PS 1
L --------------. 102
ROTATION
2500 RPM frITN 201
7.25 IN" 3/REV
78,5 GPM
Loop basically means the complete path of hoses, fittings, valves, motors and other
components the oil flows through on its way from and back to the pump. Closed Loop means
that oil entering the main pumping element comes directly back from the system without first
passing through the system reservoir. Oil is used repeatedly in a continuous loop. Hydrostatic
Transmission means that the pump is designed for use in a system in which power is
transmitted by the pressure of a fluid. It is designed to work with very little slippage and
leakage. Package means that the pump unit contains not only the main pumping element but
also the controls, valves and auxiliary pump needed for proper interface with the hydraulic
system. The displacement of these pumps can also be changed (variable displacement).
The main rotating group is depicted as a large circle with two triangles pointing towards the
work port lines. A long arrow through the circle means the pump displacement is variable. The
two main work ports are the "A" and "B" ports. Either port can discharge oil depending on the
position of the pump displacement controls.
Which ever port is not discharging oil is receiving oil. In other words, if oil is leaving port "A",

practically the same amount of oil is being returned to port "B".
SERVO
CONTROL
PUMP COMPENSATOR
(MAIN RELIEF VALVE)
MAIN PUMP
CHARGE PUMP
A charge pump built into the rotation pump provides hydraulic power to move the
swash plate.
This is represented schematically by a circle with one triangle pointed toward the
work port.
The purpose of this small pump is to provide oil to work the pump controls and
to charge the
main pump loop so that it never runs out of oil_
The first relief valve provides pressure to operate the swash Plate. The second
relief valve is
•
used on closed loop systems only.
The rotation pump is used in the rotation circuit to control the speed and direction
of the drill
string. It is a variable displacement piston pump that operateg on both sides_ cif
center. The
pump output is controlled by the operator via the rotation controller located ori-the
operator's
console.
The pump controller used with the rotation pump is proportional. Operator input
is supplied
electrically to the servo control on the pump via a proportional electric controlle
r. When the
operator moves the control handle, the eleotric input is converted to a hydraulic
input (top
triangle). Here it is amplified (left triangle) and the resulting output (lower triangle)
drives the
pump swashplate positioning system.
TORoue LIMIT
0-4000 PSI
GUAGE, ROT.
PRESSURE
0-5000
RELIEF VALVE
3750 PSI
ROTATION
2500 RPM
7.25 IN" 3/REV
78.5 GPM
7-115
back into
Some hot, dirty oil must be drained from the circuit and clean, cool oil must be put
the rotation pump and a hot oil
the loop. This is done by the charge pump that is built into
into the make-up oil. A
shuttle valve. Cool, clean oil is pumped through the charge pump and
the same
relief valve in the charge pump outlet forces the clean oil into the make-up line and
exhaust
volume that is allowed in is returned through the hot oil shuttle. The hot oil shuttle will
the rotation is in, and the charge pump will supply
low pressure oil no matter which direction
make-up oil from either side.
D HOT OIL SHUTTLE

MANIFOLD
FROM "SC" PORT ON

MAIN MANIFOLD
line to
On drills with a torque limit control, a sequence valve is added to the forward rotation
prevent the torque limit from dropping below 500 psi (3447 kPa).
Rotation Motors
motor,
There are two types of rotary heads used on the T3W Waterwell drill. One is a four
single speed drive head and the other is a four motor, two speed drive head.
and thus
The four (4) rotary head motors are fixed displacement motors and are bi-directional
is limited to 4500
can be used either in forward or reverse rotation. Note that system pressure
psi (31,027 kPa).
shown by
The schematic for the rotation motors is shown below. The main motor section is
There are case drains on
the circle with two triangles pointed inward from the two main ports.
each since they are piston motors.
06
•
12 •
15 IN" 3/REV 06
•
• I2 dmi 12 -06
12.5IN" 3/REV 2
06 •06
9.9 1Fe 3/REV
2
• 06
2
MAN.;FOLO
-20 •20
I Hor OIL sHJ - ILE

A 6
. MA R! FOLD 2
20
:VALVE DIVERTER
NI fa 5-1
P51 .
1'51 OPTIONA 2 SPEED
Al1
A 81
L.• _ .._ HEAD .. _.I

The single speed standard rotary head uses four 9.9 cu. in./rev hydraulic rotation motors with
5500 ft/lbs (7457 N-m) torque @ a rotation speed of 0-145 RPM.
The single speed heavy duty rotary head uses two 9.9 cu. in/rev hydraulic rotation motors and
two 12.5 cu.in./rev hydraulic rotation motors with 6250 ft/lbs (8474 N-m) torque @ a rotation
speed of 134 RPM.
The single speed high torque rotary head uses two 12.5 cu. intrev_hydraulic rotation motors
and two 15 cu. in./rev hydraulic rotation motors with 8,000 ft/lbs (10,847 N-m) torque @ a
rotation speed of 0-105 RPM.
The two speed standard rotary head uses four 9,.9 cu. in./rev hydraulic rotation motors with
5500 ft/lbs (7457 N-m) torque @ a rotation speed of 0-145 RPM. The second speed is 4000
ft/lbs (5423 N-m) torque @ a rotation speed of 0-195 RPM.
The two speed heavy duty rotary head uses two 9.9 cu. in/rev hydraulic rotation motors and
two 12.5 cu.in./rev hydraulic rotation motors with 6250 ft/lbs (8474 N-n) torque @ a rotation
speed of 134 RPM. The second speed is 4650 ft/lbs (6305 N-nn) torque @ a rotation speed of
0-180 RPM.
The two speed high torque rotary head uses two 12.5 cu. in/rev hydraulic rotation motors and
two 15 cu. in./rev hydraulic rotation motors with 8,000 ft/lbs (10,847 N-m) torque @ a rotation
speed of 0-105 RPM. The second speed is 5500 ft/lbs (7457 N-m) torque @ a rotation speed
of 0-145 RPM.
Main Manifold
Main Pump (30K, 40K, 55K, 70K Drills)
The main pump is located on the main hydraulic drive gearbox. It is a variable displacement,
piston, uni-directional pump with clockwise rotation. The main pump has a 95.8 gpm (362.6
liter/minute) load sensing control. The main pump has a displacement of 8.54 in3 /rev (145cc)
at 2500 rpm. The main pump supplies oil to the main manifold as needed.
Auxiliary Pump (55K, &OK Drills)
The auxiliary pump, mounted in the upper center position on the 3-hole main hydraulic drive
gearbox, is an optional pump that is only used with 55K AND 70K drills. It is a variable
displacement, piston, uni-directional pump with clockwise rotation. The auXiliary pump has a
49.6 gpm (187.7 liter/minute) load sensing control. The auxiliary pump has a displacement of
4.58 in3/rev (75cc) at 2500 rpm. The auxiliary pump supplies additional oil to the main
manifold, as needed, to supply the additional feed cylinder used on 55K and 70K drills.

To "a" and "b" ports on the 4th spool

of 10 spool valve respectively
Manifold, Shuttle A
To "b" port and "a" port
respectively on 3rd spool
of 3 spool valve
Remote
Valve
To "a" port and "b" port

• ' respectively on 1st and _J
2nd spool of 3 spool valve f=3
Main Winch Auxiliary Winch Main Winch Aux. Winch
Console Console (option) Aux. Helper (opt.)Helper
i
i To 'RP" port on
regen valve
To "SFR" and "SFE" ports

respectively on regen valve
Main
Manifold
To "P" port on
3 spool valve
outlet section
G3t•—•
Feed
Gauge Orifice
Dia. 0.020
41
,
Plf
CP%
To "P" port on 3 spool

valve inlet section
N
Nn UMW
To "MA" port on 1st and
2nd spool of 3 spool valve
To "MB" port on 1st and

2nd spool of 3 spool valve

•
Jib Arm Extend Jib Boom
Swing Cylinder Water
Cylinder
Injection
3.0 dia., 14.12, 3,0 dia., 14.12,
1.5 rod 1.5 rod
Q6 -)fi 06 :5
Water.
InjectiOn
, I Manifold
• • --
f—j1 •
v2
C-49
---"LJ-1 ?-
-11111144
—.
Main Pump
8.54 inA3/rev
2500 rpm
95.8 gpm Load A: Auxiliary Pump
Sensing Control :••••—•• Optional 55K/70K
4.58in"3/rev
2500 rpm
YL.._. 49 6'gpm Load
Sensing Control
1
7-119
Overpressure Controls
These two overpressure control valves, mounted one on each of the drilling end jacks, are
simply two position, two way valves that are opened by the jack nipples moving downward on
the valve plunger. This allows flow to drain out of the two spool valve. Once the jack has been
placed back on the ground, and the nipple is moved off the plunger, pressure is restored to the
system.
To ensure the over pressure control is operational and working properly, the following
procedure should be performed daily or before each drilling shift:
1. Locate the drill on a level, graded surface. Raise and level the drill just high
enough so that the tires are just off the ground.
2. Remove all drill rod, stabilizers, hammers, etc. from the rotary tophead.
4. Move the empty rotary tophead to the bottom of the derrick using fast feed.
5. Stall fast feed at the bottom of the derrick.
6. Raise the left jack on the drilling end off the ground.
7. Read the feed pressure gauge on the operator's console and verify the feed
pressure drops below 600 psi (41.3 bar).
NOTE: If the Feed Pressure does not drop below 600 psi (41.3 bar),
troubleshoot and repair the circuit.
8. Repeat the above for the drilling end, console (right) side jack.
9. Repeat the above process using slow feed.
If all checks are met, the over pressure control is functional and drilling can proceed.
Feed Cylinders
The feed cylinders (also called pulldown cylinders) are double acting, single rod cylinders. The
schematic symbol for the feed cylinder is shown below.
Feed
Cylinder
"Double Acting" means that the cylinder can be powered by the hydraulic system to extend
and to retract. "Single rod" means that the cylinder only has one rod extending from one end
of the cylinder tube.
7-120
DRILLING SOLUTIONS
1. The 30K/40K derrick uses one 5 in. diameter x 165.5 in. x 3.5 in. diameter rod
(127 mm x 4203.7 mm x 88.9 mm) cylinder.
2. The 55K/70K derrick uses two 5 in. diameter x 165.5 in. x 3.5 in. diameter rod
(127 mm x 4203.7mm x 88.9mm) cylinder.
Fast Feed
30K/40K- The feed system main components are the hydraulic main pump, two spool (main)
valve, fast feed controller located on the operator's console and feed cylinder. The load
sensing control in the hydraulic main pump can supply 95.8 gpm as needed to the main
manifold, which supplies the 2-spool (main) valve.
55K/70K- The feed system main components are the hydraulic main pump, hydraulic auxiliary
pump, three spool (main) valve, fast feed controller located on the operator's console and two
feed cylinders. The load sensing control in the hydraulic main pump can supply .95.8 gpm as
needed to the main manifold, which supplies the 3-spool (main) valve. In addition, the auxiliary
hydraulic pump can supply an additional 49.6 gpm as needed to the main manifold for the 3-
spool (main) valve as needed.
The fast feed is operated through one of the spool valve sections of the main valve. The spool
has a regenerative section which is initiated if the operator pushes the control all the way
forward. This action allows oil, coming from the rod end, to mix with flow from the pump and
increase the speed of the cylinder in the "down" position only.
The fast feed valve is operated by a hydraulic pilot valve mounted on the left side of the
carousel.
The fast feed, hoist and the drill feed are all controlled by the overpressure valves on the two
leveling jacks nearest to the drilling end of the drill. If either jack is off the ground or falls in a
hole, the reliefs on the main valve will vent and no pressure will be seen until the overpressure
valve is closed.
Pilot System
The three valves activated by a pilot system are the fast feed, the main winch and the auxiliary
winch. There are two pilot control valves for the main winch (and auxiliary winch); one on the
operator's console and the other on the helper's side of the drill next to the jib arm swing and
extend valves.
The main winch operates through one of the spool valve sections of the main valve that is
mounted on the back of the derrick support. Pressure to operate the main valve comes from
the main manifold.
also.
Pressure to operate the jib boom swing and extend- co.mes from the main manifold
7-121
DRILLING SOLUTIONS
Fan Pump
The cooler fan pump is mounted piggy-back on the main pump,

which is mounted on the main
hydraulic drive gear box. It is a variable displacement, piston
pump, uni-directional with
clockwise rotation. The cooler fan pump has a 39.6 gpm (149.9
liter/minute) pressure
compensation control with a displacement of 3.66 in /rev (60cc)
at 2500 rpm. The cooler fan
pump supplies oil to the cooler fan motor.
FAN MOTOR
6.0 INA3/REV
1100 RPM
ANTI CAV
-16 MANIFOLD
PUN
-06 I MANIFOLD
ye n i -12
OUT FAN PUMP,

PRESSURE
F(424, • COMPENSATION
CONTROL
3.66 INA3/REV
2500 RPM
FAN 39.6 GPM
-32
SUCTION
Main Valve
30K/40K Drills
The main manifold supplies oil to the two spool main valve on
30K and 40K T3W drills. The
feed cylinder is operated through one of the spool valve sectio
ns of the two spool main valve
that is mounted on the back side of the derrick support. It has
a regenerative section built in
and is initiated if the operator pushes the fast feed control all
the way forward. This action
allows oil, coming from the rod end, to mix with flow from the main
manifold and increase the
speed of the cylinder in the "down" position only.
The main winch operates through the second spool valve of the
two spool main valve that is
mounted on the back side of the derrick support. This spool section
has a 2500 psi relief valve.
7-122
DRILLING SOLUTIONS
To "SFR" Port and "SFE" To "M WA" Port and

T3W - 30K/40K Port respectively on Main "MWB" Port
Manifold Respecti vely on
Shuttle Manifold
Feed Cylinder
5.0 Dia. Main Winch
165.5 Stroke 12K - 6.4 inA3/rev
3.5 Rod -rzrL 18K - 7.63 inA3/rev
30K - 5.5 in^3/rev
4 ,•
To "A" Port and .
"B" Port on To "RP" Port on
Remote Valve Main Manifold
L_..
Regen Valve
29 To V3 Port on
c. Main Manifold
To LS Port on
From "VLS" I
10 Spool Valve
Port on Main
Manifold 8
N N
2 Spool Valve
To V2 Port on
To "MB" and "MA" Ports
Main Manifold Respectively on Man
Manifold
55K/70K Drills
and 70K T3W drills. The
The main manifold supplies oil to the three spool main valve on 55K
valve section two of the
feed cylinders are operated through spool valve section one and spool
support. The spools
three spool main valve that is mounted on the back side of the derrick
the fast feed control
have regenerative sections built in and are initiated if the operator pushes
coming from the rod end, to mix with flow from the
all the way forward. This action allows oil,
rs in the "down" position only. The main
main manifold and increase the speed of the cylinde
main valve that is mounted on
winch operates through the third spool valve of the three spool
psi relief valve.
the back side of the derrick support. This spool section has a 2500
7-123
DRILLING SOLUTIONS
Feed Cylinder
5.0 Dia. T3W 55K/70K To "MWA" Port and "MWB" Port
165.5 Stroke Respectively on Shuttle Manifold
Optional Cylinder 70K
3.5 Rod
za 7Fra._.°
Main Winch
To "A" Port and 1— tOOE - -KEE ,,12K - 6.4 inA3/rev
"B" Port on i 1-X- 7:63 inA3/rev
Remote Valve 30K - 5.5 inA3/rev
ienueiiuononi4sui An1
To "RP" Porton
FIR
Main Manifold
Regen Valve. Regen Valve

Optional 70K
To "SFR" Port and "SFE" Port
za Respeativelyon Main Manifold
• To V3 Porton Main Manifold

To LS Porton
From "VLS" 10 Spool Valve
Porton Main
it,hci
Manifold H
I 21
0
L 1.114
3 Spool Valve
To "MB" and "MA" Ports
Respectively on Main Manifold
To V2 Porton Main Manifold
SNO111110SON111ftia
Section 7 - Systems/T roubleshooting
• • •
10-Spool Valve
10-spool valve. Ten spool valve spool
The main manifold and the main valve supplies oil to the
sections one (1) through three (3) are shown below.
w
z
g F"4" — • .
I Scl 00S
.-
1—• •—
w0
ce 3A1VA >103HO 'O'cl
w
-J
"f)
CO
• cc
"
o w>
1-
iScl OOZY
o 'A z' t,4•>
From "V1" Port on Main Manifold

m
: 0----471
From "LS"Port on Ma nValve

1--ul <c I=1 •
r
0xcì L g1I V
i
<
" .1-
0
•
ICJ
7-125
DRILLING SOLUTIONS
Ten Spool sections four (4) through six (6)

are shown below.
—.._.._..—..
iSd 000E
411
*Mb
ISd OC
-1;
..—•••=:=4;:r."-"-^"1
0
s g
,
: —
3 co
g
• "E
2
7-126
DRILLING SOLUTIONS
shown below.
Ten Spool sections seven (7) through ten (10) are
40,
ISd 0092
*---0-00.0— • • — • • — • • — • • —0-
09 8 4(1
•-)
N.4
1
•91 1E
11 1 :I
!
0.
ISd 00SZ
c)
.—.._..—.. —Q.1
ISd 0092
r
G
•
*1
AlLa117
tre
cc •ND
I 1
tr)
r— ISd 00SZ
0
•
O
7-127
DRILLING SOLUTIONS
Valve Section One (Carousel Index)
This is a motor spool, spring centered section that

operates the carousel index motor. The
carousel motor has a displacement of 22.5 in3/re
v. The carousel index controls the rotation of
the carousel when moving drill pipe under the drill
string when adding pipe to the drill string or
removing drill pipe from the drill string.
Valve Section Two (Breakout Wrench)
The cylinder spool section controls the breakout

cylinder on standard drills. The breakout
chain/pipe wrench is used for removing drill pipe
from the rotary head or drill string at the table.
Valve Section Three (Retract Table)
This cylinder spool section operates the retract table

cylinder. Retract the table to change
bushings or install large casing. Retract the table
by lifting the control and close the table by
lowering the control.
Valve Section Four (Auxiliary Winch Opti

on)
This is a motor spool, spring centered section that
operates the auxiliary winch motor or the
high rope capacity sand reel option. The auxiliary
winch motor has a displacement of 1.64
in rev, 2000 psi. The high rope capacity sand reel
motor has a displacement of 4.0 in3 /rev.
The auxiliary winch control is used to raise and lower
the auxiliary winch or high rope capacity
sand reel option. Note: If the auxiliary winch
or high rope capacity sand reel is not ordered.
this spool section is removed.
Valve Section Five (Rod Spinner)
The rod spinner valve spool is a motor spool that

operates the hydraulic motor that activates
the rod spinner used to attach or detach drill pipe
to or from the drill string. The rod spinner
control must be pushed down (away from neutral
position) to turn the rod spinner on. Raise
the control to the neutral position to turn the rod
spinner off.
Valve Section Six (Derrick Raising Cylinders

)
This cylinder spool section operates #le derrick raising
cylinders. The derrick raising cylinders
have a 5.0 inch diameter bore (mm) x 36 inch (mm)
stroke x 3.0 inch (mm) rod with a double
holding valve. Feather the derrick raising control
when derrick approaches vertical position. Do
not slam derrick against stops.
Valve Section Seven (Leveling Jack)
This section operates the cab end, rod box side,

leveling jack. The jack is mounted directly
behind the truck cab. The standard jack has a 5.75
in. (146 mm) bore x 4.5 in. (114.3 mm) x
36 in. (914 mm) stroke with a double pilot holding
valve and an 18 in. (457 mm) jack pad.
7-128
DRILLING SOLUTIONS
•
Valve Section Eight (Leveling Jack)

le side, leveling jack. The jack is mounted
This section operates the cab end, operator's conso
a 5.75 in. (146 mm) bore x 4.5 in.
directly behind the truck cab. The standard jack has
pilot holding valve and an 18 in. (457mm)
(114.3nnm) x 36 in. (914mm) stroke with a double
jack pad.
Valve Section Nine (Leveling Jack)

ng jack. The jack is located on the side
This section operates the drill end, rod box side, leveli
has a 5.75 in. (146 mm) bore x 4.77 in.
of the deck behind the rear wheel. The standard jack
pilot holding valve and an 18 in. (457 mm)
(113.5 mm) x 48 in. (1219 mm) stroke with a double
jack pad.
Valve Section Ten (Leveling Jack)

ole side, leveling jack. The jack is located
This section operates the drill end, operator's cons
standard jack has a 5.75 in. (146 mm) bore
on the side of the deck behind the rear wheel. The
a double pilot holding valve and an 18 in.
x 4.47 in. (113.5 mm) x 48 in. (1219 mm) stroke with
(457 mm) jack pad.
• Schematic Circuit Symbols
Cylinders
A representative cylinder symbol is shown below. This

"Double-Acting" means that the cylinder can be powe
and to retract. "Single-Rod" means that the cylinder
is a double acting, single rod cylinder.
red by the hydraulic system to extend
only has one rod extending out of one end
of the cylinder tube.
DOUBLE
ACTING
CYLINDER
7-129
Motors
Representative motor symbols are shown below

