T3W Instruction Manual - Feb 2014

Atlas Copco Drilling Solutions
Instruction Manual Original Instruction

MODEL: T3W Upgrade
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.
TABLE OF CONTENTS
T3W UPGRADE
TITLE PAGE
SECTION 1 - INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
MANUAL REVISION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Manual Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Receiving the Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Identification Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Drill Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Engine Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Carrier Vehicle Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Instruction Manual Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Drill Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
T3W Waterwell Drill Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Identification of Major Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Safety First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Warnings and Cautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Equipment Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
SECTION 3 - SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Operational Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Hydraulic Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
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TABLE OF CONTENTS
T3W UPGRADE
TITLE PAGE
SECTION 4 - CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
OPERATING CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Instruments and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Top of Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Upper Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Middle Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Lower Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Under Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Helper Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Auxiliary Controls and Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
SECTION 5 - OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
OPERATING SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Safe Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Walk Around Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
PRELIMINARY START INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Driver’s Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
STARTING TRUCK ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Starting Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
STARTING DECK ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Deck Engine Starting Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Rotary Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
Pipe Handling Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
Down Hole Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64
Drilling With Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72
Carousel Reloading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75
Water Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-76
DHD Hammer Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-78
Mud Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-81
Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-86
SHUTDOWN and DRIVE AWAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-88
Shutdown Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-88
TRANSPORTING THE DRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-91
Transportation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-91
TOWING THE DRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-94
Towing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-94
SPECIAL CONDITIONS OF USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-97
Special Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-97
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TABLE OF CONTENTS
T3W UPGRADE
TITLE PAGE
SECTION 6 - MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-1 MAINTENANCE SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Maintenance Safety and Health . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Maintenance Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6-2 MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Schedule Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Truck Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Deck Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
6-3 REFILL CAPACITIES/LUBRICANTS/FUEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Lubrication Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Refill Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Filter Elements and Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Lubricant Oil & Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Coolant Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
Diesel Fuel (Cat Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
6-4 MAINTENANCE AS REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Maintenance As Required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Air Cleaners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Clean the Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
Feed Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
Cable and Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50
Receiver Separator Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
Fuel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56
6-5 MAINTENANCE (8-10 Hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-57
Overpressure Control System Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-57
Air Cleaners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58
Deck Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-60
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63
Fuel Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66
Receiver Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-68
Hydraulic Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-70
Rotary Tophead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-72
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-74
6-6 MAINTENANCE (50 Hours or Weekly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-82
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-83
Winch/Sand Reel Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-84
Cat Water Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-85
Pump Drive Gearbox. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-86
Winch (Auxiliary) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-88
6-7 MAINTENANCE (100 Hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-92
Winch (Main) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-93
John Bean Water Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-97
Feed Cable Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-98
Deck Engine Oil and Filter Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-101
Deck Engine Fuel System Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-103
Truck Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-111
Compressor Air Hose and Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-113
toc - iii
TABLE OF CONTENTS
T3W UPGRADE
TITLE PAGE
Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-117
Water Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-120
Main Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-122
Auxiliary Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-125
6-10 MAINTENANCE (1,000 Hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-126
Receiver Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-127
Rotary Tophead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-131
Main Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-134
Water Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-135
Carousel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-135
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-138
Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-138
Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-143
6-14 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-150
Bolt Head Markings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-150
Suggested Torque for Metric Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-153
6-15 MAINTENANCE (40 RM Swivel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-156
40 RM Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-156
toc - iv
TABLE OF CONTENTS
T3W UPGRADE
TITLE PAGE
SECTION 7 - TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7-1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Troubleshooting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Operator Observed Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Pneumatics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Mechanical Hydraulic Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Mechanical Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7-2 ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Electrical System Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Electrical System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Engine Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Gauges and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Cat Monitoring System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Sensors and Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Engine Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
MurphyLink PowerView . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
PowerView Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Faults and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
Electric Ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
Electrical Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54
Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-55
7-3 OPERATOR OBSERVED PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56
7-4 COMPRESSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-60
Compressor Fire Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61
Pneumatic System Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-62
Separation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-68
Electronic Air Regulation System (EARS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-69
Electronic Air Regulation Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-76
Electronic Air Regulation Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-79
Compressor Related Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-95
Electronic Fan Regulation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-97
7-5 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-99
Hydraulic System Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-99
7-7 HYDRAULIC CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-100
Rotation Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-101
Main Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-104
Main Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-109
10-Spool Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-112
Schematic Circuit Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-116
Mud Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-122
7.8 - Dixon Boss Clamp Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-126
Torque Procedure For Dixon 4 Bolt Clamp With Atlas Copco Hose . . . . . . . . . . . . . . . . . . . . . . . . . 7-126
Torque Procedure For Dixon 6 Bolt Clamp With Atlas Copco Hose . . . . . . . . . . . . . . . . . . . . . . . . . 7-128
7-9 HNBR Hose/Victaulic Coupling Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-130
Coupling Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-131
toc - v
TABLE OF CONTENTS
T3W UPGRADE
TITLE PAGE
Installation Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-135
7-10 ENGINE HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-137
7-11 WATER INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-138
CAT Water Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-138
Bean Water Injection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-151
7-12 DHD LUBRICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-161
DHD Lubricator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-161
Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-161
Lube Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-161
Flow Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-162
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-163
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-163
Pressurized Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-164
DHD Lubricator Diagnostic Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-167
toc - vi
Section 1 - Introduction
DRILLING SOLUTIONS February 2014 1-1

T3W Instruction Manual Section 1 - Introduction
MANUAL REVISION
Table 1: Latest Revision T3W Manual
REV.
REVISED BY DATE REVISION
NO.#
002 James Oney October 2011 Up-dated Dixon Boss Clamp
Installation and Instructions (Section
7.8). Added Manual Revision Table
(Section 1)
003 Wendy Canal February 2014 Minor changes for translation
purposes
1-2 February 2014 DRILLING SOLUTIONS