. The circle may contain one triangle pointed
inward from one work port (unidirectional) or a triang
le pointed inward from both ports
(bidirectional).
Motor "B" is fixed displacement. This mean

s that speed may only be changed by changing the
motor supply flow. Motor "A" is bi-directional. Dotte
d lines leaving the circle show that the
motor case leakage is taken away from the moto
r externally.
Relief Valves
Relief valves are used in many locations in the auxil

iary functions circuit. A representative
relief valve symbol is shown below.
INLET
1
ATM
The basic valve envelope (box) contains an arrow

in the normally closed position. The
adjustable length spring holds the valve spool in
the closed position until inlet pressure
overcomes the spring force. The valve opens and
closes as required to limit the maximum
pressure at its inlet.
Valve "A" is the pilot section. If there is no flow, there
is no pressure drop across the orifice "C".
Pressures from both pilots at "B" are equal and the sprin
g is able to keep the valve closed. As
the pressure increases, the pilot relief "A" opens
at the set relief pressure. Thus, there is flow
through the orifice and pilot pressure on the sprin
g side of the main relief drops. This allows
the upper pilot pressure to overcome the combinatio
n of spring and lower pilot pressure and
the main relief opens, allowing full flow through the
valve.
7-130
DRILLING SOLUTIONS
Restrictor Valves
load and divert any excess oil
Bypass type restrictor valves allow a restricted flow to the work
le of this type of valve.
to the valve bypass port.The water injection regulator is an examp
BP
PEG .I, IN
Check Valves
into the spring end of the
The check valve is a one-way valve of the hydraulic circuit. Flow
flow directi on). Flow into the seat
valve forces the ball into its seat to block fluid flow (blocked
(free flow direction). The
end of the valve pushes the ball out of its seat to permit fluid flow
e a preset, nonadjustable valve
check valve spring is typically preloaded at the factory to provid
opening pressure in the free flow direction.
CHECK VALVE ,.... __-- VALVE SPRING
,& ---- -- :BALE_
--- SEAT
----z-
Two Way Valve

that can be activated by a
The two way valve has a closed position and an open position
the valve closed so that oil cannot flow
plunger. In the normal position, the valve spring holds
howev er, the valve shifts and free
from the "P" to the "T" port. When the plunger is pressed,
flow is allowed.
PUSH DOWN TO
TWO WAY VALVE-. ALLOW FREE FLOW IN.
DIRECTION OF ARROW
DIRECTION OF
FREE FLOW
SPRING KEEPS
VALVE NORMALLY
CLOSED
7-131
DRILLING SOLUTIONS
Pilot Check Valves
Holding Valves are used throughout the hydraulic

circuit to keep motors and cylinders locked
and to provide smooth load movement.
The Pilot Check Valve is shown schematically
below. The Pilot Check Valve is another type
of holding valve used for'locking hydraulic comp
onents in place.
C1 C2
PILOT EE
CHECK
VALVE
1 V2
The valve works like a check valve in one flow

direction and locks in the reverse flow direction.
In the reverse.flow direction, the valve'can be
piloted open to allow reverse flow. Once the
valve has been piloted opeged, oil flows with very
little restriction.
Filters & Manifolds
The filter (shown below) is represented by a squa

re, tipped on one corner with the inlet and
outlet to two opposite corners and a dashed line
connecting the two remaining corners. Oil
flows into the filter through the inlet port and leave
s through the outlet port. Contamination is
captured by the porous element within the hous
ing.'
BYPASS
CHECK FILTERS
VALVE
FLOW
OUTLET
An additional feature in certain filters is the visua

l indicator used to signal a "clogged" element.
A bypass check valve is installed in line with the
flow. In case the filter becomes plugged or
dirty, the check valve will open and allow oil to
flow around the filter
There are three single element in-tank filters used
to clean the hydraulic oil. They are 3 micron
rated filters using the inside-out flow pattern. This
means that if a filter is contaminated and
has to be changed, the debris that normally woul
d be on the outside of the element would fall
into the hydraulic reservoir and contaminate the
whole reservoir. With the inside-out type, all
debris is trapped inside the filter element and can
be removed safely, without getting any
contamination in the reservoir. Using single elem
ents also keeps debris from getting into the
system since the elements don't come apart in
the container.
There is a drain manifold mounted on the deck
in front of the hydraulic reservoir. It has o-ring
fittings that prevent leaks and all the oil from the
system, except the pilot oil, is returned through
this manifold.
7-132
DRILLING SOLUTIONS
TO RIG AIR 90PSI
3 PSI K a1
10 PSI
-24 To 73"
HYDRAULIC
1,
Z 0 „...- TANK
CC _i co
-24 To "T5"
o0
O ,—
< c0
LIJ —
Cr Z h.
0
u,
co
C•1
-24
-24
To "T4"
To "T2"
Lti
I—
DRAIN FILTER
DRNI
DRN2
XX
z z
0
H
(/)
z CI)
LU
Lti
7-133
DRILLING SOLUTIONS
TO HYDRAULIC TANK
RETURN MANIFOLD
2657818817
IRING' FROM 3 SPOOL
FROM 3 SPOOL RTN3 • 401.1

- FROM PR RTN2 p) • • " R1
..:114I FROM
1 I 10 SPOOL
MANIFOLD 1
71
" RTN5-1 FROM HOS
FROM MUD IRTN5-2 17It I
PUMP (OPT)
RTN1 I FROM FAN
HOC
T7
• Ti
17
T5
COI
012
FROM RETURN MANIFOLD 2657888216
7-134
DRILLING SOLUTIONS
RETURN MANIFOLD
IN CONSOLE RETURN MANIFOLD
2657888216
2657379505
IRTN211
I RTN13I
RTN141-
RTNB I IRTN15 IRTNi6

I RTN7
t t
1 RTN9 I I? IRTN17 j • IRTN18
I RETURN MANIFOLD
RTN19 I RTN201
I RTN11..1 IRTN121 2657379505
-08
-08 I RTN22I • t RTN23
RTN241 _ I RTN25
• ? ?
I RTN27 IRTN26I
-24
3
TO PORT "T6" ON RETURN z
MANIFOLD 2657818817
Mud Pumps
y components of a mud
There are three types of mud pumps used on the T3W. The primar
lic drive pump, mud pump motor, mud
pump system are the mud pump, mud pump hydrau
and a 0.30 dia. orifice.
pump control valve, mud pump gauge on standpipe,
Mud Pump Options

is mounted in
1. 3 x 4 Centrifugal Mud Pump - The 3 x 4 centrifugal mud pump
levelin g jack on the operator's
a vertical position next to the non-drilling end
side of the drill, behind the truck cab.
GPM (1136
a. The 3 x 4 centrifugal mud pump has the capacity to deliver 300
Umin) @ 145 psi (1000 kPa).
mud pump is
b. 30K/40K - The hydraulic pump that supplies oil to the
main hydra ulic drive
mounted in the upper center position on the 3-hole
t piston pump with
gearbox. The hydraulic pump is a variable displacemen
re contro l. It
uni-directional (clockwise) rotation with load sense and pressu
inute)
has a displacement of 3.66 in3/rev. (60cc), 39.6 gpm (149.9 liter/m
@2500 rpm.
7-135
DRILLING SOLUTIONS
c. 551V70K - The hydraulic pump that

supplies oil to the mud pump is
mounted piggy-back on the auxiliary pump
located in the upper center
position on the 3-hole main hydraulic drive gear
box. The hydraulic pump is
a variable displacement piston pump with
uni-directional (clockwise)
rotation with load sense and pressure control.
It has a displacement of 3.66
in3/rev. (60cc), 39.6 gpm (149.9 liter/minute) @25
00 rpm.
d. The hydraulic motor used with the 3 x 4 cent
rifugal mud pump is a fixed
displacement, bi-directional motor with a displ
acement of 3.32 in3/rev.
2. 5 x 6 Duplex Mud Pump - The 5 x 6 dupl
ex piston mud pump is mounted
behind the truck cab.
7-136
DRILLING SOLUTIONS
ity to deliver 150 gpm (568

a. The 5 x 6 duplex piston mud pump has the capac
L/min) @ 310 psi (2137 kPa).
oil to the mud pump is
b. 30K/40K - The hydraulic pump that supplies
hydraulic drive
mounted in the upper center position on the 3-hole main
piston pump with
gearbox. The hydraulic pump is a variable displacement
pressure control. It
uni-directional (clockwise) rotation with load sense and
(149.9 liter/minute)
has a displacement of 3.66 in3 /rev. (60cc), 39.6 gpm
@2500 rpm.
oil to the mud pump is
c. 55K/70K - The hydraulic pump that supplies
the upper center
mounted piggy-back on the auxiliary pump located in
hydraulic pump is
position on the 3-hole main hydraulic drive gearbox. The
uni-d irecti onal (clockwise)
a variable displacement piston pump with
a displa cement of 3.66
rotation with load sense and pressure control. It has
rpm.
mud pump is a fixed
d. The hydraulic motor used with the 5 x 6 duplex piston
of 15 in3/rev.
displacement, bi-directional motor with a displacement
x 10 Centerline mud pump is
3. 7.5 x 10 Centerline Mud Pump - The 7.5
mounted behind the truck cab
t.. 3 r • ak
'li " '
";(%-.'
' - „.,.>1 1' .. 4 37 '1

.3 4 '1V
.-‘ '''. ,%..., 419Z 1 ..
:.0- .
4c.....!. llV
,si.,
t:44 ll
I
. «........,
. ..
r
deliver 300 gpm

a. The 7.5 x 10 Centerline mud pump has the capacity to
(1136 L/min) @ 400 psi (2758 kPa).
mud pump is
b. 30K/40K - The hydraulic pump that supplies oil to the
hydra ulic drive
mounted in the upper center position on the 3-hole main
piston pump with
gearbox. The hydraulic pump is a variable displacement
pressure control. It
uni-directional (clockwise) rotation with load sense and
7-137
DRILLING SOLUTIONS
has a displacement of 4.58 in3/rev. (75cc), 49.6 gpm

(187.74 liter/minute)
@2500 rpm.
c. 551(1701( - The hydraulic pump that supp
lies oil to the mud pump is
mounted piggy-back on the auxiliary pump located
in the upper center
position on the 3-hole main hydraulic drive gearbox. The
hydraulic pump is
a variable displacement piston pump with uni-directi
onal (clockwise)
rotation with load sense and pressure control. It has a
displacement of 4.58
00 rpm.
MUD PUMP MOTOR

15INA 3/REV.
RTN 171
(5
° I RTN 5-2 1
-16 .16
MUD. PUMP CONTROL VALVE *)•‘
ORIFICE
c 0.031 DIA.
6 DRN 2 1
X ÷
1
fti~
MUD PUMP
HYDRAULIC
DRIVE PUMP
2657818577
2500 RPM
4.58 INA 3/REV OUT
75 CC, P3
49.6 GPM LOAD
SENSING CONTROL 4 e I
2657818593
2500 RPM
3.66 IN^ 3/REV
60 CC, P2
IN
I
39.6 GPM LOAD
MUD PUMP
SENSING CONTROL 7r SUCTION
7-138
DRILLING SOLUTIONS
•
7-8 DIXON Boss Clamp Selection and Installation
Safety Information
MSHA (Mine Safety and Health Administration) Regulations
30 CFR Sections 45.13021 and 57.13021

or other suitable locking
Except where automatic shutoff valves are used, safety chains
re hose line of 3/4" inside
devices shall be used at connections to machines of high pressu
inside diameter or larger,
diameter or larger, and between high pressure hose lines of 3/4"
where a connection failure would create a hazard.
30 CFR Section 75.1730

put-off, valves shaill be, used at
(e) Safety chains, suitable locking devices, or automatic
inch inside dia-meter or larger,
connections to machines of high pressure hoSe lines'ol 3/4 of an
diameter or larger, where a
and between high pressure hose lines of 3/4 of an inch inside
paragraph, high pressure
connection failure would create a hazard. For purposes of this
•
means pressure of 100 PSI (6.9 bar) or more.
30 CFR Section 77.412

at connections to machines of high
(d) Safety chains or suitable locking devices shall be used
between high pressure hose line of
pressure hose line of 1-inch inside diameter or larger, and
create a hazard.
1-inch inside diameter or larger, where a connection failure would
S.T.A.M.P.E.D.
ng questions:
When fabricating and specifying hose assemLlies, ask the followi
1. Size:
O.D. (Outside
What is the I.D. (Inside Diameter) of the hose? What is the
length of the assembly
Diameter) of both ends of the hose? What is the overall
required?
2. Temperature:
through the
What is the temperature range of the media (product) that is flowing
range of the enviro nmen t that
hose assembly? What is the temperature
surrounds the outside of the hose assembly?
3. Application:
•
application? Is
How is the hose assembly actually being used? Is it a pressure
Are there any
it a vacuum (suction) application? Is it a gravity flow application?
perform? Is the
special requirements that the hose assembly is expected to
any pulsations or
hose being used in a horizontal or vertical position? Are there
vibrations acting on the hose assembly?
7-139
DRILLING SOLUTIONS
4. Media:
What is the media/material that is flowing through the hose
assembly? Being
specific is critical. Check for: Abrasive materials, chemical
compatibility, etc.
5. Pressure:
What is the maximum pressure including surges (or, maxim
um vacuum) that
this hose assembly will be subjected to? Always rate
the maximum working
pressure of your hose assembly by the lowest rated comp
onent in the system.
6. Ends:
What couplings have been requested by the user? Are
they the proper fittings
for the application and hose selected.
7. Dixon:
Dixon recommends that, based on the hose, fittings and
attachment method
used, all assemblies be permanently marked with the
designed working
pressure and intended media. Do not use other manu
facturer's fittings or
ferrules with Dixon products due to the difference
s in dimensions and
tolerances. We also recommend that all hose assemblies
be tested frequently.
Be Safe: Any questions on application, use or assem
bly, contact your
local Atlas Copco dealer or distributor.
Force Chart
Force Chart
Force (In Pounds)
Hose 25 50 75 100 150
I.O. 200 250 300 500 1000
PSI PSI PSI PSI PSI PSI PSI PSI PSI PSI
1/4" 1 2 4 5 7 10 12 15 25 49
3/8" 3 6 8 11 17 22 28 33 55 110
1/2" 5 10 15 20 29 39 49 59 98 196
3/4" 11 22 33 44 66 88 110 133 221 442
1" 20 39 59 79 118 157 196 236 393 785
1-1/4" 31 61 92 123 184 245 307 368 614 1227
1--1/2" 44 88 133 177 265 353 442 530 884 1767
2" 79 157 236 314 471 628 785 942 1471 3142
2-1/2" 123 245 368 491 736 982 1227 1473 2454 4909
3' 177 353 530 707 1060 1414 1767 2121 3534 7069
4" 314 628 942 1257 1885 2513 3142 3770 6283 12566
5" 491 982 1473 1964 2945 3927 4909 5891 9818 19635
6" 707 1414 2121 2827 4241 5655 7069 8482 14137 28274
8' 1257 2513 3770 5027 7540 10053 12566 15080 25133 50266
10" 1964 3927 5891 7854 11781 15708 19635 23562 39270 78540
12" 2827 5655 8482 11310 16965 22620 28274 33929 46549 113098
Note: For hose I.D.'s from 1-1/4" to 12" the force in pound
s is greater than the PSI.
7-140
DRILLING SOLUTIONS
•
longitudinally through a hose,

1. Force is the dynamic power which is exported
ds of force exerted, you
towards the ends. To arrive at the number of poun
ing pressure being used.
merely multiply the area of the I.D. times the work
red).
2. Area of a circle: (P1[3.1416] times radius squa
3. Force = Area x Pressure.
General Preparation Instructions

to all assemblies in terms of preparation.
The following contains general procedures that relate
1. Cutting the Hose - Two terms are used:

length requested excluding the
a. Cut to Length means cut the hose to the
length of the fitting(s).
overall length of the assembly
b. Overall Length (O.A.L.) refers to the
including fitting(s).
h so that when couplings
Example: The hose has to be cut to a certain lengt
•
red overall length. The
are installed the length of entire assembly is the requi
hose length to be cut to
calculation below describes the steps to determine
obtain the required overall length.
length of the assembly).
The O.A.L requirement is 50 ft. (This is the total
ll length of the fitting). The
The Fitting Length is 7 inches. (This is the overa
fitting that is inserted
Shank Length is 4 inches. (This is the length of the
into the hose).
A. Fitting Length = 7 inches.--- -
B. Shank Length = 4 inches ,

s.
C. Subtract Shank Length from Fitting Length = 3 inche
h.
D. Multiply "C" by two = 6 inches of total coupling lengt
the 50 foot overall
E. Subtract the 6 inches of total coLiplihg length from
rement of 49 fo0 - 6
required length (O.A.L) and get:a cut WI length requi
inches (49'-6").
(90° to the length of the
2. Cut Ends Square - Hose ends must be cut square
tion can reduce coupling
hose) for proper coupling insertion. Improper inser
retention.
the cutting process must
3. Clean Hose Ends - Debris left inside the hose from
cially important when an
be removed prior to coupling insertion. This is- espe
. Debris will reduce coupling
abrasive wheel or chop saw is used to make a-cut
•
retention.
4. Determine number of clamps required:
7-141
DRILLING SOLUTIONS
5. Mark Hose for Proper Clamp Placement

- The Boss Clamps and Air King
Clamps do not require a hose marking for place
ment because the clamp's
gripping finger positions the clamp automatically.
6. Static Grounding - When static grounding
is required it's essential that it be
done properly. Typically, it is accomplished by bend
ing the built-in static wire or
the helical wire (or wires) into the hose I.D. (Insid
e Diameter) so that the wire
or the wires make contact with the metal coupling.
Bend in no more wire than
necessary. One half inch is usually sufficien
t. Other methods of static
grounding may be required due to hose type, hose
manufacturer or style of
coupling_ being installed. Always contact
the hose manufacturer to verify
proper static grounding techniques for that parti
cular hose. Improper static
grounding can lead to fire, explosions reduced
assembly life, damage to
property and injury or death to personnel.
7. Hoses with Helical Wire - Determin
e which direction the helical wire is
pointing. Proper installation of pre-formed band
clamps or bands and buckles
relies upon proper orientation of the clamp tail
with the helical wire. Note: If
helical wire is not used for static grounding, trim
the wire flush with the hose.
This will prevent operator injuries during the asse
mbly.
8. Seal the Hose Ends - At each end of the
hose, the reinforcement is exposed
to the outside elements. This exposure can lead
to premature assembly failure
especially if the end of the assembly is laying in
a puddle of water or puddle of
product. If assembly is to be subjected to these cond
itions, the hose ends must
be sealed. Typically, rubber cement or shellac
can be used. Wire reinforce
hoses can corrode to the point of failure near
the clamp. Textile or fabric
reinforced hoses can "wick" water or product to
anywhere in the length of the
hose and exit the cover at the weakest spot.
9. Apply Coupling Lubricant - Lubricate the
coupling shank and hose inside
diameter prior to the coupling insertion. Dixo
n recommends using Dixon
Coupling Lubricant (DCL10 pint, DCL80 gallon).
Do not use hand soap, oil,
grease, WD40, Silicon Spray or other similar subs
tances that may attack the
hose tube material and / or reduce coupling reten
tion.
Dixon Diameter Tape Procedure

All Dixon clamping devises (Boss Clamps, Doub
le Bolt Clamps, Single Bolt Clamps, T-Bolt
Clamps, Holedall Ferrules, etc.) have a minimum
and maximum hose O.D. (Outside Diameter)
range. To ensure proper coupling performance,
it is imperative that the clamping devise
selected be the correct size for the hose O.D. being
used.
Accurate hose O.D. measurement is achieved by
using a Diameter Tape. Both ends of the
hose must be measured due to the variances allow
ed by the hose manufacturers in their
production tolerances. In addition, the hose manu
facturers change dimensional specifications
on their products without prior notification.
7-142
DRILLING SOLUTIONS
•
Procedure
from the case.
1. Grasping the tape buckle, pull several inches of tape
of the tape is marked
2. One side of the tape is a regular ruler. The other side
This is the side of the tape
INCHES OF DIA. BY 64THS. (See A on Diagram 1).
used to measure hose O.D.
. J8
18
) INCHES OF DIA. BY 64THS. Illilliiiii112,iii1lilifili 1.11111111AI ,'
Diagram 1 C D
following:
3. To understand how the diameter tape works; do the
width of the tape to the right
a. Locate the numbers (1,2,3,etc.) with a line the
of diameter.
of it (See B in Diagram 1). These represent inches
•
ers ,(See D in Diagram 1).
b. The numbers 16, 32, and 48 are reference numb
respectively.
They represent 16/64ths, 32/64ths and 48/64ths of an inch
represents 1/64th of an inch
c. Each hash mark between these two numbers
(See C) in Diagram 1).
, convert the hose
These numbers, when combined as outlined below
circumference into inches of diameter.
the following:
4. To measure the hose O.D. with the diamèter tape, do
tape around the end
a. With the diameter side of the tape facing up, loop the
inches from the
of the hose to be measured keeping the loop two to three
hose end.
the buckle to the
b. While the tape is being looped around the hose, keep
bottom of the loop.
le. Pull the tape tight.
c. Make sure that the tape is as flat on the hose as possib
d line up with one
d. The line to the right of INCHES OF DIA. BY 64THS shoul
or hash marks
of the inches of diameter marks, reference number marks
above it.
following:
5. To read the hose O.D. just measured in step 4, do the
Step 4d above
a. Determine the inches of diameter number. If the tine from
e diameter (See
lines up with one of these numbers, this is your outsid
nce the number
Diagram 2). If line from Step 4d above lines up with a refere
.
to the LEFT of an inches of diameter number, see Step 5b below
7-143
DRILLING SOLUTIONS
b. Locate the reference number (if needed)

to the LEFT of inches of diameter
number determined by the line from Step 4d abov
e. The outside diameter
will be the inches of diameter number from Step
5a above PLUS the 64ths
represented by the reference number (See Diag
ram 3). If the line from Step
4d above is to the left of a reference number,
see Step 5c.
c. Locate the hash mark (if needed) to the
LEFT of the reference number
determined by the line from Step 4d. The outs
ide diameter will be the
inches of diameter from Step 5a PLUS the 64ths
represented by reference
number from Step 5b PLUS the number of hash
marks from the reference
number including the one above the line from
Step 4d (See Diagram 4).
Diagram 2.
1,1,1,11,1,1J
II INCHES OF DIA. BY 64THS.
(2" 0 D )
Diagram 4
I
INCHES OF DIA. BY 64THS
(2-20/64" 0.0.)
Note: It is a good practice to measure each hose

end twice to ensure an
accurate measurement.
7-144
DRILLING SOLUTIONS
Boss Clamps
•
Table 7: Boss Clamps
Hose O.D.
Hose I.D. Torque Type
From: To:
1/4" 36/64" 42/64" , 6 ft/lbs 2-bolt type
3/8" 44/64" 56/64" 6 ft/lbs
1/2" 52/64" 60/64" 6 ft/lbs
1/2" 60/64" 1-4/64" 12 ft/lbs
1/2" 1-12/64" 1-12/64" 12 ft/lbs
3/4" 1-10/64" 1-18/64" 21 ft/lbs
3/4" 1-12/64" 1-20/64" 21 ft/lbs
3/4" 1-20/64" 1-32/64" 21 ft/lbs
• 3/4" 1-32/64" 1-44/64" 21 ft/lbs
1/2" 58/64" 1-2/64" 6 ft/pp 4-Bolt Type

2 gripping
fingers
1" 1-26/64" 1-36/64" 21 ft/I bs 4-Bolt Type

4 gripping
fingers
1" 1-34/64" ;1-46/64' 21 ft/I bs 4-Bolt Type

2 gripping
1" 1-44/64" 1-60/64" - 21 ft/lbs fingers
1" 1-60/64" 2-8/64" 21 ft/lbs
1-1/4" 1-32/64" - 1-50/64" 40 ft/lbs
1-1/4" 1-44/64" 1-56/64" 21 ft/lbs 4-Bolt Type

4 gripping
- - fingers
1-1 /4" 1-50/64" 2-6/64" 40 ft/lbs 4-Bolt Type

2 gripping
fingers
1-1/4" 1-56/64" 2-4/64" 21 ft/lbs 4-Bolt Type
•
4 gripping
fingers
7-145
DRILLING SOLUTIONS
Hose O.D.
From: To:
1-1/4" 2-8/64" 2-24/64" 40 ft/lbs 4-Bolt Type
1-1/2" 1-52/64" 2 gripping
2" 40 ft/lbs
fingers
1-1/2" 2" 2-14/64" 40 ft/lbs
1-1/2" 2" 2-8/64" 21 ft/lbs 4-Bolt Type
1-1/2" 2-4/64" 4 gripping
2-16/64" 40 ft/lbs
fingers
1-1/2" 2-12/64" 2-24/64" 40 ft/lbs 4-Bolt Type
1-1/2" 2-24/64" 2 gripping
2-36/64" 40 ft/lbs
fingers
1-1/2" 2-36/64" 2-48/64" 40 ft/lbs
2 2-16/64" 2-32/64" 40 lbs 4-Bolt Type
4 gripping
fingers
2-22/64" 2-34/64" 60 lbs 4-Bolt Type
2 gripping
fingers
2" 2-32/64" 2-48/64" 40 lbs. 4-Bolt Type
4 gripping
fingers
2" 2-32/64" 2-50/64" 60 ft/lbs 4-Bolt Type
2" 2-48/64" 2 gripping
3-4/64" 60 ft/lbs
fingers
2" 2-48/64" 3/4/64" 60 ft/lbs 4-Bolt Type
4 gripping
fingers
2" 3-6/64" 3-28/64" 60 ft/lbs 4-Bolt Type
2 gripping
fingers
2-1/2" 3-4/64" 3-32/64" 60 lbs 4-Bolt Type
4 gripping
fingers
2-1/2" 3-6/64' 3-28/64" 60 ft/lbs 4-Bolt Type
2-1/2" 3-22/64" 2 gripping
3-60/64" 150 ft/lbs
fingers
3" 3-32/64" 3-48/64" 60 ft/lbs 4-Bolt Type
4 gripping
fingers
7-146
DRILLING SOLUTIONS
Hose O.D.
From: To:
3" 3-32/64" 3-60/64" 150 ft/lbs 4-Bolt Type

2 gripping
fingers
3" 3-48/64" 4" 150 ft/lbs 4-Bolt Type

4 gripping
fingers
3" 3-52/64" 4-4/64" 150 ft/lbs 4-Bolt Type

2 gripping
fingers
3" 4" 4-12/64" 200 ft/lbs 4-Bolt Type

4 gripping
fingers
3" 4-4/64" 4-28/64" 200 lbs 4-Bolt Type

2 gripping
•
fingers
3" 4-12/64" 4-32/64" 200 ft/lbs 4-Bolt Type

4 gripping
fingers
3" 4-16/64: 4-52/64" 150 ft/lbs Three Piece

6-Bolt Type
4" 4-40/64" 5" 150 ft/lbs
4" 4-56/64" 5-16/64" 200 ft/lbs
4" 5-16/64" 5-38/64" 200 ft/lbs
4" 5-34/64" 5-60/64" 200 ft/I bs
6" 6-56/64" 7-24/64" 200 ft/lbs
6" 7-32/64" 8" 200 ft/lbs
Note:
1. The bolts used in the Boss interlocking clamps are not standard bolts. They
vary from standard bolts in their length, diameter, overall thread length and
material hardness. These bolts can be re-torqued, but it is not recommended
that they be reused, as they are designed for a single bend only. Dixon
recommends using only factory supplied replacement bolts.
• 2. Torque values for clamps are based on dry bolts. The use of lubricant on bolts
will adversely effect clamp performance.
3. Do not lubricate bolts.
DRILLING SOLUTIONS
7-147
4. Recommended torque rating is in ft./lbs.

Boss Clamp Selection
1. Measure the hose Free O.D. (Outside Diameter) with a diameter tape.
Free
O.D. is the outside diameter before the stem is inserted.
2. Determine the hose I.D. (Inside Diameter).
3. On the Boss Clamp Chart, locate the Hose I.D. column.
4. Locate the section of clamps in that column that correspond with the hose
I.D.
5. From that section of the clamps, find the clamp that has an O.D. range in
the
Hose O.D. From / To column that best fits the hose O.D. just measured.
Additional information
1. For steam hose, select the clamp that has a maximum range as close
to (but
not smaller than) the measured hose O.D. This will allow the clamp to be
re-
tightened many times to adjust for Cold-Flow which speeds up with increas
ed
temperature and /or hot and cold cycles.
2. For hard wall constructed hose (wire present) with an O.D. at or near
the
clamp's maximum range, use of the next largest clamp may be require
d. See
"Criteria For Sufficient Fit of a BoSs Clamp"to determine proper clamp
fit.
3. For soft wall constructed hose (no wire present) having an O.D. at
or near
clamp's minimum range, use of the next smallest clamp may be require
d. See
"Criteria For Sufficient Fit of a Boss Clamp" to determine proper clamp
fit.
Notes:
1. Use of an incorrectly sized "Boss" clamp can result in damage to propert

y and
serious injury to personnel.
2. Refer to the "DIXON DIAMETER TAPE PROCEDURE"for instruct
ions on how
to read a diameter tape.
3. Refer to "INSTALLATION OF BOSS 2 BOLT CLAMP"for assembly
techniques
when using a two bolt "Boss"' clamp.
4. Refer to "INSTALLATION OF BOSS 4 BOLT CLAMP"for assembly techniq
ues
when using a four bolt "Boss" clamp.
5. Refer to "INSTALLATION OF BOSS 6 BOLT CLAMP" for assembly techniq
ues
when using a six bolt "Boss" clamp.
Criteria For Sufficient Fit of a Boss Clamp
Notes:
1. Sufficient fit criteria provides inspection guidelines when the clamp has
been
assembled in accordance with prescribed procedures and all of the bolts
are
tightened to 150 FT/LBS. FOR 3 INCH CLAMP, 60 FT/LBS FOR THE 2-1/2
AND 2 INCH CLAMPS.
7-148
DRILLING SOLUTIONS
2. The failure to adhere to these guid

elines could produce poor clamp
performance, leaking assemblies or even
separation of hose and coupling that
may cause property damage and /or serio
us injury to personnel.
Minimum Range
1. 1/32" clearance between

clamp halves (both sides) for clamps
designed to fit 1/4" I.D. through 2" I.D. hose that are
.
2. 1/16" clearance between clam
p halves (both sides for 4 bolt clamps)
segments (6 bolt clamps) for clamps desi or all
gned to fit 2-1/2" I.D. through 6" I.D.
hose.
3. 1/32" clearance between clam
p gripping fingers (all gripping fingers) and
groove for all sizes. stem
Maximum Range
1. Use 1/32 inch interlock between

the clamp gripping finger and stem collar
gripping fingers) for clamps designed to fit (all
1/4 inch I.D. through 2 inch I.D.
2. Use 1/16 inch interlock between the
clamp gripping finger and stem collar (all
gripping fingers) for clamps designed to fit
2-1/2 inch l'.D. through 6 inch I.D.
3. Use 1/32 inch interlock between dove
tail extensions (both sides) for clamps
designed to fit 1/4 inch I.D. through 2 inch
I.D. hose.
4. Use 1/16 inch interlock between dovetai
l extensions on both sides (4 bolt
clamps) or all segments (6 bolt clamps) for
clamps designed to fit 2-1/2 inch I.D.
through 6 inch I.D. hose.
Installation of Boss 2-Bolt Clamp

BOSS GJ MALE GRIPPING FINGER STEM COLLAR
FRONT BOLT
WING NUT SQUARE HEAD OF

FRONT BOLT
OPPOSITE FRONT BOLT
Procedure
1. Prepare the hose. Refer to "GENERAL PREPARATION INST

RUCTIONS".
2. Place the stem in a vise.
a. For male stems, tighten the vise on the

hex.
b. For female stems (wing nut), place a spud in the
vice, tighten and then
thread the wing nut onto the spud.
DRILLING SOLUTIONS
7-149
Installation of Boss 6-Bolt Clamp
Procedure
PREPARATION INSTRUCTIONS."
1. Prepare the hose. Refer to "GENERAL
2. Place the stem in a vise.
a. For male stems, tighten the vise on the hex.

the vice, tighten and then
b. For female stems (wing nut), place a spud in
thread the wing nut onto the spud.
p Selection".
3. Select the proper Boss Clamp. Refer to "Boss Clam
collar.
4. Position the clamp gripping fingers behind the stem
ement on all six nuts.
5. Tighten the bolts by hand until there is equal thread engag
s 6 Bolt Clamp"
6. Tighten nuts on bolts in the following sequence. See "Bos
illustration.
snug the nut
a. Bolt "1" - one full turn. Before tightening each bolt in sequence,
by hand if loose.
b. Bolt "2 "- one full turn.
c. Bolt "3" - one full turn.
d. Bolt "4" - one full turn.
e. Bolt "5" - one full turn.
f. Bolt "6" - one full turn.
torque value
g. Repeat "1" to "6" until all bolts are tightened to recommended
bolts.
listed on "BOSS CLAMPS" chart. Torque values are based upon dry
clamp perfo rman ce. Use a torqu e
Lubricant on bolts will adversely effect
wrench.
h. Remove assembly from vice.
DRILLING SOLUTIONS
7-152
7. Test assembly if required. Refer to "TESTING".

Notes:
1. Clamp bolts are designed to bend during tightening. This "bending" allows the
clamp to conform to the hose circumference.
2. Periodic bolt re-tightening is necessary due to "Cold-Flow" present in all rubber
hoses.
3. Boss clamps (including the nuts and bolts), are; for single use only. Do not
reuse. Once removed, discard.
4. Refer to the "Criteria For Sufficient Fit of, a Boss Clamp" for guidelines to
determine proper assembly.
Testing
The following is for general hydrostatic testing and electrical continuity testing. Other
procedures may need to be employed. Follow the RMA (Rubber Manufacturers Association)
hydrostatic test procedures IP-11-1 through IP-11-8 or ASTM D-380 (latest revision). Consult
the hose manufacturer if questions arise. If an assembly requires both hydrostatic and
electrical continuity testing, perform the electrical continuity test first.
Hydrostatic Testing
1. Determine the assembly working pressure. The assembly working pressure is

the lesser pressure rating of either the hose or the couplings.
2. Determine the test pressure. Test pressure is 1-1/2 times the assembly working
pressure.
3. Lay the assembly in a straight line.
4. Install test caps or test plugs to both ends.
5. Connect bleed-off valve to one end and test pump intermediate hose to other
end of test sample.
6. Position test pump (or test sample) so that test pump and test sample are at a
90° angle to each other.
7. Fill test sample with water. Elevate end with bleed-off valve to purge air from
sample. Make certain that all air is removed.
8. Bulwark ends of test sample to prevent damage from accidental coupling
separation.
9. Activate pump until test pressure is achieved.
10. Hold test pressure for 15 minutes.
11. Turn off pump and relieve pressure from test sample.
12. Remove test fixtures from test sample.

13. Drain water from test sample.

14. Complete test report for sample just tested.
CAUTION
No one is to stand near ends of test samples while under pressure for any reason.
Electrical Continuity Testing
1. No standard exists for testing electrical continuity. Generally speaking, this type
of testing is done with either a continuity meter or a multimeter.
2. The continuity meter simply has a light that goes on when each coupling is
simultaneously touched with a probe. A multimeter registers electricity in ohms
(W).
3. Always contact the hose manufacturer for instructions on the proper method
and criteria for electrical continuity testing.

7-9 WATER INJECTION
Cat Water Injection

CAUTION
CAT PUMPS are positive displacement pumps, therefore, a properly designed pressure
relief or safety valve must be installed in the discharge piping. Failure to installsuch a
relief mechanism could result in personal injury or damage to the pump or system.
Installation and Startup
Optimum performance of the pump is dependent upon the entire fluid system-and will be
obtained only with the proper selection, installation of plumbing and operation of the pump and
accessories.
Specifications
•
Maximum specifications refer to individual attributes. It is not implied that all maxims can be
performed simultaneously.
Lubrication
Before starting pump, fill crankcase to dot on oil dipstick per specification with Cat Pump
Crankcase Oil, lSO-68 multi-viscosity petroleum based lubricating oil with anti-wear
and rust inhibitor additives. Approximate amounts are shown below.
Table 8:
12 gpm size (45.42 liters) 40 oz. (1.18 liters)

25 gpm size (94.63 liters) 84 oz. (2.48 liters)
Change initial fill after 50 hours running period. Change oil every three months or at 500 hour
intervals thereafter. If the pump is used in extremely dirty or humid conditions, it is strongly
recommended pump be enclosed.
Oilers
Prior to initial operation, fill the three oilers with Cat Pump Oil. With the oiler shutoff lever in a
vertical position, screw the dome down to seat the needle valve tightly (the shutoff valve
•
becomes loose). Then back the needle off the valve seat slightly (approximately 1/8 turn) and
tighten the lock nut. Prior to initial operation, saturate wicks. Then run pump one to two hours
with three to four drops per hour from each oiler; thereafter, one drop per hour per oiler.
Flipping the shutoff lever to the horizontal position shuts off the oil flow. Additional lubrication
may be required with increased hours of operation and temperature.

Inlet Conditions
Refer to the complete Inlet Condition Check List before starting your system. Do not run
the pump dry.
Nozzles
A worn nozzle will result in loss of pressure. Do not adjust pressure regulating device to
compensate. Replace nozzle and reset to system pressure.
Discharge Plumbing
1. OPEN ALL VALVES BEFORE STARTING SYSTEM to avoid deadhead

overpressure condition and severe damage to the pump or system.
2. Install a pulsation dampening device mounted directly to the discharge line.
Optimum precharge should be calibrated at 30-50% of the operating system.
3. A reliable pressure gauge should be installed near the discharge outlet of the
high pressure manifold. This is extremely important for adjusting pressure
regulating devices and also for proper sizing of the nozzle or restricting orifice.
The pump is rated for a maximum pressure; this is the pressure which would
be read at the discharge manifold of the pump, NOT AT THE GUN OR
NOZZLE end of a long hose.
4. A pressure regulator or unloader valve must be installed to prevent
overpressure in the event the discharge or downstream plumbing becomes
plugged or is turned off. Severe damage to the pump will result if this condition
occurs without a relief valve in the line. Discharge regulating devices should be
at minimum pressure setting at startup. START SYSTEM WITH ALL VALVES
OPEN OR /N THE LOW PRESSURE SETTING.
5. Note: Use PTFE liquid (sparingly) or tape when connecting plumbing. Exercise
caution not to wrap tape beyond the last thread to avoid tape from becoming
lodged in the pump or accessories. This condition will cause a malfunction of
the pump or system.
Pumped Fluids
Some fluids may require a flush between operations or before storing. For extended
storing or between use in cold climates, drain all pumped fluids from pump and flush with
antifreeze solution to prevent freezing and damage to the pump. DO NOT RUN PUMP
WITH FROZEN FLUID.
Inlet Condition Check List
Inadequate inlet conditions can cause serious malfunctions in the best designed pump.
Surprisingly, the simplest of things can cause the most severe problems or go unnoticed to the
unfamiliar or untrained eye.

REVIEW THIS CHECK LIST BEFORE OPERATION OF ANY SYSTEM. Remember, no two
systems are alike, so there can be no one best way to set up a system. All factors must be
carefully considered.
The inlet supply should be adequate to accommodate the maximum flow being delivered by
the pump.
1. Open inlet shutoff valve and turn on water supply to avoid cavitating pump. Do
not run pump dry.
2. Avoid closed loop systems especially with high temperature, ultra-high
pressure or large volumes. Conditions vary with regulating/unloader valve.
3. Low vapor pressure fluids, such as solvents, require a booster pump and a
C.A.T. (Captive Acceleration Tube) to maintain adequate inlet supply.
4. Higher viscosity fluids require a positive head and a C.A.T. to assure'adequate
inlet supply.
5. Higher temperature fluids tend to vaporize and require positive heads and
C.A.T. to assure adequate inlet supply.
6. When using an inlet supply reservoir, you must size it to provide adequ6-te fluid
to accommodate the maximum output of the pump, generally â -minimum of 10
times the GPM (however, a combination of system factors can change this
requirement); provide adequate baffling in the tank to eliminate air bubbles and
turbulence; and install diffusers on all return lines to the tank.
The inlet line size should be adequate to avoid starving the pump.
1. Line size must be a minimum of one size larger than the pump inlet fitting. Avoid
thick walled fittings, tees, 90 degree elbows or valves in the inlet line of the
pump to reduce the risk of flow restriction' and Cavitation.
2. The line must be a flexible hose, not a rigid pipe, and reinforced on the
suction systems to avoid collaps'irlg.
3. The simpler the inlet plumbing, the less the potential for problems. Keep the
length to a minimum, the number of elbows and joints to a minimum (ideally no
elbows) and the inlet accessories to a minimum.
4. Use pipe sealant to assure air-tight, positive sealing pipe joints.
Inlet pressure should fall within the specifications of the pump.
1. Acceleration loss of fluids may be increased by high RPM, high temperatures,

low vapor pressures or high viscosity and "may require pressurized inlet and
C.A.T. to maintain adequate inlet supply.
2. Optimum pump performance is obtained with +20 psi (1.4 bar) inlet pressure
and a C.A.T. for certain applications. With an adequate inlet plumbing, most
pumps will perform with a flooded suction. The maximum inlet pressure is 40
psi (2.8 bar). Negative suction up to -8.5 psi (-0.5 bar) can be reached with
optimum plumbing conditions.

Inlet accessories are designed to protect against over pressurization, control inlet flow,
contamination or temperature and provide ease of servicing.
1. A shutoff valve is recommended to facilitate maintenance.

2. Installation of a C.A.T (Captive Acceleration Tube) is essential in applications
with stressful conditions such as high temperatures, a booster pump feed or
long inlet lines. Do not use C.A.T. with negative inlet pressure.
3. A stand pipe can be used in some applications to help maintain a positive head
in the inlet line.
4. Inspect and clean inlet filters on a regular schedule.
5. A pressure gauge is recommended to monitor the inlet pressure and it should
be mounted AS CLOSE TO THE PUMP INLET as possible. Short term,
intermittent cavitation will not register on a standard gauge.
6. All accessories should be sized to avoid restricting the inlet flow.
7. All accessories should be compatible with the solution being pumped in order
to prevent premature failure or malfunction.
Bypass to inlet care should be exercised when deciding the method of bypass from control
valves.
1. It is recommended the bypass be directed to a baffled reservoir tank, with at

least one baffle between the bypass line and the inlet line to the pump.
2. Although not recommended, bypass fluid may be returned to the inlet line of the
pump if the system is properly designed to protect your pump. When using this
method, a pressure reducing valve should be installed onto the inlet line
(between the bypass connection and the inlet to the pump) to avoid
excessive pressure to the inlet of the pump. It is also recommended that a
thermo valve be used in the bypass line to monitor the temperature build-up
in the bypass loop to avoid premature seal failure.
3. A low pressure, flexible cloth braid (not metal braid) hose should be used from
the bypass connection to the inlet of the pump.
4. Caution should be taken. Do not undersize the bypass hose diameter and
length. Typical length is 24 inches (609.6 mm).
5. Check the pressure in the bypass line to avoid over pressurizing the inlet.
Diagnosis & Maintenance
Table 9:
Problem Probable Cause Solution
Pulsation Faulty Pulsation Dampener Check precharge. If the

precharge is low, recharge
it or install a new one.

•
Low Pressure Worn Nozzle Replace nozzle of proper

size
Belt Slippage Tighten or replace. Use
correct belt type and length
Air leak in inlet plumbing Disassemble, reseal and
reassemble
Pressure gauge Check with new gauge;
inoperative or not replace worn or damaged
registering accurately gauge.
Relief valve stuck, partially Clean and adjust relief
plugged or improperly valve; check for ikorn or
adjusted; valve seat worn dirty valve seats. Repair
with valve kit.
Inlet suction strainer Clean. Use adequate size.
clogged or improper size Check more frequently.
• Worn piston assembly.

Abrasives in pumped fluid
or severe cavitation.
Inadequate water supply.
Fouled or dirty inlet or

discharge valves.
Worn inlet or discharge
Install proper filter. Suction
at inlet manifold must be
limited to lifting less than
20 feet of water or -8.5psi
vacuum.
clean inlet and discharge
valve assemblies
Replace worn valves,
valves, , valve seats
Leaky discharge hose Replace discharge hose
and check for air tight
connections
Pump runs extremely Restricted inlet or air Proper size inlet plumbing;
rough, pressure very low entering the inlet plumbing check for air tight seal
Damaged cup Or stuck inlet Replace worn cups or
or discharge valve valves; clean out foreign
material.
Worn inlet seals.allowing Install new inlet manifold
air into system or -leaking seals and possibly seals
fluid

Cylinder o-ring blown next Pressures in excess of Check for plugged nozzle,
to discharge manifold. rated psi or distorted closed valves or for an
manifold from freezing improperly adjusted
damage. bypass valve. Replace
defective manifold or o-
ring. Protect from freezing.
Leakage at the cylinder 0- Loose cylinders. Cylinder Remove spacer shims on
rings, at the discharge motion caused by improper manifold studs. Do not
manifold and black shimming of the discharge remove too many shims or
povvderysybstance in the manifold. the ears of the manifold will
area of the 0-ring be bowed when the
manifold is retightened,
causing looseness in the
center cylinder.
Water leakage from under Worn inlet manifold seals. Install new 0-rings and
the inlet manifbld Leaking sleeve 0-ring. seals as required. Replace
scored sleeves.
Oil leak between Worn crankcase piston rod Replace crankcase piston
crankcase and pumping seals rod seals
section
Excess oil from wicks Reduce quantity of oil per
oiling
Oil leaking in the area of Worn crankshaft seal or Remove oil seal retainer
the crankshaft improperly installed oil seal and replace damaged
retaining packing gasket and/or seals
Bad bearing Replace bearing.
Excessive play in the end Worn main ball bearing Replace bearing. Properly
of the crankshaft pulley from excessive tension on tension belt. Use correct
drive belt type and length.
Water in crankcase May be caused by humid Change oil every 3 months
air condensing into water or 500 hour intervals using
inside the crankcase. CAT Pumps Special Multi-
Viscosity IS068 oil (SAE40
anti-rust) (other approved
oil every month or 200
hours).
Leakage of manifold inlet Replace seals, sleeve and
seals and/or piston rod 0-rings.
sleeve 0-ring
Oil leaking from side of Worn crankshaft seals Replace seals
crankcase


Oil leaking at the rear Damaged or improperly Replace oil gauge, cover
portion of the crankcase installed oil gauge or worn 0-ring, or drain plug 0-ring
crankcase rear cover 0- as needed.
ring, or drain plug 0-ring
Oil leakage from drain plug Loose drain plug or worn Tighten drain plug or
drain plug 0-ring replace 0-ring
Loud knocking noise in Pulley loose on crankshaft Check key and tighten set
pump screw
Check alignment and belt
position
Broken or worn bearing Replace bearing
Frequent or premature Scored rods or sleeves Replace rods and sleeves
failure of the inlet manifold
seals Overpressure to inlet Reduce inlet pressure per
manifold instructions.
Stressful inlet conditions Install C.A.T.
Short cup life Abrasive material in the Install proper filtration on
fluid being pumped pump inlet plumbing.
Excessive pressure and/or Check discharge pressure,
temperature of fluid being fluid temperature or control
pumped valve bypass
Running pump dry Do not run pump without
water
Front edge of piston sharp Replace with new piston
Chrome plating of Install new cups and
cylinders damaged cylinders. Pump only fluid
causing excessive wear of compatible with chrome.
cups. May be caused by
pumping acid solution.
Short life on cups on Stressful inlet conditions.
cylinders. Install C.A.T.
Strong surging at the inlet Foreign particles in the Check for smooth mating
and low pressure on the inlet or discharge valve or surfaces on inlet valves
i
discharge side. worn inlet and/or discharge and discharge valve seats.
valves. Flat valves and inlet valves
may be lapped on a very
fine oil stone; Quiet Valve
parts must be replaced.

Servicing the Valve Assemblies
Disassembly:
1. Remove the fasteners securing the discharge manifold to the crankcase of the
pump.
2. Support the discharge manifold and tap from the backside with a soft mallet.
Gradually work free from cylinders.
3. Valve assemblies will remain in the manifold. Pump models with 0-ring
groove on the outside of the valve seat require the assistance of a Valve
Seat Removal Tool to remove the valve seat. The valve, spring and retainer
will fall out when the manifold is inverted. Pump models without the 0-ring
groove on the outside of the valve seat permit the seat, valve, spring and
retainer all to fall out when the manifold is inverted.
Reassembly:
1. Examine the retainer for wear and replace as needed. Replace the retainer in
manifold chamber with nylon tab down.
2. Examine spring for fatigue and replace as needed. Insert spring into center of
retainer.
3. Inspect the valves for wear, ridges or pitting and replace as needed. Note:
Seating side of flat valves may be lapped on flat surface using 240 grit paper.
Quiet valves, due to their shape, must be replaced. Insert valve over spring
with dimpled side up.

4. Examine all 0-rings and backup rings on the valve seat. Replace them if they
are used or worn. Always lubricate 0-rings for ease of installation and to avoid
damage. Note: First install 0-ring in groove on seat towards seating surface,
then backup ring. Note: Models without outer groove on seat require the 0-ring
to be placed on the lip of the retainer.
5. Examine valve seats for wear, pitting or grooves. Lap the Flat Valve seats with
240 grit paper or replace if there is evidence of excessive wear. Quiet Valve
seats must be replaced if worn. Install geats'with dish side down.
6. Lubricate 0-rings on exposed cylinder. Exercise caution when slipping
manifold over cylinders to avoid damaging cylinder 0-rings. Completely press
manifold over cylinder.
7. Replace fasteners and torque pertorque chart on following pages. Note:
Replace all original shims if used.'When new manifold is used, re-shim
pump. When starting the pump, check to see that there is no cylinder motion.
This will cause premature failure of the cylinder 0-rings. Center cylinder motion
indicates improper shimming.
Servicing the Valve Pumping Section
Disassembly:
1. Remove the discharge manifold as previously explained.

2. Grasp cylinders by hand and with an up and down motion, pull the cylinders
from inlet manifold.
3. Remove cotterpin, nut and washer from piston rod.
4. Next remove the retainer, spacer, piston-cup assembly and inlet valve.
Reassembly:
1. Examine inlet valve surface for pitting, scale or grooves. Reverse valve and
sand inlet side of valve using 240 grit paper for clean surface or replace if
evidence of excessive wear. Slip onto rod.
2. Examine piston seating surface and lightly sand on flat surface using 240 grit
paper. If extreme pitting or sharp edges, replace piston.
3. Examine cup for wear, cracking, tearing or separation from the piston. If worn,
replace and lubricate before installing on pistori:Wote-cup installation: Wipe
cup inserter with oil. slip backup ring (whert used') onto piston. Puth cup over
inserter and square with all surfaces: Fafilty installation causes premature
cup failure. Some models use a one piece pistpripssembly. The cup does not- .
separate from the piston. Replace entire aSgenii*: Lubricate piston assembly
and slip piston-cup assembly onto the piston i :o:iriih
d lip facing . ditcharge.- 4:.
• • e
4. Next, replace the piston spacer and retainer on rod.
,.t
5. Replace washer, thread on nut. Torque per torque chart. Note: Always replace
with new stainless steel cotterpin. Turn ends under.

6. Examine cylinder walls for scoring or etching which causes premature wear of
cups and replace as needed.
7. Lubricate the cylinder and replace o-rings and/or backup rings if worn or
damaged. Backup rings go to low pressure side of the 0-rings. Carefully
slip cylinder over rod ends and push into inlet manifold with the backup ring to
the discharge, stroke marking on the inside of the cylinder to the
crankcase.
8. Position discharge manifold onto pumps as described. Replace fasteners and
torque per specifications chart shown on following pages.
Servicing Sleeves and Seals
Disassembly:
1. Remove discharge manifold and piston assemblies as described.

2. Remove inlet manifold containing seals.
3. Grasp sleeves and with a pulling and twisting motion remove the sleeve from
the piston rod. Note: Grasp sleeve with pliers only if replacing worn sleeves, as
the procedure will mar the sleeves.
4. Next, remove the seal retainer.
5. Remove and examine 0-rings and/or backup rings on piston rod for wear and
replace as needed.
Reassembly:
1. Visually inspect that the barrier-slinger S in position.

2. Lubricate new 0-rings and/or backup rings and slip onto piston rod. Install the
first 0-ring (A) in the groove on the piston rod. Next, position the backup ring
(B) against the stepped shoulder. Then install the second 0-ring (C). Exercise
caution as you slip the 0-ring over thread end of the piston rod.
///./.././r1 CB A
art==
3. Examine sleeves for scoring or etching and replace. Immerse sleeves (D) in
oil and carefully twist and push sleeve onto rod with machined counter
bore end (E) first.
4. Next, install seal retainers. If wicks are used, replace wicks. Thoroughly
saturate with oil, place in seal retainer and install retainer.
5. Place inlet manifold on pair of clearance blocks with crankcase side down and
drive out old seals.

6. Invert inlet manifold with crankcase side up and install new seals. Lubricate
O.D. of seal and install Prrrrm-A-Lube seal with garter spring down. If using
blue dot seal, install blue dot seal facing up. Note: The 25 gpm model does not
have Prrrrm-A-Lube option. Install with spring down.
7. Slip lubricated seal inserters onto piston rod ends, position inlet manifold onto
pump and remove seal inserters. Some models secure inlet manifold to
crankcase. Replace fasteners and torque per specification chart shown on
following pages.
8. Reassemble piston assemblies and discharge manifold as described.
9. Replace original quantity of shims on each stud before replacing discharge
manifold.
Servicing Crankcase Section
1. While the inlet manifold, sleeves and seal retainers are removed, examine the
seals in the crankcase for wear.
2. Check oil for proper level and for evidence of water in oil or other contaminants.
3. Rotate crankshaft by hand to feel for smooth bearing movement.
4. Examine crankshaft oil seal externally for drying, cracking or leaking.
Torque Chart
Table 10: Piston Rod Nut
Pump Model Thread Tool Size Torque
12 gpm M7 x 1.0 10mm Hex 70-120 in/lbs (8-13 Nm)

25 gpm M8 x 1.25 13mm Hex 90-150 in/lbs (10-17 Nm)
Table 11: Manifold Stud/Nut and Cylinder Bolts
Pump Model Thread ToOl Size-- ' Torque
12 gpm M10 x 1.5 17mm Hex 250 in/lbs (28 Nm)

25 gpm M12 x 1.75 19mm Hex 370 in/lbs (42 Nm)

Manifold Torque Sequence
4 BOLT MANIFOLD 8 BOLT MANIFOLD
3 2 8 1 3 5
cv
01\ a
1 4 6 4 2 7
Pulse Pump Injection Head
The pulse pump is optional for high pressure Cat pumps only.
Operation
With gun open, start drive pump. After water starts to flow out the nozzle (minimum 200 psi/
13.8 bar). open bleed valve one turn to purge air from pulse pump, thus priming the pulse
pump. After all air is, paged, torque valve 100 and 120 in/lbs (11.3 and 13.56 Nm). Then set
drive pump for proper discharge presSure.
A CAUTION
Pulse Pump will not operate with a pressurized inlet to the drive pump.
L CAUTION
Do not operate the pulse pump dry. This could damage the diaphragm.
Performance
After the unit is operating, adjust metering valve to obtain desired water/chemical ratio. Check
chemical output by measuring chemical supply tank. Note: A metering valve not supplied
by Cat Pumps with pulse pump.
Mixing Ratio varies with output of drive pump, the model pulse pump being used and whether
a metering valve is used.
Maintenance
Before shutting system down, flush pulse pump by placing chemical supply line in water. If
volume of chemical decreases, lap the discharge valve, suction valve seat and valve with 440
grit paper. Check diaphragm for leaks.

Trouble Shooting
No Chemical Supply From Pulse Pump
1. Failure of diaphragm or spring

2. Air in chemical supply line
3. Foreign material in inlet or discharge valves
4. Pressurized inlet to drive pump
Limited Chemical Supply From Pulse Pump
1. Air in chemical supply line

2. Clog in manifold port fitting
3. Loose lock nut of diaphragm spring
4. Worn inlet and discharge valves
Bean Water Injection

This section is designed to help with routine maintenance and do-it-yourself service that the
John Bean pump or equipment may req0re.
18 gpm and 25 gpm


INJECTION PUMP PLUG
OIL FILL
OIL
FILL
DRAIN IS DRAIN)
UNDERNEATH
Installation
1. Pump Location - Locate the pump as close to the source of supply as

possible. It is desirable to set the pump in a clean and dry place with sufficient
lighting and adequate space for inspection and maintenance.
2. Foundation - The pump should be mounted in a vertical position and securely
fastened in order to maintain alignment and prevent vibration. Note: 35gpm
water pump mounts horizontally.

3. Suction Line
a. General - When installing pipe and fittings, be sure the inside of all parts
are free from dirt, scale, burrs and other foreign material which might
interfere with the pump operation. Make sure all joints are tight and free
from air leaks which cause cavitation and loss of pump capacity.
Return the overflow from a relief valve or pressure regulator directly to the
supply tank. Care must be taken not to locate return where it will cause
excessive turbulence directly at the suction inlet.
b. Length and Size - The suction line from source to pump inlet should be as
short and direct as possible, using either piping or durable non-collapsing
hosing as circumstances warrant.
The suction pipe size should be at least the same as the pump inlet
connection, or preferably larger to avoid limiting the pump capacity. The
supply source should be located above the inlet connection for smoother
operation of the pump and longer packing life. When a static lift is used, the
lift should be kept as small as possible. Elbows, nipples and unions should
be kept at an absolute minimum. To isolate mechanical and hydraulic
vibrations, hose connections are recommended at the pump for both
suction and discharge.
Install both the suction and discharge piping so it is supported
independently, thus avoiding vibrations as well as strain on the pump.
c. Gate Valves - In order to cut off the supply of liquid during maintenance
inspections, a gate valve is recommended as close as possible to the inlet
side of the pump. ThP openings in the gate valve should not be smaller than
the pump inlet openings.
d. Suction Dampener - Where long suction lines occur, it may be necessary
to install a suction dampener to minimize vibration.
e. Drain Plugs - Drain plugs or drain cocks are advisable for use at low points
in both the suction and discharge lines. This is especially true if temperature
conditions drop to the freezing point or lower.
f. Strainer - Install a strainer in the suction line to remove particles which
might interfere with the valves. Strainers may be of the open type at the end
of the suction line or fully enclosed, having a removable cover for
inspection. It is very important that strainers are cleaned periodically and
sized properly so they do not restrict suction flow.
g. Pump Connections - Install unions as close as possible to the inlet and

outlet openings of the pump to facilitate any future servicing, should the
need arise.
4. Discharge Lines
a. Size and Length - Install the discharge piping as short and direct as
possible, using the same size pipe as the pump outlet connection. When
the discharge hose is extra long, use the next larger size diameter hose to
minimize friction.

b. Relief Valve - Select a relief valve of adequate capacity and install in

discharge line between the pump and check valve (if used) or the shutoff
valve. Bean relief valves bypass excess liquids to prevent extreme
pressures. They are easily adjusted for pressure control.
c. Pressure Gauge - A pressure gauge is recommended to aid in checking or
adjusting pressures and it should be installed in the discharge line near the
relief valve.
d. Discharge Dampener - Install a pulsation dampener of adequate size in
the discharge line to ensure smooth delivery by dampening pulsations and
minimizing surging.
e. Power Source - If the pump is driven by an electric motor, use wire of
sufficient size to carry the load with the additional protection of fuses or
thermal relays.
If the pump and motor are connected by a flexible coupling, be sure the two
shafts are in good alignment with each other.
f. Direction of Rotation - The pump may be operated in either direction with
satisfactory results.
Servicing Instructions
Safety First!. Disconnect the power source before performing any service on the pump.
1. General Care of the Pump.
a. Drain and refill the pump crankcase with clean SAE30 Texaco Meropa 100
oil or SAE30 Shell Omala 100 oil after the first 100 hours of operation.
Following the first 100 hours, of operation, for best results change the oil
every 750 hours of operation.
Table 12: Lubrication Chart for John Bean Water Injection Pumps
Pump Size Lubrication Approximate Quantity

FMC John Bean 18 gpm SAE Texaco Meropa 100 64 ounces (1.89 liter)
(68.13 liters) or Shell Omala 100 oil.
FMC John Bean 25 gpm 64 Ounces (1.89 liter)
(94.63 liters)
FMC John Bean 35 gpm 64 ounces (1.89 liter)
(132.48 liters)
b. Keep all piping and mounting bolts tight.

c. Replace all worn parts promptly with OEM replacement parts.

2. Care in Freezing Weather
CAUTION
Important - Precautions must be taken to avoid damage to the pump from

liquid allowed to freeze in the valve chamber.
12 12
14 -40' 13
e'19 15
16 0--- 17
11
18
19
39-
a. Drain all connecting piping.

b. Refer to above pump drawing. Remove capscrew (1), clamp(2), valve (3),
valve disc and spring (5) to drain the valve chamber (9) when freezing
temperatures are expected. Remove the "top" discharge valves or raise
them to be sure that no liquid is trapped under the "inner" suction valves.

3. Servicing the Plunger Packings
a. Release valve chamber (9) from pump case by removing the four
capscrews (10) shown above.
b. Lift the chamber free of the cylinders (12). Remove the cap screws (13), the
cup washers (14) and plunger packings (15).
c. Lift the cylinders (12) from the pump case (21).
d. Inspect the o-rings (17) and the umbrellas (1.8)-, Weither of these parts are
worn or damaged, they should be replacedr4oeke-t-knife can be used for
easiest removal of the umbrellas. Clean all-parts thoroughly and replace the
worn parts with exact OEM replacement parts.
e. When reassembling plunger packings, inspect the bottom gasket (11) and
replace if necessary. Note: If it-is necessary to replace one gasket at either
top or bottom of the cylinders, then all bottom or top cylinder gaskets should
be replaced. Torque capscrews to 8-10 ft/lbs (11-13.5 Nm). Note: For
easier installation of the umbrella, Soak in hot water for approximately two
to three minutes to soften.
f. Fold the plastic umbrellas (18), as shown in below, to insert them through
openings and over ends of crosshead rods.
g• Press tops of umbrellas to, plaCe'p,ilpt wasners (19) over ends of rods with
groove up.
h. Place o-rings (17) and packtrig-jinolders (16) in position on ends of
crosshead rods.
i. Place cylinders (12) in position in the mounting plate recess.
j. Oil the plunger packings (15) and press them in the open end of the
cylinders, with the cup "up". Use the thumb to press the packings into each
cylinder firmly and squarely on the plunger rod end.
k. Turn the pump by hand to raise each plunger rod to the top of the stroke,
as needed.
• I. Place the cup washers (14), with the ribbed side against the plunger
packing, inside the cups of the packing.

m. Secure packing and washers to plunger rods with capscrews (13),

tightening them until the washers and cups seat firmly on the plunger rods.
Torque to 15-20 ft/lbs (20-27 Nm).
n. Inspect top cylinder gaskets (11) and replace all if any show defects,
holding them in place in the valve chamber by using heavy oil or grease if
necessary.
o. Return the valve chamber to position over the cylinder, making sure that
gaskets (11) and cylinders .(1 2)„pre properly positioned in the top and
bottom recesses. j
p. Tighten capscrews (10) alternately and evenly until the parts are snugly
seated. Torque capscrews 20-25 ft/lbs (27-34 Nm).
,c;
q. Important: Clean buildup from cylinders. Submerge the cylinder in uncut
muriat acid (28% hydrochloric acid) for three (3) minutes, rinse in clear
water, wash with strong.spap; !submerge in acid for two (2) more minutes,
rinse in clear water and wipe Off.
4. Servicing the Pump Valves
a. Remove the capscrew (1) and clamp bar (2) from the valve chamber (9)
and lift out valve covers (3) with o-rings (4) attached.
,
b. Remove the discharge valve springs and disc assemblies (6) and valve
cages (5).
c. Insert the round end of valve eat puller tool (39) through the opening at the
center of the valve seats (7). loosen the seats from the valve chamber (9)
with a "rocking" motion of the tool.' s,
d. Remove the valve seats froni°JheAdIses with the opposite end (curved
end) of the puller tool (39). ° =":
e. Repeat the four preceding steps (step a ;- c and d) to remove the suction
valve parts which are identical to the'd*harge valve parts and are located
immediately "under them in the:461Ve -dh6mber.
f. Clean all parts and inspect thdm.:136place all worn parts as needed. Note:
Valve seats (7) may be used either side "up", thus if one side shows wear,
the opposite side may be used to provide a new seat.
g. With the o-ring (4) in place on each valve seat (7), place a few drops of light
oil on the ring and seat and place each squarely in the bottom of the recess
in the valve chamber.
h. Place the valve cages (5) on the valve seats (7) and the spring and disc
assemblies (6) inside each cage.
i. Repeat steps (7) and (8) to install the "outer" discharge valve parts.
Place the valve covers (3), with o-rings on the bottom groove, over each
valve assembly.

k. Replace clamp bar (2) and capscrews (1), tightening capscrew (1) snugly
only. Do not overtighten capscrew (1). Overtightening can damage
valve parts. Torque to 30 ft/lbs (40.6 Nm).
5. Servicing the Crankshaft
a. Remove pipe plug (37) and drain oil from pump case.
28 29 30
IP
39
35 37
36
b. Disconnect piping and remove pump from mounting.

c. Remove capscrews (36), wave washers {35) and mounting base (34)
carefully to protect the gasket (33).
d. Remove capscrews from the connecting rod assemblies (24). Use a center
punch or other suitable instrument to mark caps and rods for prOper
rematching when they are reassembled.
e. Remove oil slingers (32) from the crankshafts (26) and (27).

to
f. Push the connecting rods and crosshead assemblies into the pump case
clear the crankshafts (26) and (27).
g. Remove the driven sheave from the crankshaft extension.
at outside of
h. Remove the snap rings (28) from groove in pump case
bearings (30 and 31).
ends (outside)
i. Use a suitable wood block and hammer to tap against gear
of each crankshaft to remove oil seals and bearing s at opposi te side of
pump case. Crankshafts, with bearings at gear ends, may then be removed
from bottom of case.
FL CAUTION]
ng
Never pound directly on bearings (31) when removing or replaci
them on the crankshaft.
A block of wood with a suitable sized opening or block supports to assure
this
reasonable equal support around the bearing in a press is best for
important work.
s (if
k. After inspecting and replacing all the worn parts, press new bearing
ly
needed) against the shoulders on the crankshaft, then place the assemb
through openings into the pump case.
I. Important: Timing the Pump - Arrows on gears must be located exactly

as shown above to properly time the pump.
case,
m. With the crankshaft and bearings assembly in place in the pump
the cranksh aft with the "lip"
place the oil seals (29) carefully over the ends of
of the seals facing the inside of the pump case. Care should be taken
seal
when passing seals over the crankcase to avoid folding the lip of the
under or damaging the lip.

n. Set the snap rings (28) in the grooves in the bearing housings against
the
oil seals and tap the crankcase to allow a slight end play in the cranksha
ft.
o. Assemble the connecting rods and crossheads, being sure to rematch
the
rod and cap properly as marked when disassembled. Use 6-8 ft/lbs (8-11
Nm) torque on capscrews.
p. Complete the assembly by reversing steps (1) through (8), being sure to
replace the drain plug (37).
q. Remove plug (21A) and fill the crankcase with clean SAE30 non detergent
motor oil to the filler plug level. Clean and replace the filler plug.
Turn the pump a few revolutions by hand to be sure all parts are running freely
before using the pump.
6. Servicing the Crossheads
a. Remove the valve chamber, the cylinders and the plunger packings as
described in paragraph (1) and (2) of Servicing the Plunger Packings.
b. Remove o-ring seal (17), backup washer (19) and the crosshead umbrellas
(18) that are shown in figure 7-9-5.
c. Remove the mounting base and the connecting rods as described in
paragraphs (1) through (4) of Servicing the Crankshaft.
d. Turn the crankshaft by hand to allow removal of the-crossheads through the
pump case opening.
e. Reverse paragraphs (1) through (3) when reassembling the crossheads.
Be sure that all parts are reassembled ip'their exact former positions.
7. Operation
„..
a. Check the drain plug located tirittie! i;tottorn of the base to ensure that it is
properly tightened.
b. Add clean SAE30 API service 'claSs4ation MM or better oil to the pump
crankcase. Maintain oil at the filler plt.fg-ifyel..
• ;
c. Inspect the pump to see that all nuts,..and screws are tight.
d. Turn the pump sheave by--hand a fer times to make sure the pump
operates freely.
e. Start the pump and check its speed. After liquid transfer has been made,
set the pressure gauge to the desired reading.
f. Since the power required to drive the pump varies directly with the pressure
and the amount of fluid handled, it is recommended that the unit be
operated according to specifications.

either overheating the bearings or

If the speed is increased excessively, there is danger of
causing cavitation in the fluid end of the pump.
drastically reduced in addition to
If pressure is increased excessively, bearing life will be
breakage of other parts.
or speed results in overloading the
Exceeding pump specification limits for either pressure
power source.
A JC

7-10 ENGINE HEATER
Introduction
This section is provided to present an overview of the engin
e block heater,system currently
used on Drilling Solutions drills.
The preheater will preheat an engine block to ensure reliab
le starting in cold weather. At the
same time it may be used throughout the year to reduc
e the wear associated with cold starts.
EXHAUST PORTt COOLANT OUTLET
TOP VIEW
COOLANT
OUTLET
COOLANT INLET PORT CONNECTION
R.H. SIDE
VIEW
L.H. SIDE VIEW

COOLANT INLET
FUEL SUPPLY
CONNECTION
CONNECTION
EXHAUST PORT Figure 7-10-1

FRONT VIEW
DRILLING SOLUTIONS
7-177
Technical Specifications
Do Not use Gasoline.

Table 13:
Volts Current Fuel Rate Coolant Flow

Heat Rating
Model Nominal Gallon/hour Gallon/minute
BTU/hr. (kw) Amps (L/hr) (L/min)
(renge)
7.5 .32 (1.2) 8.0 (30)
x45-12 45,000 (13.0) ,, 12 (10:01-15)
x45-24 - --24 (20-30) 3.75
Ignition Type: Electric spark ignition
Fuel Types: -. Diesel #1, #2, Kerosine
Coolant Temperature: .150°F to 185°F (65°C to 85°C) @

.-:7 r ‘-i: heater
Enclosure Dimensions:: - 12.5W ,x 11H x 20.5L inches

.-z (318W x 280H x 521L mm)
,-r
Weight, Heater only: — 40 ibs..(18 kg)
, . .
Weight, with Enclosure: 55 lbs. (25 kg)
Operating Temperature Range: -40°F to 122°F (-40°C to 50°C)
Heat Exchanger Capacity: 1 quart U.S. (0.97 liter)
Dimensions
Figure 7-10-2
DRILLING SOLUTIONS
7-178
Principal of Operation
10
12
13 TOP VIEW
L.H. SIDE VIEW

R.H. SIDE VIEW
13
Figure 7-10-3
1. Fuel Pump
A gear pump driven from the same motor as the compressor pulls
fuel from the tank. The fuel
is filtered at the fuel pump inlet. The gear pump will develop a
maximum pressure of 10 psi
(.69 bar) on the outlet side of the pump (figure 7-10-3),
2. Fuel Regulator
Reduces fuel to atmospheric pressure. Siphoning action from

the nozzle draws fuel from the
regulator. Without this siphoning there is no fuel flow.
3. Air Compressor
A diaphragm type compressor supplies air to the fuel nozzle.
DRILLING SOLUTIONS
7-179
4. Ignition coil
ignition electrode, sparking to the
An automotive type ignition coil supplies high voltage to the
combustion tube.
5. Coolant Pump
style pump is used because of its
The coolant pump circulates the engine coolant. An impeller
It is not self priming. The pump must
low current draw and free flow during engine operation.
operate (DO NOT run dry).
be flooded and the system must be purged of all air for it to
6. PROHEAT Control Module (PMC)

ls outputs to the motors and
Utilizes a microprocessor to monitor conditions and contro
ting. One of the key features is the
sensors. It has powerful diagnostics to assist in troubleshoo
to indicate function or component
diagnostic display on the front of the PMC which has LEDS
problems.
Figure 7-10-4
ing for the blower, compressor,

Note: The PCM is unique in that it uses "ground side" switch
s and ignition coil will show
coolant pump and ignition coil. The positive wire to the motor
voltage even when the heater is switched "OFF" .
7. Nozzle
housing. The compressed air
An air/fuel aspirating type spray nozzle is located inside the
. This siphons fuel from the
flows through the nozzle at high speed creating a venturi effect
fine mist which is sprayed out of
regulator and combines it with the air, creating an extremely
ines the air/fuel ratio.
the nozzle into the combustion chamber. The nozzle determ
8. Blower
ly 90% of the combustion air at
The blower uses an impeller type fan to supply approximate
chamber during the 3-minute
low pressure. It is also used to cool and purge the combustion
shutdown sequence.
DRILLING SOLUTIONS
7-180
9. Inspection Port
The inspection port allows for visual inspection of

the combustion process and is invaluable
for reducing time spent on troubleshooting and servi
cing the heater.
10. Heat Exchanger
The heat exchanger is a two part cast aluminum hous

ing. Coolant will typically rise 10°F to
15°F (6°C to 8°C) in temperature as it passes throu
gh the heat exchanger, depending on the
flow rate.
11. Ignition Electrode
The electrode is located near the nozzle just out of

the air/fuel mixture path. During the ignition
sequence the spark jumps the gap between the elect
rode and the combustion tube, igniting
the air/fuel mixture. Spark duration is 60 seconds.
12. Coolant Temperature Sensor
The coolant temperature sensor measures coolant

temperature'at die outlet port of the heat
exchanger.
Afpx
13. Overheat Breaker Sensor
04.
The overheat breaker sensor protects the heater fibtte
ctarii445shoeild it be operated without
coolant. The overheat breaker monitors the surfadde-t
emper lure of the heat exchanger
casting. When the temperature reaches 286°F (14A
) the breaker "trips out". This shuts off
the power to the air compressor, extinguishing the flame
. The breaker can be reset by pushing
down on the red button located under the rubber cap.
14. Flame Sensor

The flame sensor photo-electronically measures the
intensity of the flame. It is the flame
sensor that signals to the PCM that the air/fuel mixtu
re is burning properly.
15. On/Off Switch

•
NOICATOPIUCIKI
LocATSCIN TCOOLZ
DRILLING SOLUTIONS
7-181
"on" and "off". It has an indicator lamp that

The On/Off switch is used to switch the heater
A flashing red light indicates a heater diagnostic code
displays a red light when switched "on".
ay will be lit. The "on/off" switch is not
and one of the LEDs on the PCM diagnostic displ
r.
used on all the drills and is replaced with a time
16. Seven (7) Day Timer
IT410M•40 HEATING SYSTEMS

MANUAL INDICATOR
LIGHT (RED)
MON
AM
D -- MANU AL
12:00 BUTTON
EH— TIMER SET

CLOCK 71M1 . O. DAY 9BUTTON
iih
TIMER ID
CLOCK vo# LIGHT
(GREEN)
7 DAY TIMER
and "off". This can be done manually or by a

The 7-day timer is used to switch the heater "on"
displays a red light when switched or timed
preset time and day. It has an indicator lamp that
ibstic code and one of the LEDs on the PCM
"on". A flashing red light indicates a heater diagr
Sequence" for details).
diagnostic display will be lit (see "Normal Opergting
4
Normal Operating Sequence

if used) and the PCM "ON"
1. Switch "ON"- The timer lamp (orthe orriqffswitch
LED will light. The heater goes to,!'pre-ohecls';:t:
cycle. This takes several
2. Pre-Check - The PCM perforrn 1 09.0/../zii6gfnbstic
es, short circuits and open
seconds, checking components, fcr, prober rang
r goes to "ignition".
circuits. If there are no errors indicated2the heate
, ignition spark,
3. Ignition - The blower starts first, followed by the coolant pump
rode spar ks, 60 seconds
air compressor and fuel pump. The ignition elect sens or "sees"
Once the flame
maximum, until the flame sensor "sees" a flame.
a flame, the heater goes to "full outPufl.'
coolant temperature
4. Full Output - The heater runs at full output until the
time, the heater shuts the
reaches 185°F (85°C) at the heater outlet. At this
flame off and goes to "purge".
diately. The blower
5. Purge - The air compressor and fuel pump shut off imme
tes, the blower stops and the
and coolant pump continue to run. After 3 minu
heater goes to "standby".
gh the system until the
6. Standby- The coolant pump circulates the coolant throu
er outle t; then it will enter
temperature drops to 150°F (65°C) at the heat
will conti nue to repeat steps 2
Precheck and repeat steps 2 thru 6. The heater
thru 5 until it is turned "OFF".
DRILLING SOLUTIONS
7-182
7. Switch "OFF" - If the heater is in Full Outpu

t, it will purge first and then shut
"OFF". If the heater is in Standby, it will shut "OFF
" immediately. Note: The
heater will purge for three reasons:
a. The coolant reaches 185°F (85°C).

b. There is a function or component problem
(see "Troubleshooting &
Repair").
c. The heater is operating at Full Output when it
is.shut "OFF".
Function and Component Diagnostics
The microprocessor in the PCM continually monit

ors all the heat& systems. If the internal
diagnostics discover a problem, a diagnostic code
will be displayed on the PCM function
display. The timer red "ON" light will also flash the diagn
ostic. code followed by a pause and
then repeated. The number of flashes correspond to
the numbered,diagnostic code; eg. 5
flashes indicate a VOLTAGE ERROR. See Diagnostic
Code.Description-belOw fora complete
list of error flash codes. If this occurs, refer to the troubl
eshooting section to assist in problem
diagnosis.
1.START
.—Q/;
I 2.FLAME OUT
may, 3. COOLANT FLOW
4.OVER HEAT
muc.......,---40
ml--e 5. VOLTAGE
IIIII---• 6. FLAME SENSOR
lig-------e 7. TEMP SENSOR

E. FUEL PUMP (SEE NOTE)
milt \ S. COMPRESSOR
,
et 10. IGNITION COIL
"Vb 11. COOLANT PUMP
Figure 7-10-6 12. BLOWER
Table 15: Diagnostic Codes
Code No. Description of Diagnostic Code No. of Flashes

1 Start 1
2 Flame Out 2
3 Coolant Flow 3
4 Coolant Overheat 4
5 Voltage (High/Low) 5
6 Flame Sensor 6
7 Temperature Sensor 7
DRILLING SOLUTIONS
7-183
No. of Flashes
Code No. Description of Diagnostic Code
8
8 Fuel Pump*
9
9 Compressor
Ignition Coil 10
10
Coolant Pump 11
11
Blower (Combustion) 12
12
Not Used 13
13
ressor motor. The fuel pump is not being

* The fuel pump is a gear pump driven by the comp
code appear, there is a fault in the
monitored electrically. Should this component diagnostic
anical problems with the fuel pump will
main wire harness connector or in the PCM. All mech
diagnostic code.
be indicated as either a (1) START or a (2) FLAME OUT
Troubleshooting & Repair

z 1. START
ON ii-al A 2. FLAME OUT
,...,,,, 3. COOLANT FLOW
FUNCTION i 111,.....-------*
DIAGNOSTICS ming__—
~~_ ____--• 4. OVERHEAT
~~-• 5. VOLTAGE
. 1--• 6. FLAME SENSOR

" 111111. -• 7. TEMP SENSOR
..
COMPONENT 1 --'..
F. "1... ---"`•• 8. FUEL PUMP (SEE NOTE)
DIAGNOSTICS ss, 9. COMPRESSOR
11111.
1041
011 10. IGNITION COIL
11. COOLANT PUMP
Figure 7-10-7 12. BLOWER
sections:
The Troubleshooting & Repair Guide is divided into four
ostic panel will cause the
1. Function Errors: Errors displayed on the PCM diagn
ly the result of a system
heater to shut down. These diagnostic codes are usual
problem.
yed at the same time.
It is possible to have two or more diagnostic codes displa
nction with a component
A function diagnostic code may be displayed in conju
diagnostic code.
r components. In
2. Component Faults: This section covers the individual heate
on the PCM function
many cases there is a corresponding indicator light
em, not a
display. The indicator light only indicates an electrical probl
can also cause Func tion diagnostic
mechanical failure. Component problems
codes.
DRILLING SOLUTIONS
7-184
3. Component: This section includes the electrode gap, fuse, nozzle and fuel
regulator.
4. These are problems that are not specifically described in the Functional
or
Component diagnostic sections.
Note: Always let the heater run through two cycles when troubleshooting. The
heater will attempt one restart after any function or component diagnostic code.
The heater will not start if it is in a purge cycle or if the coolant temperature is
above 150°F (65°C).
On
A continuously flashing "ON" indicator indicates a problem in the PCM.
Figure 7-10-8
Check: Heater PCM Function
1. Turn the heater switch located on the timer to "OFF". Reset the PCM by
removing the power connection for 10 seconds, then reconnecting it. If the "ON"
light continues to flash, replacd the PCM.
Function Diagnostic
(1) Start
A START diagnostic code indicates that the flame sensor did not see a flame during the 60
second ignition period.
1 START
i ill
FUNCTION mms
DIAGNOSTICS mod
meg
•
III
mom.
00•4
COMPONENT _ 1=m11
DIAGNOSTICS my
id
Figure 7-10-9

If the START diagnostic code is displayed, turn the heater "OFF" and then "ON" to restart.
Observe the heater operation through the inspection window.
Symptom: Flame Visible. The heater shuts down after 60 second ignition period.
1. Check: Flame Sensor
a. Inspect for open circuit in the wiring.

b. Inspect the lens for cleanliness.
2. Check: Fuel System
a. Is there restriction in the fuel system?

b. Is the nozzle plugged?
c. Is the fuel pump operating?
d. Is the pressure regulator defective?
e. Is the compressor functioning?
f. What type of fuel is being used?
Symptom: No Flame Visible. The spark continues for the 60 second ignition period. The
heater shuts down after the 60 second ignition period.
a. Is there a restriction in the fuel system?

a
c. Is the fuel pump operating? ,
,4Zre:
Note: A spark should be visible across thegdp,between the ignition electrode
and the combustion tube.
Symptom: Heater is BackfiHng.Bactdiringisutiy caused by a severe restriction of
combustion air or air in the fuel line., 1 DirlrN ;
1. Check: Inlet Air Flow
a. Is the blower error displayed?

b. Blower Operation:
(1) Is the blower turning?
(2) Is the blower turning slowly?
c. Check for restrictions at the fan inlet port and in the exhaust system.
d. Check for carbon buildup in the combustion chamber.

a. Is fuel level low?

b. Is air leaking into fuel system?
Symptom: No Flame Visible and No Spark. The heater shuts down after the 60 second
ignition period.
1. Check: Ignition System
a. Check for a poor electrical connection between the ignition coil and the high
tension lead.
b. Check for a poor electrical connection between the electrode and the high
tension lead.
c. Inspect the electrode gap. Check for carbon bridging from ignition electrode
to the combustion tube.
d. Inspect the primary electrical connections to ignition coil and coii function.
e. Is the heater chassis ground wire attached? The ground is connected to the
boss located near the fuel pump.
(2) Flame Out
A Flame Out diagnostic code occurs when the heater has started successfully but is unable to
maintain a steady flame.
2. FLAME OUT
FUNCTION
ERRORS
COMPONENT
FAULTS
Figure 7-10-10
If during ignition the flame sensor does not see a flame, the ignition electrode is switched on
immediately. If the flame is not reestablished within 10 seconds the heater will,shut down and
the "FLAME OUT" diagnostic code will be displayed. The heater will go into the "Purge" mode
and attempt to restart in 3 minutes, depending on the coolant temperature.
If the flame fails to re-ignite on the second attempt, a "START" diagnostic code will be
displayed on the function control panel. If, however, the flame sensor senses enough .of a
flame during Ignition, it will enter Full Output mode. During Full Output, if the flame sensor fails
to see a flame then the "FLAME OUT" diagnostic code will be displayed.

a. Is there restriction in the fuel system?

c. Is the fuel, pump operating?
f. What type of fuel is being used?
(3) Coolant Flow
A COOLANT FLOW diagnostic code is displayed when the coolant temperature reaches
185°F (85°C) in less than one minute after ignition.This indicates that the coolant flow is
severely restricted or blocked. This feature aids in:detecting coolant flow problems that can
degrade the heater performance.
FUNCTION COOLANT FLOW

ERRORS
111
1111
mug
COMPONENT
FAU LTS
FIGURE 7-10-11
4NIF
An in-line flow indicator is a valuable troubleshooting tool used to check the coolant flow and
direction; check for air in the system; and check for restrictions caused by the drill systems,
ie., shuttle valves, manual valves and air operated valves.
1. Check: Coolant Flow
a. Coolant Lines: For restrictions and blockages. Are clamps tight?

b. Shutoff Valves: Ensure shutoff valves are open and functioning properly.
c. Fittings: Fittings must be at least 1/2"npt or larger. Avoid using 90° fittings
where possible.
d. Coolant Flow Direction: The heater must be plumbed so the coolant
pump is pumping the coiOlt in same direction as the engine coolant
pump. The heater Y..)e'44ed when the engine is running.
e. Coolant Pump: Dods the pump/function properly?

f. Coolant System Capacity: The coolant system must contain at

least three
gallons (11 liters) of coolant. If system contains less the coolant may reach
185°F (85°C) in less than one minute causing a COOLANT FLOW
diagnostic code.
Note: If coolant system is contaminated with magnetic material, it may
cause
the impeller to seize.
(4) Overheat
An OVERHEAT diagnostic code is displayed when the overheat breaker has

tripped, shutting
the heater down. This occurs if the heater has been started with little or no
coolant in the heat
exchanger.
mai
FUNCTION Ewe
ERRORS mmag
Ner. ---- 4 - OVE R H EAT
III
COMPONENT imas
el▪illi
▪
FAULTS MI
mil
4.0 FIGURE-7-10-12
1. Check: Coolant Flow
a. Is there coolant in the system?.,

b. Determine if there is a blockage or air in the plumbing.
The compressor motor is wired in series with the overheat breaker. The breaker
contains a normally closed therm° switch. When the thermostat reaches
the
preset temperature of 286°F (1419C), the contacts open shutting the
compressor and fuel pump off, instantly shutting the heater down. It cannot be
restarted until the breaker is manually reset.
To reset the breaker, remove the rubber cap covering the top of the overhe
at
breaker and press the red reset button on top. If the breaker will not reset, allow
the heater to cool.
2. Test Procedure
POLARITY NOT
IMPORTANT
RED RESET SUTTON PLUNGER
SPRING
Figure 7-10-13
7-189
overheat breaker
Connect a multimeter (adjusted to measure resistance) to the
. If the sensor
connector (figure 7-10-13). The sensor should be normally closed
has tripped, the circuit should be open.
CAUTION
the overheat
Do not reset the Overheat breaker until the cause of
condition has been determined.
(5) Voltage
to the heater is out of the
A VOLTAGE diagnostic code indicates that the supply voltage
normal range.
FUNCTION
ERRORS
- 5 - VOLTAGE
COMPONENT>.
FAULTS,
;
-Figt4re 7-10-14
1. Voltage Ranges:
a. 12 Volt Heater - 10.0 to 15.0:Volts

b. 24 Volt Heater - 20.0 to 30.0 Volts.
2. Check: Vehicle Voltage
r Voltage
a. The heater voltage must be within the specified range. See Heate
Measurement for procedure to measure heater voltag e.
ions
Note: Bad connections may show good voltage under no load condit
, measu re the voltag e. Then
but not under full load. With the heater "OFF"
is more than
turn the heater "ON" and measure again. If the voltage drop
ctions and the power
one volt, check the deck engine battery conne
connection at the PCM.
check the
b. If the measured voltage is higher than the specified range then
voltage regulator.
is
Note: If engine batteries are marginal, starting engine while the heater
a voltag e error or cause
running may drop the voltage enough to cause
random component errors (brown out).
DRILLING SOLUTIONS
7-190
To reset the PCM, turn the heater "OFF" and then back "ON" at the timer.
If the problem
continues, load test the batteries to confirm their condition. Each battery should
be
independently tested.
Current: Checking current draw is done at power harness connec
tions on the batterie s.
1. Check the current draw on the red POSITIVE wire with heater
not running. It
should read 80 to 100 mA.
2. Check current draw on the red POSITIVE wire with the heater
running in full
output, ignition "OFF". It should read 6.5 to 7.5 amps.
3. Check current draw on the black NEGATIVE wire with heater not
running and
the red POSITIVE wire disconnected. It should read 0 mA. This test
is to
confirm whether or not there is a power leakage from the drill through
the
heater.
Heater Voltage Measurement
The positive terminal of the ignition coil is always hot relative to the heater
chassis ground as
long as power is connected to the heater. This is supply voltage to the heater.
Figure 7-10-15
1. Test Procedure:
a. Locate the rubber boot on end of the ignition coil and peel back to expose
the positive and negative terminals.
b. Select the DC Volts range of a multimeter and connect as shown in figure
7-10-15. The positive lead of the multimeter should be attached to positive
coil lead. The negative lead of multimeter should be attached to the heater
chassis at the heater ground boss (see figure 7-10-30).
c. Read the voltage with the heater running or trying to run.
d. Normal Voltage Ranges:
12 Volt Heater - 10.0 to 15.0 Volts
24 Volt Heater - 20.0 to 30.0 Volts
DRILLING SOLUTIONS
7-191
(6) Flame Sensor

short circuit in the flame sensor
A FLAME SENSOR diagnostic code indicates an electrical
circuit. The flame sensor is an
wiring or a flame sensor failure. It will not indicate an open
or has an open circuit, it cannot
optical device which "sees" the flame. If the sensor lens is dirty
OUT diagnostic code to display.
"see" the flame and results in either a START or a FLAME
FUNCTION
ERRORS
a mot
SENSOR
nee —6 FLAME
imil ,
r•Ill ',.
COMPONENT imos
FAULTS 111
ma
mod
mo Figurer:TO-16
1. Check: Flame S.ensor.
a. Inspect- t "e flag Oensor for a short circuit.

b. Inspect the me sensor lens for cleanliness.
c. Test the flame si nsor (See larne Sensor Test Procedure).
z
t
DRILLING SOLUTIONS
7-192
•
Start Unit
Is there
a Flame
Sensor Code?
Is there
a Flame?
Replace
Sensor
Sensor
OK
After 60
Seconds is
— Yes No
there a Start
Yes Code
1
Is there
Check Main Harness a Spark? Yes.
for a Short Circuit.
Replace if necessary
Clean Sensor if
2 necessary and Restart
No
Try with New PCM.
Replace if necessary Disconnect Old
Sensor/Connect Test
Sensor/Hold up to Check Fuel
Inspection Port/Restart System
Replace I
No
After 60
Seconds is
1LT
Yes
Check Main Harness
for Open Circuit.
Sensor there a Start Replace if necessary
Code
Try with New PCM/

Replace if necessary/
After 60 Seconds if
there is a Start Error
Figure 7-10-17 go to Fuel System

(7) Temp Sensor
A TEMP SENSOR diagnostic code indicates a short or open circuit in the temperature sensor
wiring or the coolant teniR?rature is out of range, below -58°F (-50°C) or above 266°F (130°C).
The resistance of the-tempkattiTS-dhscir is proportional to temperature.
_.
Ns.
FUNCTION
ERRORS
-SENSOR--
- TEMP
COMPONENT
FAULTS
- Figure 7-10-18
1. Check: Temperature Sensor (CODE Indicated)
a. Inspect v. r-iPg-f.6r-shari -or-open .circuits.

f
b. Test thefensor:
2. Test Procedure
-
a. Connect multirneter (adjusted to measure resistance) to temperature
sensor as shown in figure 7-10-19. Polarity of sensor connections to the
multimeter is not important.
Figure 7-10-19
b. Measure the sensor resistance versus temperature under following

conditions:
+ at room temperature
+ in a freezer
+ in boiling water
c. Compare the measured values against the graph in figure 7-10-20. If values
do not approximately match, then sensor is defective and must be replaced.

Coolant Temperature Sensor Graph

TEMPERATURE
CENTIGRADE TEMPERATURE
FARENHEIT
150° I I I • r g I 6
1400 290°
I 1 s • I s a
le 1.... s 120231 130°C (266°F) OUT OF RANGE (UPPER Limn) -
g • s
_ • 260°
120° .
• g •
lio° ,-.- • s g
g I 2:10"
loop I
I s
90° .... 2tie
15410 85° C (1 85°F) UPPER SET POINT
80° I i
• a
70° _ 170°
135411 65° C 150°F) LOWER SET POINT
60°
I I 0
50° 0... I I* I 1 C I
I r 1 I 1 a e
ao°
1 e g s
30° I 0
I $
20° • I
I e I 1 s 1
10° e I
, e s i s
00 s
I
1 1 1 e
g
e t
,
50°
-10° :
s g I e
e i s • 20°
-20° . .
e s g a
• ,
-30° e 1 1 g 1 e -10°
I I I C
-40° ......-..i
-50° ..— 51512 -50°C (-58°F) OUT OF RANGE (LOWER LIMIT) e -40°
: e
t i 1 s s s
-60° 4 s
I I . • o • s
• • • o • s
- 70° o
400 600 800 1000 1200 1400 1600 1800 2000 2200
RESISTANCE OHMS
Figure 7-10-20
7,--Table 16:
Room Temperature 70°F (20°C) Resistance 950 ohms
Boiling Water 212°F (100`:C) Resistance 1700 ohms
(8) Fuel Pump
FUNCTION
ERRORS my
Imo
•
- FUEL PUMP
COMPONENT _
FAULTS
Figure 7-10-21
vow
DRILLING SOLUTIONS
7-195
Therefore, there is no fuel

The fuel gear pump is driven by the same motor as the compressor.
code would indicate a fault in the
pump electrical diagnostic code. A FUEL PUMP diagnostic
PCM only.
will be indicated by a
A short or open circuit fault in the motor that drives the fuel pump
COMPRESSOR diagnostic code.
gs, jammed gears or a
A mechanical fault within the fuel pump such as stripped drive couplin
faulty pressure relief valve, would be indicated by:
1. START diagnostic code.

2. FLAME OUT diagnostic code.
3. Blown fuse in the PCM. Indicates that the pump is seized.
1. Check: Fuel Pump
a. Check fuel pump as per procedure (See Fuel System).

b. Check relief valve for contamination.
c. Check filter for contamination.
d. Check drive couplings.
COMPRESSOR
RELIEF VALVE
PRESSURE
ADJUSTING
SCREW
DRIVE COUPLING X 2
O-RING
FUEL PUMP
OUTLET
INLET
FIMNG
FILTER
BOLTS X 2
ADAPTER
Figure 7-10-22

(9) Compressor
A COMPRESSOR diagnostic code indicates an open circuit in the wire harness, a short in the
wire harness between the positive and negative leads or an internal short in the motor. This
component is ground side switched in the PCM.
0
=
FUNCTION i
ERRORS imill
=NI
COMPONENT i
FAULTS
a
emll
le
9 - COMPRESSOR
III
il
4w Figure 7-10-23
Symptom: Air Compressor not running (code indicated).
1. Check: Air Compressor wiring & function.
a. Check that compressor is connected to harness correctly.

b. Check the connector pins for damage or corrosion.
c. Check harness for pinched or abraded,wire
.
d. Test compressor. If it tests OK replaqpPCM.
2. Test Procedure
a. Connect air compressor directly to 'a powel- source of rated voltage (12/24
Volts) and see if the motor runs. If not, -teplace the compressor.
b. Measure air compressor motor,_ esistance by using a multimeter, and then
measure resistance across cqmpressor connector pins. If resistance shows
an open or short circuit, replade the compressor assembly.
c. Measure air compressor current. Use a test lead.
FIGURE 7-10-24
PRESSURE
ADJUSTING
SCREW

Table 17:
MODEL CURRENT DRAW (AMPS)
X45-12 3.50 - 5.00 @ 12 VOLTS
X45-24 1.5 - 3.00 @ 24 VOLTS
flow.
Symptom: Air compressor running (NO CODE indicated). No or low air
te (0-15
1. Check: Air flow using pressure gauge. Ensure gauge is accura
psi).
7-10-25. The
2. Procedure: Install the pressure gauge as shown in figure
pressure reading for X45:6.5 psi (.45 bar) @ 12/24 Volts.
i F • END VIEW OF
COMPRESSO ADJUSTING SCREW
FIGURE 7-10-25 INCREASE
PRESSURE
DECREASE
PRESSURE
LINE NOZZLE
AIR INLET ADJUSTMENT
ELECTRICAL
SCREW
MOTOR
FUEL
PUMP
Figure 7-10-26
LINE FROM COMPRESSOR
High Pressure Reading indiMes:
a. Blocked nozzle. Air passage only (See Nozzle - Figure 7-10-39).

b. Compressor is out of adjustment. Re-adjust the compressor using the
adjustment screw as indicated in figure 7-10-26.
Low Pressure Reading indicates:
a. Pinched or leaking air line from the compressor outlet fitting to the fan end
inlet.
b. Plugged compressor inlet filter. Retest with the filter removed.
Normal Reading but a rich or lean flame:
a. Check for contaminated nozzle, fuel passage (See Nozzle).

b. Check the blower.
c. Check the fuel regulator.
d. Check fuel system.

3. Pressure Adjustment:
a. Locate adjusting screw on the compressor head (figure 7-10-26).

b. Adjust as necessary. Ensure that voltage is nominally 12 or 24 Volts.
Symptom: Air Compressor running (NO CODE) indicated). Fuse blown in PCM.
1. Check: Air Compressor operation.
a. Check harness for pinched or abraded wires. The positive wire must not
short to the ground.
b. Check motor for internal short.
c. Check for seized motor or fuel pump.
Disconnect the PCM electrical power prior to trying to turn the compressor counter
weight by hand.
REMOVE FOUR SQLTS, AtiD

COVER FCgACCE8S'TO THE
COMPRESSOR t'..41NTE.RWEIGHT--
BY HAND TCHECKEQ
O Rti.EIZED
MOTOR OR PbEi; PUMP,
Figure 7-10-27
(10) Ignition Coil
An IGNITION COIL diagnostic code indicates an open circuit in the wire harness, a short in
the wire harness between the positive and negative leads or an internal short in the coil. The
fuse will blow if there is a short to ground in the positive lead or the coil. The ignition coil is the
easiest place to measure the voltage on the heater. This component is ground side switched
in the PCM.
i 1.g
FUNCTIO
0
N ly
Figure 7-10-28
ERRORS mill
•=e
MI
•
I meld
mme
COMPONENT la
FAULTS 'il 10 - IGNITION COIL
ill
ig
411.

the
The heater chassis is grounded from the PCM as shown in figure 7-10-30. Ensure
ground is securely connected. Failure to ensure a proper ground may result in electric
shock.
Symptom: No Spark a# 'the electrode (code indicated).
1. Check: Coil Wiring
a. Inspect the wiring harness to ensure the ring terminals are secured to the
coil. Make sure the polarity is correct.
b. Inspect for broken or abraded wires in the wire harness.
c. Test coil (see figure 7-10-29).
d. if an IGNITION COIL diagnostic code occurs and no fault is found in the coil
and wiring, then the PCM must be checked.
Symptom: No Spark at the electrode (NO code indicated.)
1. Check: High tension wires and electrode.
a. Inspect the high tension lead between the coil and the electrode.
b. Inspect the ground lead between the second electrode and heater chassis.
c. Is electrode gap adjusted correctly? (See Electrode Gap figure 7-10-35).
2. Test Procedure:
a. Measure ignition coil resistance. Use a multimeter to measure resistance

across the positive and negative terminals. The resistance should be less
than 1 ohm. If the resistance is "oljen circuit" or 0 ohms (short circuit) then
replace the ignition coil.
b. Note: Remove positive and negative wires from the coil when testing.

GROUND WIRE
FROM PCM
- ,
CHASSIS
GROUND
BOSS
Figure 7-10-30 ,
IGNITION COIL TEST
Figure 7-10-29
(11) Coolant Pump
A COOLANT PUMP diagnostic code indicates an open circuit in the wire harness, a short in
the wire harness between the positive and negative leads or an internal short in the motor. This
Figure 7-10-31
mmd
FUNCTION
ERRORS
mood
U
mid
mmd
mod
COMPONENT w og
FAULTS
a _11.COOLANT PUMP
The coolant pump is not self priming. Ensure that the coolant system has been purged of air
by running the deck engine for at least ten minutes following installation or service (Do Not run
dry).
Symptom: Coolant Pump not running (code indicated).
1. Check: Coolant Pump wiring & function.
a. Check that the coolant pump is connected to harness correctly (See the
Heater Wiring Diagram).
b. Check the connector pins for damage or corrosion.
c. Check the harness for pinched or abraded wires.
d. Test the pump. If it tests OK replace PCM (See Test Procedure and Figure
•
7-10-32).

Symptom: Coolant Pump not running (no code indicated). Fuse blown in PCM.
1. Check: Coolant Pump function.
a. Coolant Pump Not Running No Code Indicated).

b. Fuse Blown In PCM
Symptom: Cooling Pump not pumping (no code indicated).
1. Check: Coolant Pump function.
a. Check to see if the impeller is turning freely. If not, replace the pump.
Symptom: Coolant Pump leaking.
1. Check: Leak location.
a. Check hose clamps. Tighten if necessary

b. Check pump housing seal. Replace pump if required.
2. Test Procedure:
a. Connect coolant pump directly to the rated voltage (12/24 Volts) and see if
it runs. If not, replace the pump.
Figure 7-10-32
Table 18: Coolant Pump Test
Model Current Draw (Amps)
X45-12 1.5 - 4.00 @ 12 Volts

X45-24 ' ' 0.75 - 2.00 @ 24 Volts
b. Measure coolant pump motor resistance. With a multimeter, measure the

resistance across the coolant pump connector pins. If resistance shows an
open circuit or an internal short circuit, replace the coolant pump.
c. Measure coolant pump current using a test lead.

(12) Blower
A BLOWER diagnostic code indicates an open circuit in the wire harness, a short in the wire
harness between the positive and negative leads or an internal short in the motor. This
Figure 7-10-33
FUNCTION ▪s
1.
ERRORS m.s
1.6
U
=NS
mod
COMPONENT =mg
FAULTS
=me -12 - BLOWER
4•1
Note: An RPM check was added to the PCM. This feature measures the blower RPM and will
give an error should it fall below the necessary RPM to maintain sufficient combustion air.
CAUTION
When a blower fails, the combustion chamber must be checked for carbon buildup and
cleaned as necessary.
Symptom: Blower not running (code indicated).
1. Check: Blower wiring & function.
a. Check if blower is connected to:harness correctly (See Wiring Diagram).

b. Check the connector pins for,darnage or corrosion.
c. Check harness for pinched or abraded wires.
d. Test the blower. If the blower tests OK replace PCM (See Test Procedure
and figure 7-10-34).
Symptom: Blower not running (no code indicated). Fuse blown in PCM.
1. Check: Blower function.
a. Check harness for pinched or abraded wires. Positive lead must not short
to ground.
b. Check motor for internal short (See Test Procedure and figure 7-10-34).
Symptom: Blower turning slowly (no code indicated).
1. Check: Blower function.
• a. Check for fan blade rubbing on housing.

b. Check for fan blade slipping on motor shaft.
DRILLING SOLUTIONS
7-203
2. Test Procedure
a. Connect the blower to a power supply of the rated voltage. Does the blower
turn? If not, replace the blower.
Figure 7-10-34
Table 19: Blower Test
Model Current Draw (Amps)
X45-12 .75 - 1?.5 @ 12 Volts

X45-244 , .5 - to @ 24 Volts
_
b. Measure blower motor resistdnce. ,Using a multimeter, measure resistance
across the blower connector pins. If resistance shows an open circuit or an
internal short circuit, replace the blower assembly.
c. Measure the blower current using a test•,lead.
Components y
,•- ! j!
The electrode gap is factory set and should not require adjustment.
ELECTRODE
GAP DETAIL
COMBUSTOR
TUBE
Figure 7-10-35
Note: Ensure that the electrode is not bent during servicing. To readjust the electrode, bend it
to the correct setting.

Fuse
If, when the heater is turned "ON", the heater does not run and the "ON" light does not light,
check the fuse in the PCM. The fuse will blow if there is a short to ground in a positive lead or
internally for the following components: ON/OFF switch, air compressor, ignition coil, coolant
pump and blower. Reversing polarity at the battery will, also cause the fuse to blow. This will
not harm the PCM.
CAUTI0k,
Repeated replacement of the fuse or using it coiredtli'ratedluses without correcting

the problem can damage the PCM.
1. Check: Heater wiring
a. Check polarity of battery connections.

b. Test the internal wire harness for short circuits.
GROUND
ON HEAT
EXCHANGER
FIGURE 7-10-36
HARNESS TO
COMPONENTS
PIN LOCATIONS MOULDED

INTO CONNECTOR
COIL
321
BLOWER COMPRESSOR
COOLANT
PUMP
• The following page describes the test procedure for a blown fuse with power connected and
the heater switched off.
DRILLING SOLUTIONS
7-205
Check for correct battery polarity I Fuse Blown Test Procedure

with Power Connected and
Remove Fuse Heater Switched "OFF"
Disconnect from PCM:
• Internal Wire Harness
(18 Pin Connector) NOTE: Ensure positive wire from
• Switch Harness the PCM to the ignition coil
does not ground.
Replace Fuse
(15 amp only)
No
Reconnect Internal Wire Harness

(18 Pin Connector)
Yes
Disconnect all components from

Internal Wire Harness
(10 connections) (See NOTE)
Yes
Yes
Check Switch Harness
and Connections for
Short Circuit
Replace
Internal Wire Harness oil
Harness
Check Component as per Figure 7-10-37

Troubleshooting Guide

Nozzle
The nozzle (and the compressor) regulate the fuel air mixture. A set orifice size allows a certain
amount of fuel and air to flow through the distributor (see figure 7-10-38). Problems in the
nozzle can cause poor burning. This will be indicated by a,SjekRT . oEFLAME OUT diagnostic
_ - - --
code on the PCM function display.
1. Check: Nozzle
a. Inspect the nozzle for blockage.

b. Clean or replace nozzle as necessary.
c. Check and clean fuel passage in the fan'en-d., 4:4.... I . r.• Mg..,
NO NICKS IN 0-RING'
COUNTERBORE STEM DRILUBIT-
0.060 Inches
DISTRIBUTOR
L-
X3:39 Nr11----
CLOCKWISE
HOLES & GROOVES ASSEMBLE
TO DISTRIBUTOR
APPLY COMPRESSED TURN COUNTER

CLOCKWISE TO
AIR IN THIS DIRECTION DISASSEMBLE Figure 7-107:38..
2. Nozzle Cleaning Procedure:
a. Remove nozzle from fan end.

b. Disassemble nozzle as shown-in figure 7-1Q738.
,
c. Use a cleaner/degreaser to thoroughly wash the separate parts.
)..„
d. Dislodging contaminants irldIttrrtrOtdr counterbore can be'done by lightly.
hand spinning a drill bit (0.060" dia.)-and-thenrwashing. Do not use a tip
cleaner in the fuel orifice.
e. Reassemble nozzle and torque to 30 inch pounds'-(3.39 Nm).
f. Use compressed air for cleaning only in the 'direction indicated by the arrow
in figure 7-110-38. rsV
/
zle in fan end.
g. Lubricate the o-ring with diesel Nei and.teipstalr'noz
„
Note: See Step 6 of FuelSy$tem Troublesh oting to confirm that the
nozzle is functioning correctly. All of the nozzlestpartt Are_ matched pails.
Do not interchange.
7-207
Fuel Regulator
The fuel regulator reduces the fuel pressure supplied by the fuel pump from 5 psi (0.34 bar)
down to atmospheric pressure. Compressed air flowing through the nozzle creates a venturi
effect which siphons fuel from the regulator. If the compressed air flow through the nozzle
stops, the regulator closes, shuttifig-off the fuel flow.
1. Check: Fuel 14egulator

r •
a. Ensure that the vent hole in the regulator is not plugged.

b. Ensure that-all fuel line Ouine.ctions are tight. Check the clamps.
2. Test Procedure:
a. Disconnect fuel line at the nozzle fuel inlet fitting and place it in a container.
b. Start the heater- 'heart a small blunt pin in the regulator vent hole and
gently depress the diaphragm (figure 7-10-40).
c. Fuel should flow out of the fuel line. If there is no fuel flow, the regulator is
plugged.
Note: Should a fuel regulator fail, the combustion chamber must be
checked for carbon buildup and cleaned as necessary.
FUEL REGULATOR
Figure 7-10-40
VENT HOLE
BLUNT PIN TO DEPRESS DIAPHRAGM

UNDER VENT HOLE

Fuel System
Fuel System Schematic AIR FILTER

AIR
COMPRESSOR
COMPRESSED AIR 6 TO 8 PSI
FUEL PUMP
0
-o SUCTION
FUEL INLET
FUEL PICKUP
FUEL 5 PSI PRESSURE
FUEL REGULATOR
Figure 7-10-41 FUEL TANK
Step 1 - Is there fuel in the tank?
1. Check the fuel tank for fuel.

Step 2 - Start the heater.
through
1. Start the heater. The heater will try to start twice. Wait until it has gone
two cycles (approximately 10 minutes). The heater diagnos tic system will tell
you what it thinks is wrong. While it is running observe for:
• 't
a. Is there flame? Yes, means there is ignition' and.fuel. Refer to Is ignition

spark turning OFF? No, go to step -•
b. Is ignition spark turning "OFF"? Yes, ileri-,the Flame Sensor sees a

flame. No, then the flame is' either too weak, or the Flame Sensor and/or
circuit is faulty. See Flame Sensor (figure 700-16).
Step 3 - Does the Fuel Pump work?
hooting.
1. This component must be tested before proceeding with further troubles
a. Disconnect the fuel line at the inlet to the regulator. Start the heater. Check
fuel flow, approximately 1 pint (1/2 liter) in 60 seconds.
and
b. Run fuel pump by connecting remote power to compressor motor
checking for fuel flow.
Step 4 - Does the Regulator work?
level as
1. Disconnect the fuel line at the fuel inlet fitting. Hold the line at the same
the inlet. Start the heater. There should be no fuel flow. This indicate s that the
regulator is holding the fuel pressure.
7-209
DRILLING SOLUTIONS
2. Lightly push on the regulator diaphragm (use a blunt tool). Fuel should flow
from the line (see figure 7-10-40).
3. Note: A regulator that is stuck open will produce a rich flame and blockage in
the regulator needle valve seat will produce a lean flame.
Step 5 - Does the Compressor work?
1. Check the pressure output (See figure 7-10-24 and figure 7-10-25).
Step 6 - Isolate the Nozzle and Compressor.
1. Split the fuel system by drawing fuel from a remote source. Disconnect the fuel
line at the outlet of the fuel regulator. Put this end into a small container of fuel
that is about the same level as the center of the regulator (See figure 7-10-42).
This will eliminate the fuel pump and the regulator from the system. Start the
heater. If there is still a fuel problem, it must be in the Compressor or Nozzle.
PLACE THIS LINE IN A

CONTAINER OF FUEL
MAINTAIN FUEL LEVEL AT

CENTER OF THE REGULATOR
REMOVE FUEL LINE

Figure 7-10-42 FROM REGULATOR
Step 7 - Is the Fuel Nozzle contaminated?
1. Clean the nozzle with a cleaner/degreaser which will wash contamination out
the back end of the nozzle.
Operational Problems
Heater Operational Problems that are not specifically described in the function or component
diagnostic section are shown below.
Smoking Exhaust and Smelly Exhaust Fumes
These symptoms are usually an indication of an extremely rich air/fuel mixture.
1. Check:
a. Is the heater connected to the correct voltage? (Refer to figure 7-10-15).
7-210
DRILLING SOLUTIONS
b. Is the blower functioning? Is the air inlet restricted?

c. Is the compressor functioning? (Refer to figure 7-10-24).
d. Is the exhaust restricted?
e. Is it a new heater? New heaters may smoke for 15 minutes as oil is burned
off the exhaust pipe. This is normal.
Low Heat Output
If the heater appears to be functioning properly but the driver complains of low heat, this is
often indicative of a coolant flow restriction. Refer to figure 7-10-11.
Engine Temperature Gauge Reads Low
Depending on its location, the engine temperature sensor may not be directly in the path of
coolant flow from the heater. In these cases the gauge may read significantly lower than actual
coolant temperature.
Backfiring
,
Backfiring occurs when there is air in the fuel supply lines.
1. Check:
a. Check fuel level in fuel tank. Is the pickup submerged?

b. Check for air leaks. Are all the fuel line,clarli' ps tight?
c. Check for severely restricted combustion air blockage at\th-e blow-er inlet,
combustion chamber or in the exhaust system.
Maintenance
Weekly Maintenance
Run the heater a minimum of once a week to keep new fuel in the heater's critical components.
Annual Maintenance
Check the system annually before each heating season. There are several maintenance
procedures you can perform to keep your heater in service. Read this maintenance section
carefully. Always return to your authorized Drilling Solutions dealer or distributor for major
maintenance.
7-211
Clean Heater Enclosure
Remove the heater enclosure cover and blow out the compartment with compressed air.
Clean any accumulated debris or dust from the components. Make sure the opening around
the exhaust pipe is clear. Visually inspect all the components for wear or damage.
Figure 7-10-43
Heat Exchanger
To maintain optimum heat output, clean any combustion deposits that may have accumulated
on the heat exchanger fins.
1. Remove ignition lead from ignition electrode.

2. Remove blower connector.
3. Remove the three (3) bolts securing the fan end assembly.
4. Remove the fan end assembly and combustion tube to access the inside of the
heat exchanger (figure 7-10-44). Use a wire brush to loosen the deposits and
an air hose to blow them out.
COMBUSTION TUBE
HEAT EXCHANGER FINS

Figure 7-10-44
Exhaust System
Check the exhaust system carefully. Make sure the exhaust pipe is vented safely away from
the vehicle cab. Check the pipe fbr dents, restrictions or severely corroded areas. Replace the
exhaust pipe and clamps if necessary. Ensure the exhaust pipe clamp is tight.
7-212
DRILLING SOLUTIONS
Electrical System
7-10-45). Replace if
Check the internal and the external wire harnesses for damage (figure
required.
Figure 7-10-45
Clean Air Intake

Clean as required.
Check the combustion air inlet screen (figure 7-10-46) for restrictions.
AIR INLET SCREEN
Figure 7-10-46
Fuel System
the clamps on the fuel
Check the fuel system for damaged fuel lines or leakage. Make sure
lines are secure.
AIR FILTER
GROMMET
HOSE CLAMP FUEL TANK

FUEL LINE
FUEL FILTER
HOSE CLAMP
FUEL UNE
Figure 7-10-47 FUEL PICKUP
7-213
DRILLING SOLUTIONS
Engine Batteries
Check the condition of the batteries and the power connections. The heater will not function
properly with weak batteries or corroded connections. If you are unsure of their condition, load
test each battery separately and replace as required. Clean terminals to remove all corrosion.
Figure. 7-10
Operation Test
Run the Systliki for at leest...15 minutes or until the heater cycles "OFF" and then "ON" again.
34, POWER + 12V/+24V (3 AMP LIMIT)

3-B GROUND (-)
3A
2A
2-A POWER +12V/+24V (OUTPUT)
2Lik
• GROUND (-)
SIGNAL (TO HEATER)
2-D INDICATOR +12V/+24 VOLTS
NiAdPOWER +12V/+24V (INPUT)

1-B GROUND (-)
1-C NOT USED
171,77117
=el
1B
Figure 7-10-4 9
7-214
DRILLING SOLUTIONS
• Heater Wiring Diagram
The following represents the heater wiring diagram.
18 PIN CONNECTOR'
PIN-OUT LOCATION
A (+I PINK.- -
OVERHEAT SENSOR
13,.{=) PINK • 9. Z"
rA A (+) ORANGE. I • Al
COMPRESSOR 81
B (-) BLACK/ORANGE
FUEL PUMP
• Cl
(-) BLACK/GREEN C3
r
HEATER CHASSIS (GROUND)
(GROUND VIA
COMBUSTION TUBE)
IGNITION • D2
IGNITION
COIL • D1
ELECTRODE
(-) BLACK
jk
(-01../RPLE
• A3
BLOWER 62
B (-) BLACK/PURPLE
■ A ,"( -- 1-1 BLUE • A2

• B3
COOLANT B (-) BLACK/SLUE
PUMP
'A (+1 WHITE • F2

FLAME 1.4 E2
SENSOR B (-) BLACK/WHITE
T
.1+1 GRAY -• F3
TEMPERATURE 4=01 E3
SENSOR B (-) BROWN
SPARE y REorwrinE:: *El

1 A MAX. •
Fl
B (-) GREEN/WHITE
Figure 7-10-50 18 PIN CONNECTOR

HARNESS SIDE
7-215
Heater Wiring Diagram (continued)
The following is a continuation of the heater wiring diagram.
Figure 7-10-51
15
AMP
FUSE
B
NOTE: TRANSISTORS
SWITCHED BY
MICROPROCESSOR
HEATER
CONTROLLER
ON—OFF TOGGLE
SWITCH OR TIMER
(UNDER DRIVERS
SEAT)
BLACK
1
2D O
2C GREEN
-
SWITCH INPUT CONNECTOR (4 PIN)
F.,
o
cc Lu
00
2 ,O POWER CONNECTOR (3 PIN)
r'N a.
_11+ ) ENGINE
= BATTERY
1A — (+) RED — (12/24
/—) VOLT)
NOT USED (—) BLACK
•••••••:11. WO VEHICLE
GROUND
18 PIN CONNECTOR
CONTROLLER SIDE

Timer
General Description
The 7 day timer can be preset for a single start time, one day at a time or program,med start
times per day constantly activated for multiple days of the week. The clock can be-preset for
12 or 24 hour time display. The heater run time, duration can be preset for 1 or 3 hOuis. The
manual button can be used to override the program acid-run the,heater indefinitely until it is
switched off.
T1 PROGRAM DAY OF
INDICATOR THE WEEK TIME AM INDICATOR
HEATER ACTI,VATED
LIGHT (REDJ
Figure 7-10-52
TIMER ACTIVATED
LIG-HT(GREEN)
T2 PROGRAM I "
\ PM INDICATOR
INDICATOR
CLOCK DAY\ 'ADVANCE
TIME ADVANCE, 4
Note:
1. The timer must be set for the drill system voltage

2. If power to the timer is interruptecinthe display will flash "12:00 am MON." in
12 hour format or "00:00 MON."on'24 hour-forririat. Stored programmed times
will remain set in memory.
Heater Connection
CAUTION
Power to the controller must be disconnected beforeconnecting_the _'
1. Connect the heater switch harness to the timer as follows:
a. Black to Black
•
b. Green to Green
c. White to White
d. Red to Red

L, CAUTION
Incorrectly wiring the timer connections may result in timer damage.
Wiring & Switch Settings
Before using timer, set the dip switch settings for your application.
Note: If the timer is connected to a heater which does not have an operational signal wire, then
the white timer wire must be jumpered to the green "ON SIGNAL" wire for the timer's red "ON"
indicator to light (see figure 7-10-53).
CLOCK MODE FACTORY SETTING

24 hOur dock 12 hour mode
TIMEOUT MODE FACTORY SETTING

1 hour duration 3 hour duration
SYSTEM MODE FACTORY SETTING

dual timer, multiple days single timer, single day
with automatic reset
VOLTAGE MODE ---,FACTORY SETTING
24 volts 12 volts
RED WIRE (power)
BLACK WIRE (ground)
GREY WIRE (keyswitch

backlighting optional)
GREEN WIRE
("ON" signal to heater)
WHITE WIRE (operational
Figure 7-10-53 signal from heater)
(see "Note:")

To Set Clock (Time & Day)
MANUAL
MON TUE WED THU FRI BAT SUN
UULJ
T: 1 2 0 7. Figure 7-10-54
DAY O
D TIMER
1. Press and hold "Clock".

2. Press "Left Arrow" Time Retard or "Right Arrow' Time -Advance to set time.
3. Press "Day" to set day.
4. Release "Clock".
Note: The 12 or 24 hour option is set using Dip Switch No. 1 on back of timer:
a. ON = 12 hour mode.
b. OFF = 24 hour mode.
c. (Factory preset: 12 hour mode)
To Set Single Timer Mode
JANuAL
O
*
00IT 1 .r ,ri
IIMON TUE WED TIM FRI SAT SUN
AM
0
12 ICJ' Li LI PM
DAY 1111C:(
CLOCK 41 TIME I.
MO
000 0 TIMER
1. Press and hold "Timer". (Green light Will go_on}and T1 will flash).
_ " Time Advance to set "ON"
2. Press "Left Arrow" Time Retard or "Right Arrow
time.
3. Press "Day" to set day.
4. Release "Timer". (Green light and "T1" will remain lit to indicate active timer).
Timer set in the single timer mode only will allow you to set one "ON" time. With
the T1 time activated, the timer will go "ON" at the preset time and will be
•
deactivated at the end of its duration time. To reactivate the timer, press
"Timer".

Note: When set time is reached, the heater switches on. Red and green lights
are on. The 1 or 3 hour duration option is set using Dip Switch No. 2 on back of
timer.
a. ON = 3 hour duration.
b. OFF = 1 hour duration.
c. (Factory preset: 3 hour duration)
To Set Dual Timer Mode
In the dual timer mode setting you can program your timer to come "ON" daily, Monday
through Friday, Monday through Saturday or Monday through Sunday. It also has a built in
repeat function so that you do not have to reactivate the timer after every duration time.
Note: In dual timer mode you can set T1, T2 or both T1 and T2. Timer mode option is set using
Dip Switch No. 3 on back of timer.
1. ON = single timer (T1 only).

2. OFF = dual timer (T1 and T2).
3. (Factory preset: T1 only)
Figure 7-10-56
MOM TYE MH row MI Sal RI
72 I: c0 PM
L
a"
1. Press and hold "Timer". (Green light will go on and "T1" will flash).
2. Press "Left Arrow" Time Retard or "Right Arrow" Time Advance to set "ON"
time.
3. Press "Day" to set day(s).
4. Release "Timer". (Green light and "T1" will remain lit to indicate active T1
program). T1 program is now activated. Follow steps 5 thru 8 for T2
program.
Figure 7-10-57
NON TUE ITED TED RI UT MUMiMai
4i
mg<
reb" i±r6 Eir

5. Press and hold "Timer". (Green light will remain on and "T2" will flash).
6. Press "Left Arrow" Time Retard or "Right Arrow" Time Advance to set "ON"
time
7. Press "Day" to set day(s).
8. Release "Timer". (Green light and "T2" will remain lit to indicate active T2
program).
9. Press "Timer" once more to activate both "T1" and "T2". ("Ti" and "T2" will
remain lit to indicate active "T1" and "T2" program.)
Note: Timer will repeat each set day until switched off. Example: Drill timer set
T1 at 6:00 a.m. Monday thru Friday. Set T2 at 2:00 p.m. Monday thru Friday.
Timer will repeat each cycle each week until it is switched off.
Manual & Timed Heater Operation
The "Manual" button is used to turn the heater on and off when desired.
MON TUE WFO TRIO FRI SAT SUN

1 n AM
2 IL • LI U PM
Figure 7-10-58
1. Press "Manual" to activate the heater. (Red light will go oh and the-heater will
operate indefinitely.)
2. Press "Manual" again to deactivate the heater. (Red light will go out and the
heater will turn off).
3. Note:
a. "Manual" and "Timer" cannot be active at the same time. If "Manual" is

active and "Timer" is pressed, the heater will turn off and the red light goes
out.
b. If "Timer" is active and "Manual" is pressed, "Timer" is deactivated and the
green light goes out.
c. When the heater has been turned onr by the "T1 Timer" in a single timer
mode, the heater can be turned off by preseing either "Manual" or "Timer".
Both red and green lights will go out.
•
d. If the heater has been turned on by the "T1 or T-2.„Timer in dual mode..,
pressing "Manual" will turn the heater off but leaves tISe timer(s) activated
Pressing "Timer will turn off the heater and deactiVatethe tiper(§):
7-221
DRILLING SOLUTIONS
Diagnostics
When the timer is installed on a heater, the timer's red "Heater Activated Light" will be lit
constantly while the heater is running normally. In the case of a heater error, the timer's red
light will flash an error code followed by a pause.
,MANUAL
NON TN WO THU NO SAT MI
T2
f i 12: On_ IP:
OAT
" (±31±3
E3 Figure 7-10-59
Example: "Repeatedly flashing five pulses separated by a pause indicates a heater voltage
error".
The heater error codes are as follovv,s:
Table 20: Heater Error Codes
1 Flash Start Error

2 Flashes Flame Out
3 Flashes Coolant Flow
4 Flashes Overheat
5 Flashes Voltage
6 Flashes Fla-me Sensor
, -
7 Flashes Temperature Sensor
8 Flashes Fuel Pump
9 Flashes Compressor
10 Flashes Ignition Coil
11 Flashes Coolant Pump
12 Flashes Brower
13 Not Used
These errors correspond to those displayed on the Control Module diagnostic panel shown in
figure 7-10-6.

7-11 DHD LUBRICATOR
DHD Lubricator
The Down-Hole-Drill (DHD) lubricator (60 Gallon System CPN 5734755;-7-G-allon System
CPN 57353369) is a sub system of a rotary drill. The sub systelm consists of five parts; a
reservoir, a timer, an oil pump, flow switch/indicator light and dlsai- ap.ipiag..J,hgAystem
lubricates the DHD by pumping a prescribed amount of oil ba. 4t:16,1EYHDIfimialprili7
compressor size. An operator is given three settings: 2 pints/hr (.9,4_pie_rthrj for'air`66Mpressor
capacity less than 600 cfm, 3 pints/hr (1.4 liter/hr) for air compressor c4pagity gyer,690 cfrfi
and up to 900 cfm, and 4 pints/hr (1.89 liter/hr)-for air cdrrWesOotai55-8*.gireaterrth-an 900
cfm. --------
Timer
The timer (CPN 57354342) cyclically delivers 12 volts to the pump coil and the indicator lamp
circuits. The unit houses the electronic components in a NEMA 4 rated housing (waterproof).
The timer uses a three pole switch allowing the operator to select the required oil bases on
DHD/air compressor size. External to the timer are the injection lube system electrical
terminals. The unit can use either a 12VDC or 24VDC input.
General Operation
One cycle consists of an ON (or energized) period, which lasts for one second, and the
remaining part of the cycle is referred to as the OFF (or de-energized) period, which has a
variable setting. The off period is either 11, 15, or 22.5 seconds depending on the switch
setting. The intervals were sized to operate the injection lube pump, CPN 57352973, over the
entire range of compressor capacities. The goal is to meet 1/3pt/hr/100cfm. The terminal strip
allows for both inputs and outputs. The tirneraccepts both 12VDC and 24VDC. To use the
12VDC, one must remove the protected terminal and switch with the 24 VDC terminal screw.
The protected terminal prevents against accidently hooking up 24VDC to the 12 VDC input.
Lube Injection Pump

The injector lube pump (CPN 57352973) is a positive displacement, pneumatically driven
device. The pump uses three inputs (air, oil, and electricity) to deliver oil (.375 in3/stroke) at
pressures up to 2000 psi. The pump has two distinct sections: pneumatic and hydraulic.
1. The pneumatic section uses the 12VDC input to energize a coil and shift the
plunger. Once shifted, up to 400 psi air is delivered:into the piston chamber.
2. The hydraulic section moves the oil from the reservoir through the discharge
•
check valve/flow switch into the pressurized air line.

General Operation
1. The spring loaded plunger blocks the air inlet port when the coil is not charged.
This allows the piston, with help from its spring, to retract. The shifting of the
piston creates a vacuum on its hydraulic side thus drawing the cylinder full of
oil.
2. The timer charges the coil for one second with 12VDC. The charged coil
retracts the plunger, allowing air into the air piston chamber. The plunger also
covers the air discharge port opening. With the discharge port blocked, air
pressurizes the chamber.
3. As air pressurizes the piston chamber it moves the piston. This motion of the
piston forces oil back into the inlet until the piston covers the inlet. After the inlet
is blocked, the piston will force (.44 in3 of) oil out the discharge port, through
the 1 psi check valve, and into the flow switch.
4. The pump must use a 1 psi check valve downstream of the discharge port. This
allows oil to be drawn only from the reservoir during piston retract. The system
must also use a 1 psi check valve at the hard piping intake. These two check
valves keeps the discharge line primed.
Flow Switch
The flow switch (CPN 57353021) is a device that monitors the flow of rock drill oil into the
discharge line. The flow switch is connected to a light in the operator's cab. This enables the
operator to verify the lubrication of the DHD. The flow switch consists of a magnetic poppet
and a reed switch which monitors the poppet's location.
4
General Operation
1. The poppet in the flow switch is normally in the closed position cutting off oil
flow from the pump's oil discharge outlet and the 1 psi check valve.
2. As oil is discharged from the pump it overcomes the check valve and spring
force on the poppet. The poppet is forced backwards and it is detected by the
reed switch which in turn closes and completes the indicator light circuit. When
the electric circuit is completed a light verifies that the poppet was displaced. If
this circuit is not completed then the operator knows the danger that can be
caused to the DHD. Additionally, when the poppet is displaced oil can then
travel out of the flow switch's discharge and into the lube line. After the pump
fully strokes the spring returns the poppet to its original starting position. This
is made possible by the cross porting holes in the housing which eliminates
vacuum behind the poppet.

Diagnostics
This section assumes the drill uses the latest lubrication injection system produced. The
system uses the higher output pump (CPN 57352973), timer unit with three-poled switch
(CPN57354342), flow switch (CPN57353021), indicator light (CPN57297137) and 60 or 7
gallon reservoirs. All diagnostics can be performed with:
1. Multimeter
2. 2000 psi pressure gauge
3. 400 psi relief valve (CPN 57359549)
4. Measuring cup
The sections below should be followed in a sequence, but a serviceman can start in any order
depending on the complaint.
There are three basic inputs needed to operate the injection lube system; oil, pressurized air
and electricity. This section describes each input and how to check to see if it is correct. Each
section also suggests repairs.
Oil
Oil Flow Into The Pump

1. The following chart provides recommended oil types for various temperature
ranges.
Table 21: Recommended Oil Type for Temperature Range
Less than 20°F (-6.6°C) Medium grade rock drill oil, 450 SUS at 100°F (37.7°C)
20°F to 90°F (-6.6°C to 32°C) Medium grade rock drill oil, 450 SUS at 100°F (37.7°C)
Above 90°F (32°C) Heavy grade rock drill oil, 750 SUS at 100°F (37.7°C)
2. Check oil level in reservoir. Reservoir has a 1 inch stand on the oil outlet port.
3. Check oil flow into pump. Shut off oil flow into pump using shutoff valve.
Remove the flow switch and check valve. Open shutoff valve. Oil should flow
freely at a rate of 1 cup (8 ounces) per 15 minutes when the oil is at 50°F
(10°C).
4. tf the oil doesn't flow:
•
a. Is the inlet piping plugged? (Back flush the inlet piping).
b. Is the correct viscosity oil being used? (Change out the oil).
c. Is the pump piston retracted, opening the inlet port?
DRILLING SOLUTIONS 7.225

5. The pump piston not being retracted may be a result of:
a. Broken piston return spring. (Replace the spring).

b. Grit in air piston chamber, causing piston to stick. (Clean and reseal the
pump).
c. Air valve leaking causing air pressure to displace piston. (Replace the
plunger and plunger spring).
d. Electronic timer holding system in the "ON" position. (Replace the timer
unit).
Adequate Electrical Power To Pump Coil
1. Is unit wired properly?

2. Are all connections secure? (Tighten or re-crimp connectors as required).
3. is the timer properly wired? All blasthole or track mounted rigs use 24VDC,
while some truck mounted rigs use 12VDC. Verify proper voltage to timer. (Re-
wire as needed).
Note: 12VDC means 12 volts nominal and actual voltage is between 9VDC and
15VDC. Also 24VDC means 24 volts nominally and actual voltage may be
between 20VDC and 30VDC.
4. When the timer cycles "1 second ON", is 12VDC present at the coil? (Replace
timer if no output signal).
5. Can electrical current flow through the coil?
a. Check the coil resistance. With both wires disconnected, coil resistance
should be approximately 12 ohms. If not, replace the coil.
b. Check all connections for continuity.
Pressurized Air
Adequate Air Pressure
1. Tap into the air line and confirm that the lubrication pump line pressure is equal
to the console gauge.
2. Verify that air does not leak from the pump discharge port when unit is off or
during the off cycle when pump is operating. Air blow-by is a sign that the valve
plunger has failed and is needing to be replaced.

Output
With all the inputs verified and correct, the pump discharge can now be tested. Do this in steps;
at low back pressure and at full back pressure. Low back pressure just pumps oil across the
1 psi discharge check valve. High back pressure pumps oil across a 400 psi relief valve (CPN
5739549).
Low Back Pressure
Disconnect the discharge hose, at the flow switch, and pump oil into a measuring cup. The unit
should pump known volume in a given time. The Timer Setting -.Pump Output table shown
below lists the pumped output for a given timer setting. During this test, count the number of
pump strokes. This confirms that the timer is cycling at the proper rate,
Table 22: Timer Setting - Pump Output
Timer Setting Volume Period Cycles
2 pint (.94 liter)/hr 1 cup 15 minutes 38
3 pint (1.4 liter)/hr 1 cup 10 minutes 57
4 pint (1.89 liter) 1 cup 7.5 minutes 76
If the volume is low and the number of cycles is correct, the pump has leakage and should be
resealed or replaced. This is not likely, and if leakage occurs at this back pressure it should be
evident. If the volume is low and the number of cycles are low the timer has failed and should
be replaced.
High Back Pressure
Disconnect the discharge hose at the flow switch, remove the fitting from the flow switch
discharge port and install the 400 psi relief valve. While maintaining an inlet air pressure above
200 psi, measure the volume, cycles, and time. Then compare results to the Timer Setting -
Pump Output table.
Again, if the volume is low and the number of cycles correct, the pump has leakage. With the
high back pressure this is more likely. When the pump strokes, oil can go in three directions:
1. Out the discharge port. (This is the desired effect).

2. Out the intake port. (This occurs when the clearancebetween piston and barrel
increases. Change out the pump).
3. Out the breather. (This occurs when discharge seals wear. Re-seal the pump
•
(CPN 57307886).
If the volume is low and the number of cycles is low, change out the timer.

Output Detection
The DHD indicator light on the console is a light emitting diode (LED). This type of device has
a much longer life vs. incandescent type !amps. As described in the Operations Section, the
LED is wired to the flow switch, which is a device that monitors the flow of rock drill oil into the
discharge line. Fluid displaces the poppet and closes the switch, which energizes the LED.
Much like the pump, we must ensure the unit is wired correctly. And unlike the pump we must
ensure the unit is adjusted properly.
Indicator Light Wiring Circuit
1. Using the schematic, trace all wires. The indicator circuit gets its power from
the 12VDC out terminal on the timer unit.
2. Check for 12VDC at the 12 VDC out terminal on the timer unit, during ON cycle.
3. Check for voltage at the indicator light. If 12 volt is present at the LED, replace
it.
4. Check all connections.
5. Check for good ground to terminal (GND).
TO KEY ACTIVATED
WIRE fN CONSOLE (-) NEGATIVE
BATTERY
STSS4342
LUBRICATOR CATED AT TANK
ON-OFF
LOCATED ON
CONSOLE
5A DHDI DH02 1.1..1, SOLENOID

VALVE AT TANK
FLOW INDICATOR
(4) ON CONSOLE
573S3021
DHD TIMER ,'LOW SNITCH 5729 7137
LOCATED AT TAN)(
Figure 7.10-1
0
LOW SWITCH
FIXED 10 SECON3 DELAY SLACK
H.AR N ESS
C.340111111ffr
SECONDS 6ND
" ,,,2v
22_ , • -•
*IV OUT
001-- PUMP
•..24v ‘111101101me
4(1-.; IN Kr' 19
K] W-1-= FLOW SWITCH
DHD LUBRICATOR TIMER

Flow Switch Adjustment
As discussed in the Flow Switch General Operation, the poppet/reed switch position is critical.
The poppet has a magnet embedded in itself. This magnet pulls the reed switch closed.
1. Close the inlet valve on the reservoir. Select the "2 pt./hr" timer position (switch
up) and flip the ON/OFF switch to "ON". With inlet closed no oil is pumped and
poppet is only slightly displaced. The console light should not illuminate. If it
does, turn the reed adjusting setscrew counter clockwise until the light stops
flashing.
2. Open the inlet valve. With the timer still on, oil should flow out of discharge line
and the light should start flashing during each pump cycle. If the light does not
come on, do the following:
a. Turn the reed adjusting setscrew clockwise until the light starts coming on.
b. If the light does not come on, repeat Step 1.
3. Connect a 400 psi relief valve, CPN5735949 or equal, to discharge line. Make
sure air pressure to pump is at or greater than 200 psi. Oil should flow across
relief and the light should come on during "ON" cycle. If the light does not come
on, do the following:
a. Turn the reed adjusting setscrew clockwise until the light starts coming on.
b. If the light does not come on, repeat Step 1.
4. As a check, block the discharge and verify the light does not illuminate.
DHD Lubricator Diagnostic Summary
Adequate Oil To The Pump
1. Correct oil/viscosity.
2. Reservoir level adequate.
3. Inlet piping clear.
4. Pump piston retracted, opening inlet port.
Adequate Electrical Power
1. Wired properly and connections secure.

2. Proper voltage to the timer unit at correct terminal,
3. 12VDC at "12VDC out" terminal when timer is "ON".
4. Coil resistance is 12 ohm.

Adequate Air Supply
1. Supply air is equal to console gauge.

2. Air is not leaking from pump air discharge port when timer is "OFF".
Output
1. Against low back pressure, low output/proper cycles, reseal or replace pump.
2. Against low back pressure, low output/low cycles, replace timer.
3. Against 400 psi back pressure, low volume/proper cycles, re-seal or replace
pump.
4. Against 400 psi back pressure, low volume/low cycles, replace timer.
Flow Indicator Light Wiring
1. Wired properly and connections secure.

2. 12VDC at "12VDC out" terminal of timer unit when cycled "ON".
3. 12 VDC at indicator light during ON cycle.
Flow Switch Adjustment
1. Shut off oil inlet. Light should not come on. Turn setscrew CCW until light stops
flashing. TZt4.itj
2. Open inlet valve. Light should 444(xitigi_pump.,Cycle. Turn setscrew CW until
light starts flashing.

•
Section 8 - Glossary

T3W Instruction Manual Section 8- Glossary
GLOSSARY OF TERMS
-A-
Actuator
A motor or cylinder that is being put into motion by the flow of a hydraulic pump.
Adapter-Adaptor (both spellings are accepted)
A device used to connect two different sizes or types of threads. It is used to connect
rotary head spindles to drill pipe, drill pipe to stabilizers and stabilizers to drill bits.
ANFO
Ammonium Nitrate Fuel Oil mixture: explosive most commonly used in blastholes.
Annulus
The space between the drill pipe and the outer diameter of the hole made by the bit.
Annunciator
An electrical signaling device on a switchboard.
API
American Petroleum Institute.
ASME
American Society of Mechanical Engineers.
ASTM
American Society of Testing Materials.
Auto Lube System
An air powered pump that provides grease to various components of the drill through
hoses. It can be manual or computer controlled.
Axle (Main Shaft)
The tube connecting the tracks of a Blasthole drill to the main frame.
Bank
Vertical surface of an elevation; also called face.
Beco Thread
A coarse type of thread used on drill pipe for blastholes.
Bench-, ,
Work area on top edge of an elevation. The work area for blasthole drills.
Bit, Auger

Section 8 - Glossary T3W Instruction Manual
A type of bit used to drill soft formations. It usually has a series of flutes on the outside.
Bit, Claw
A wing-type bit that has multiple flukes. Sometimes called a Drag Bit.
Bit Breaker
A device installed in the centralizer table to hold a bit stationary while the drill pipe is
being removed from the bit by reversing the rotation. Also called Bit Basket.
Bit, DHD
A solid, one piece bit, with shaped tungsten carbide inserts in the face. Used in
percussion drilling.
Bit, Roller
Also called a Tricone bit. It usually has three conical rollers fitted with steel or tungsten
carbide teeth that rip the rock loose using down pressure.
Bits
Tools that pulverize formations so that material can be removed from the hole.
Generally 3-blade, 3-cone or percussion.
Blasthole
A drilled hole used for purposes of excavation rather than exploration, geological
information or water wells. Usually limited to 200 feet.
Blasting
The act of igniting explosives in a borehole to produce broken rock.
Blowdown
Term used when releasing compressed air from the receiver tank on a compressor
when the drill is stopped.
Blowdown Valve
The valve that opens when the drill is stopped and releases all the air pressure in the
receiver tank.
Bore
To make a hole in the ground with a drill.
Borehole
The hole made by a bit.
Box End
Fitting on the female end of a drill pipe. See Pin End.
•
Breakout
Refers to the act of loosening threaded pipe joints; and of unscrewing one section of
pipe from another, while coming out of the hole.

Breakout Wrench
A wrench, connected to a hydraulic cylinder, used to turn the upper piece of pipe while
the lower pipe is being held by the Fork Chuck or Sliding Wrench.
Bridge
An obstruction in the hole. Usually caused by a caving formation or something falling
in the hole.
Burden
Distance from the blasthole to the nearest face. Distance measured from face to a row
of holes.
Buttons
Short, rounded teeth of sintered tungsten carbide inserts which serve as teeth in drill
bits used for drilling very hard rock.
Butterfly Valve
The inlet valve of the air compressor.
Burden
Distance between a blasthole and the nearest free or open face; the material to be
displaced.
PrOCIV
Cable
A strong, heavy steel, wire rope. Also known asWire Rope. Used for pulldown and
pullback in the derrick. Also used in hoisting. May be rotating or rotation resistant.
Cable Reel
A device that holds the electrical power cable on electric driven blasthole drills.
Carousel
A rotating device that holds extra drill pipe. It can be moved under the rotary head to
add and remove drill pipe from the string, or the rotary head moves over it.
Carbide, Tungsten
W2C. A very hard compound used in inserts in rock bits. It has a very high melting
point. It is very strong in one direction but very brittle in another.
Casing
Spebal pipe used to hold the overburden back in water wells. May be steel or plastic.
Casing, Drive Shoe
Coupling of forged steel to protect lower end of casing in overburden.
Cathead
Rotating drum used to spool hemp rope to pick up tools manually.

Catwalks
Walkways around a working area of a drill.
Cavitation
The pitting of a solid surface by the formation of low pressure bubbles formed in the
fluid. Air being allowed into the inlet of pumps.
Centralizer Bushing
A circular ring installed around the drill pipe in the drill table to keep the pipe aligned
properly with the rotary head. It usually has a replaceable insert in the center.
Chain Wrench
A special wrench, consisting of a chain section and a metal vee section, with jaws, that
grips the drill pipe and/or the DHD to tighten or loosen the connections.
Clinometer
A device for measuring the angle of the drill pipe with the ground. Also referred to as
an Inclinometer.
Collar the Hole
Opening at the top of the blasthole; the mouth where rock has been broken by blasting.
Usually the first few feet of the blasthole that are cracked and broken.
Compressor
An asymmetrical rotary screw driven device for compressing air. May be single or two
stages, depending on the discharge pressure.
Console
The panel that contains most of the drill's controls. Also called the Operator's Panel.
Conventional Mud
A drilling fluid containing essentially bentonite clay and water.
Conveyor
Equipment used to carry material to crushers and screens for reduction and
separation.
Cooler (HOC, COC)
Most drills have two coolers; one for the hydraulic fluid-and the other for the
compressor oil. The engine radiator is sometimes referred to as an engine cooler.
Coring
The act of procuring a sample of the formation being drilled for geological information
purposes.
•
Coupling
A connector for drill rods, pipe or casing with identical threads, male or female, at each
end.

Cribbing
A set of wooden ties or metal plates used to add surface area to the jack pads to
prevent the pad from sinking into the ground. Also called blocking.
Crown Sheaves
The upper sheaves in a derrick that supports the cable that connects to the rotary
head.
Crosshead
The outer metal can surrounding the leveling jack cylinders. The crosshead slide is
the lower portion that connects to the bottom of the cylinders and the crosshead cap
is the flanged piece on top of the crosshead.
Crusher
Device used to reduce broken rock to a smaller fragment size.
Cut (verb)
Process of excavating material to lower the level of part of an elevation.
Cut (noun)
Part of an excavation of a specified depth an width.
Cuttings
Particles of formation obtained from the hole during drilling operations.
D
Decking
Process of alternating explosives with inert material in a blasthole to properly distribute
explosives or reduce vibrations. Also refers to the metal catwalks around the outside
of the drill.
Deephole
Rotary drills used to drill water wells, exploration holes and monitoring holes.
Delay Interval
Elapsed time between detonation of individual blastholes in a multiple hole blast.
Derrick
A tall framework over a drilled hole used to support drilling equipment. The part of the
drill that contains the feed system and the rotary head. See Tower and Mast.
DHD
Down Hole Drill. An air driven, piston powered device for drilling hard rock. It is also
called a Hammer.
DHD Bushings
The split bushings used to maintain alignment of the DHD while passing through the

drill table. See Split Bushings.

Differential Pressure
The difference in pressure between the inlet and outlet of a component, i.e., a cooler.
Dip
The angle between a horizontal plane and the plane of the ore vein, measured at right
angles to the Strike.
Diverter Valve
A two position, three way, valve that allows one hydraulic pump to perform two
separate functions.
Dressing a Bit
Sharpening DHD drill bits with a grinder to shape the carbides.
Drifter
An out-of-the-hole drill that rotates the drill rod and provides a percussive force, by
means of a striking bar, through the rod to the bit.
Drill
A machine for drilling rock, or unconsolidated formations. Also called a Rotary Drill.
The act of boring a hole in the ground.
Drill Collar
A heavy, thick-walled section of pipe used to add drilling weight to the bit and stabilize
the drill string.
Drill Rod
See Drill Pipe. Hollow, flush-jointed, coupled rods used on small percussion type rock
drills. Used with drifters mostly
Drill Pipe
Hollow tubing, specially welded to tool joints, used in drilling larger holes than drill rods.
Drill/Propel Valve
A switch that shifts the diverter valves to allow pump flow to go from drill functions to
propel motors.
Drill String
The string of pipe, including subs, stabilizers, collars and bit, extending from the bit to
the rotary head, that carries the air or mud down to thetit and provides rotation to the
bit.
Driller (Operator)
•
The employee directly in charge of a drill. Operation of the drill is their main duty'"
Drill Table
The area at the bottom of the derrick that contains the centralizer bushing or master
bushing that the drill pipe travels through.
8-7
DRILLING SOLUTIONS
Dust Collector
A vacuum device with a hose attached to the dust hood that pulls cuttings away from
the hole and deposits them to the side of the drill.
F
Face
Vertical surface on an elevation. Also called bank.
Feed Cable
Cables, anchored on the top and the bottom of the derrick, that pass through the
traveling sheave block and connect to the top and bottom of the rotary head. They are
adjusted by tightening the threaded rods on each end.
Feed Chain
Heavy duty chain links connected to the rotary head through upper and lower
sprockets and the traveling sheave block. They are adjusted similar to cable.
Fill
Process of moving material into a depression to raise its level; often follows the cut
process.
Fish- '
An object accidentally lost in the hole.
Fishing
Operations on the drill for the pUrpoSe Of retrieving the fish from the hole.
Fishing Magnet
Run in the hole on non-metailic line, to pick up any small pieces of metal.
Fishing Tools
Tools of various kinds run in the hole to assist in retrieving a fish from the hole.
Overshots fit over the pipe while Taps fit inside the pipe.
Flats
Machined areas on the side of drill pipe or other components where wrenches can be
installed to hold or break the joints. Some pipe has two flats, others have four flats.
Floor
Level area at the base of a bank or face.
Fork Chuck
The hand held or "flop-down" wrench used to hold the top of the pipe in the Drill Table
while adding or removing other pipe.

•G
Grouting
To fill the hole or annulus with grout, i.e., cement and water.
•H
Hammer
A different name for a Down Hole Drill.
Hammer Bushing
Split bushings installed in the drill table to allow the DHD to start the hole in a straight
line. It is removed once the DHD is below the table. Also called DHD Bushings.
Haul Distance
Distance material has to be moved, such as from a cut to a fill.
Hauling Equipment
Trucks and other conveyances for moving material. Also called Haul Trucks.
Hazard
Any condition of the drilling equipment or the environment that might tend to cause
accidents or fire.
Hoist
Windlass used to pick up drill pipe and other heavy objects. See Winch.
Hoist Plug
A lifting device installed in the box end of a tool. Opposite of Lifting Bail.
Hole
A bore made by rotating a bit into the ground.
Hole Openers
Large bit with pilot used to increase the diameter of a hole.
Hose, Drilling
Connects rotary head to top of hard piping to allow movement of rotary head. Also
called Standpipe Hose.
Hose, Suction
Attaches to mud pump inlet with other end submerged in mud pit.
•
Hydraulic Cylinders
Double acting cylinders that are extended and retracted to perform various funbtidns
on a drill. They are powered by hydraulic fluid from a pump.

Hydraulic Motors
Piston or vane type motors, driven by hydraulic pumps, that rotate various devices on
a drill.
Hydraulic Pumps
Piston, vane and gear type hydraulic pumps that provide flow for the various actuators
on the drill.
Hydrostatic Head
The pressure exerted by a column of fluid, usually expressed in pounds per square
inch.
0.4•0 IAli
Inclinometer
An instrument for measuring the angle to the horizontal or vertical of a drill hole or vein.
I.W.R.C.
Abbreviation for Independent Wire Rope Center. This refers to type of construction of
wire rope. This wire rope center is in effect a separate wire rope in itself that provides
a core for the line and prevents it from crushing.
Interstage Pressure
The air pressure present between stages of a two-stage compressor while the
compressor is making air.
1%0 j .m1
J Wrench e:irt
Specially shaped wrench to fit the backhead of a DHD. Used to hold DHD in the table
or to remove the backhead from the wear sleeve.
My. K..
Kelly Bar
A fluted or square drill pipe that is turned by a rotary table using a set of pins.
L
Leveling Jacks
Hydraulic cylinders mounted in a crosshead that raise and lower the drill.
Also referred to as Outriggers or Stabilizers.
Lifting Bail
A threaded cap for picking up pipe, bits, DHDs and stabilizers. It screws on the pin end.
Some bails have a swivel hook while others have solid tops. See Hoist Plug.

Loaders
Large, front end bucket equipment used to pick up material for loading in various types
of hauling equipment.
MINIMO\O
Main Frame
The welded component of a track mounted drill. The truck frame on a wheeled drill.
Makeup
The act of tightening threaded joints. Making a connection.
Making Hole
The act of drilling.
Making Up a Joint
The act of screwing a joint of pipe into another joint or section of pipe.
Manifold
A pipe or chamber that has several openings for hose connections,
Mast
A vertical pole. See Derrick.
Micron -:- Mu
A unit of length equal to one millionth part of a meter, or one thousandth part of a
millimeter. About 4/100,000th inch.
Mid-Inlet Swivel
Device for removing cuttings from the hole while drilling with Reverse Circulation
Equipment.
Mine Plan
Plan for making cuts and creating elevations, benches for efficient removal of material.
The mine plan considers a variety of factors, including: the type and location of
material, the size and number of shovels, loaders, and hauling equipment, haul'
distances, blasthole patterns, etc.
Mist Drilling
A method of rotary drilling where water is dispersed in the air as the drilling fluid.
Mud
A water or oil -base drilling fluid whose properties have been altered by solids. Mud is
a term commonly given to drilling fluids. It is used in place of air when drilling
unconsolidated formations.
• Mud Drilling
Using a bentonite clay and water as the drilling fluid.

Mud Pit
A hole dug in the ground or a steel pit to hold the drilling mud as it is being circulated
in the hole.
Mud Pump
Pumps that are used to circulate the drilling mud.
0.4000.10
Oscillation Yoke
The beam connecting each track of a blasthole track drill with the main frame that
allows the tracks to move independently up and down.
Open Hole
Any uncased,portion of a hole.
Operator
The person who performs the drilling operation with the drill. See Driller.
Overburden
Any unconsolidated material lying on top of the bedrock or the coal seam.
p
Parasitic Load
The load imposed on the engine by the direct connection of the compressor and main
pump drive during starting.
Pattern
Layout and distances between blastholes, specifically including burden and spacing.
Penetration Rate
Speed at which a bit advances while drilling, measured in feet per hour.
Percussion Drill
Drill that chips and penetrates rock with repeated blows.
Pin End
Fitting on male end of drill pipe. See Box End.
Pioneer Work
Drilling in rough, broken or inclined areas, Removing the original layers of dirt and
('
Pipe Dope
Special lubricant used to protect the threads on pipe joints. See Thread Lube.

•
Pipe Support
A device that holds the lower section of pipe in place while connecting to the next joint
with the rotary head when angle drilling. Also called Rod Support.
Pit
An excavation in the ground for the removal of mineral deposits,
PLC
Programmable Logic Controller. A device that monitors many aspects of a drill's
operation.
Potable Water
Water that is safe to drink.
Powder Factor/Specific Charge
Relationship between the weight of explosives in a blasthole and the volume of
materials to be displaced. It is measured in pounds per cubic yard or kilograms per
cubic meter.
Power Pack Base
The welded channel frame that contains the prime mover, the compressor and the
hydraulic pumps and gearbox.
Power Pack
he complete sub-assembly of base, engine, compressor, and hydraulic drive.
Presplitting
Process of drilling a line of small diameter holes spaced relatively close together,
generally before drilling a production blast and loaded with light explosive charges to
create a clean, unbroken rock face.
Production Rate
Penetration during a given reporting period. This rate includes all lost time, including
maintenance, breakdowns, long moves, inclement weather, etc.
Propel
To cause to move forward or onward. To drive or,tram.
Protectors, Thread
Steel or plastic covers to cover the box and pin ends of drill pipe when they are not
being used.
Pump, Water Injection
Pump used to pump water into the drill air stream to keep the dust settled and to assist
•
in flushing the hole.
Pullback
The force available to remove the drill string from the hole.

Pulldown
Force exerted on the drill bit by the thrust of the drill rig and from the weight of the drill
string.
0\0 RION,
Raise
A mine opening, like a shaft, driven upward from the back of a level to a level above,
or to the surface.
Rate Of Penetration
The rate in which the drill proceeds in the deepening of the hole. It is usually expressed
in feet per hour.
Reamer
Bit-like tool, generally run directly above the bit to enlarge and maintain a straight hole.
Reservoir
The tank used for storing the hydraulic oil used in the hydraulic system.
Reverse Circulation Drilling
Using a double wall pipe to force air/water down the hole and removing the cuttings
between the two pipes. See Mid-Inlet Swivel.
Rod Changer
See Carousel. A device that holds extra drill rod (pipe).
Rotary Drilling
The method of drilling that depends on-the rotation of a column of pipe to the bottom
of which is attached a bit. Air or fluid is circulated to remove the cuttings.
Rotary Head
A movable gearbox used to provide rotation to the drill string. It is connected to the
feed chains or cables on each end and to the drill string through the spindle.
Ms. S1.41
Safety Hook
Attached to end of hoist line to secure hoist plug or lifting bail. Has a safety latch to
prevent load from slipping off hook.
Scales
Equipment used to determine the weight and value of material being transported from
a quarry.
Screens
Devices used to separate broken material into groups of similar size.

Shock Sub
A device used to isolate the shock of drilling from the rotary head. It is made of hard
rubber layers mounted inside of steel outer rings.
Shooting
Exploding high explosives in a hole to shatter the rock. See Blasting.
Single Pass Drill
Drill rig with a long tower that permits drilling a blasthole withbut stopping to add drill
pipe (rod). Uses a Kelly in place of regular pipe. Uses a rotary table to turn the Kelly
instead of a rotary head.
Stemming
Material of a specified depth added on top of a powder column to confine the blasthole
and make the explosion more efficient.
Strip Mine
A large section of land used to remove coal deposits.
Shot
A charge of high explosives deposited in a series of holes to shatter the red(
Shutdown
A term that can mean the end of the shift or workday or an unplanned stopping of the
drill due to a system failure.
Sliding Fork
A wrench that slides around the flats of the drill pipe to hold lower section. Controlled
by hydraulic cylinder(s). Used in place of Fork Chuck.
Slips
Used in the rotary table to hold and break out drill pipe. Also used to hold casing in the
table.
Spacing
Distance between blastholes measured parallel with the face.
Spear
Tools of various design that are screwed or wedged inside of bits, pipe, etc., that are
lodged in the hole. See Fishing Tools.
Spindle
The short section of pipe that rotates within the rotary head and protrudes out each
end
• Speed Switch
An electronic device that changes states when the engine reaches a certain speed.
Used to control dual oil pressure switches.

Split Bushings
The removable bushings that allow the DHD or Stabilizer to pass through the drill table
while drilling a straight hole. See DHD Bushings.
Stabilizer, Drill Pipe
Heavy -walled pipe having special spiral or fluted ribs extending around the diameter,
within 1/8 "to 1/4" of hole size. Most stabilizers are fitted just above the bit, while in-line
stabilizers keep the hole straight.
Standpipe
Part of the circulating system. The hard and flexible piping from the main valve to the
flexible hosing leading to the rotary head. Water injection, DHD oil and foam are
injected into this line.
Static Water Level
The distance,from the top of ground down to the standing water level.
Strike
The bearing of the outcrop of an inclined bed or structure on a level surface. See Dip.
Stuck In The Hole
Refers to drill pipe inadvertently becoming fastened in the hole.
Subdrilling
Bottom portion of a blasthole drilled below the floor level to permit upward
displacement of material and thereby prevent a toe at the bottom of a face.
Substitute (Sub)
A coupling with different type or diameter of threads at either end. The term pin
denotes a male thread, and box, a female thread. To connect two components with
different threads. See Adapter.
Supercharge Pressure
Inlet oil pressure to the main purnp(s) that has been pressurized to prevent cavitation.
Swivel
A coupling on top of the rotary head to allow the spindle to rotate while the main hose
remains stationary.
-T-
Table Drive
Drill design that locates the drill pipe rotation mechanism on the drill deck in a
stationary position instead of using the rotary head.
Threaded and Coupled Casing (T&C)
Steel casing using a coupling between each section of pipe. Thread style is right hand,
fine thread.

•
Thread Lube
A special compound used to lubricate the threads of drill pipe. See Pipe Dope.
Tongs
A type of wrench used to make up and break out drill pipe using external forces, such
as hydraulic cylinders or cables.
Tool Joint
A drill pipe coupler consisting of a pin and box of various dasigns and sizes. Deephole
drills normally use API style threads, while Blasthole drills use Beco style threads.
Top Head Drill
Drill design that locates the drill pipe rotation head in the drill tower and it moves up
and down with the drill string. See Rotary Head.
Torque
A turning or twisting force. A moment caused by force acting on an arm. A one pound
force acting on a one foot arm would produce one lb-ft of torque.
Tower
A tall, slender structure used for observation, signaling or pumping. See Derrick and
Mast. Term used to indicate the derrick on a blasthole drill.
Turning To The Right
Slang term for making hole.
Tram
A cable car or a four-wheeled open box in a coal mine. See Propel.
Trammed
To move in a tram.
Tramming
Process of moving a drill with the tower up from a completed blasthole to the location
of the next. See propelling
Traveling Sheave Block
A series of sheaves, connected to the feed chains or cables, that are moved up and
down the derrick by the feed cylinders.
Twist Off
To twist a joint of pipe in two by excessive torque applied by the rotary head or rotary
table.
•
0%1U Oft/
UL88
The unloader valve that controls pressure and volume on a high-pressure comprassor

T3W Instruction Manua/ Section 8- Glossary
system.
Undercarriage
The means of moving a track type vehicle. It contains the track frame, rollers,
grousers, rock guards, drive sprocket, propel motors and planetary drive.
Uphole Velocity
The speed (in feet per minute) that the cuttings travel out of the hole.
This is dependent on the bit size, the compressor size and the pipe size.
Ift•IWOMO
Washpipe
Hard surfaced steel tubes inserted in swivels to allow rotation of drill string and prolong
life of packing. They are replaceable in most swivels.
Water Table
The underground level at which water is found. See Static Level.
Water Well
A hole drilled for the purpose of obtaining potable water.
Weight On Bit
In rotary drilling, a specified weight is required on the bit for maximum performance. A
gauge on the console is calibrated to correspond to the drill string weight.
Whipstock
A device inserted in the well used for deflecting or directional drilling.
Wiggins Quick Fill
A Centralized Service Station that connects to various systems on the drill to allow
remote filling of engine oil, compressor oil and hydraulic oil.
Winch
A stationary hoisting machine having a drum around which is wound a rope.
Wiper, Pipe
An annular rubber disk for wiping drill pipe clean of cuttings when it is being withdrawn
from the hole.
Wire Rope
Rope made of twisted strands of steel wire. Also called Cable.

f
E
•
Atlas Copco Drilling Solutions,

A Company Within the Atlas Copco Gr
P.O. Box 462288, 2100 North First Street
Garland, Texas 75040
www.atlascopco.com/drillingsolutions

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ATLAS COPCO

Read the instruction manual before operating this equipment.

Continuing Product Improvement and advancement of product design

By giving complete information, you will enable us to fill your order

When ordering Replacement Parts, specify:

1. Unit Serial Number

Refer all communications concerning this unit to our nearest Branch

CALIFORNIA PROPOSITION 65 INFORMATION

57895211 FRAME, COMMONS

57869257 ENGINE ELEC. INSTLN, T3W

57895211 FRAME, COMMONS

D2657895211 REV 000

REF . PART NO. QTY UNIT DESCRIPTION

57391773 KIT,CAB SHEILD INSTL

2.APPLY A BEAD OF SEALANT

3.SHIELD SHALL BE CUT TO MATCH

C2657391773 REV 003

REF. PART NO. QTY UNIT DESCRIPTION

D2657847990 REV 006

57847990 FRAME INSTitt.. ATION,T3VV

D2657847990 REV 006

95104147 2.0 EA - CAPSCREW,HEX

REF. PART NO.

024.0 57311128 2.0 EA BAR 1.75 X 3.5 X 6

D2657845356 REV 004

57925174 TIE DOWN TOWER ASSY

C2657925174 REV 000

57925174 T E DOWN TOWER ASSY

57846180 ROD BOX,INSTALLATION

D2657846180 REV 000

57895237 BOX, TOOL, INST

PENDING REV 000

REF. PART NO. QTY UNIT DESCRIPTION NOTES

D2657770919 REV 001

002.0 57131732 1.0 EA DOOR

58051830 KIT, SAFETY

Truck Chassis illustration

Truck Safety Kit is

B58051830 REV 001

REF, PART NO. QTY UNIT DESCRIPTION NOTES

THIS PAGE IS INTENTIONALY BLANK

TB2657866048 REV 000

TB2657866048 REV 000

57866048 JACK INSTALLATION,T3W

REF. PART NO. QTY UNIT DESCRIPTION NOTES

THIS PAGE IS INTENTIONALY BLANK

MAINFRAME REF. --\\

TB2657844649 REV 000

• TB2657844649 REV 000

57844649 CONSOLE INSTLN T3W

TB2657844649 REV 000

REF, PART NO. QTY UNIT DESCRIPTION NOTES

D2657843880 REV 005

• D2657843880 REV 005

D2657843880 REV 005

D2657843880 REV 005

D2657843880 REV 005

D2657843880 REV 005

REF. PART NO. QTY UNIT DESCRIPTION NOTES

REF. PART NO. QTY UNIT DESCRIPTION NOTES