Section 1 - Introduction T3W Instruction Manual
This page is intentionally blank

INTRODUCTION
General Information
This Instruction manual has been developed to present the operations and preventive main-
tenance requirements for safe, effective operation and maintenance of the Atlas Copco Drilling
Solutions T3W Waterwell Drill.
This manual provides operators and maintenance personnel with the knowledge of the
fundamental rules and criteria to be followed for on-site use and maintenance of a T3W
Waterwell Drill.
The operator and maintenance personnel must read and fully understand this Instruction
manual before operating or servicing the drill. This manual has been organized to present the
safety precautions, operation requirements and appropriate information needed to:
1. Safely operate the T3W Waterwell drill while achieving 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 conditions.
4. Perform the necessary pre-operational and post-operational checks on the drill.
If any part of this manual cannot be understood, contact your supervisor 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 and Instruction manuals 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 and serial number of your drill when you
contact the local Atlas Copco service or parts office.

Manual Organization
This manual is organized as follows to allow the reader to easily find specific information as
needed.
• Section 1 - General Description
• Section 2 - Safety
• Section 3 - Specifications
• Section 4 - Controls
• Section 5 - Operation
• Section 6 - Maintenance
• Section 7 - Troubleshooting
• Glossary
It is essential that this manual is fully understood and followed to provide the highest
performance and safety when operating the drill. If any part of this manual cannot be
understood, contact your supervisor or local Drilling Solutions Distributor.
Receiving the Drill

The drill has been accurately tested, checked, and prepared for shipment. Every part of the
drill, including detached parts, has been accurately checked before being shipped from the
factory.
When receiving the drill, inspect the shipment for damage that may have occurred during
transport. Review the shipping documentation to verify that no parts are missing. If any parts
are damaged or missing, inform the freight agent as soon as possible.
Identification Data
An exact description of the model type and the serial number of your T3W drill will facilitate
fast and efficient response from our parts and service support operations.
Always provide the model of your drill and its serial number when you contact the local Drilling
Solutions service or parts office.
We advise you to enter your drill data on the following lines to maintain drill and engine
information necessary to facilitate fast and efficient response from our parts and service
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
_________________________________________________________________________
Drill Identification
The drill identification plate is located on the operator console as shown below.
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 instruction manual for further information on the
identification information. Have the following engine data available when communicating 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
Carrier Vehicle Identification

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

The instruction manuals are located within easy reach of the operator. A tool cabinet located
beneath the oil cooler provides space for the operator parts and instruction manuals. Truck
vehicle instructions are located in the truck cab in the driver side door.
General Information
1. All safety rules in section 2 and the Safety First manual must be observed.
2. If further information is required concerning recommended water well drilling
applications, contact your local Atlas Copco Drilling Solutions distributor.
3. Atlas Copco Drilling Solutions reserves the right to make any changes or
modifications without prior notice and without incurring any liability to retrofit
machines previously shipped from the factory.

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 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 through a clutch or
an in/out box on the other end. The power pack is mounted to the drill truck frame.
The tower is constructed of welded steel tubing. A carousel type drill rod changer is mounted
inside the tower and holds either seven or nine drill rods, depending on the O.D. of the rod. 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 tower is raised and lowered by two hydraulic cylinders.
Drill rod changing is done by emptying the carousel first, then pulling rod from the pipe rack.
Pulling rod out of the hole is done just the opposite, after replacing one piece of rod in the
carousel to stow the rotary head.
All drilling functions are controlled from the operator console adjacent to the drill table. The
operating controls and gauges are positioned within easy reach of the operator.
To permit optimum performance on a wide range of applications and site requirements, the
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 or nine drill rod carousel
6. Easily accessed operator console and platform
7. Drill pipe rack
8. Air cylinder operated, self adjusting, cam action breakout wrench
9. Retractable table with an air operated bottom holding wrench
10. Four leveling jacks
Engine
The drill uses a water-cooled engine with direct injection and turbo chargers. Electric starting
and belt driven alternator battery charging is standard on all T3W Waterwell 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 compressor. The engine power/rpm is
controlled by the engine speed control. The engine is shut down either by the removable ON/
OFF key switch or the emergency stop (E-Stop) button.
Carrier
The 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.
Tower
The tower is constructed of welded tubular steel with cross bracing on both sides and the back.
A set of sheaves at the top and bottom of the tower support the feed cables. The tower
assembly features the hydraulically driven rotary head and the hydraulic drill feed systems.
The feed system consists of the rotary head, the hydraulic feed cylinder and a set of cables
connected to the top and bottom of the rotary head assembly.
Drill rod changing is done by emptying the carousel first, then pulling rod from the pipe rack.
Pulling rod out of the hole is done just the opposite, after replacing one piece of pipe in the
carousel to stow the rotary tophead.
Controls
All operational functions can be controlled from the operator console. All of the controls, with
the exception of the helper’s jib boom and jib hoist control located on the helper side of the drill
table, are positioned for operator convenience on the operator console. The operator 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 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.
! DANGER
Your life may be endangered if the following is not complied with: DO

NOT add attachments to the drill that intrude into the operator protective
area, reduce visibility, restrict emergency exits or add weight exceeding
certification weight. See the operator manual or contact your dealer for
complete inspection requirements and maintenance instructions.

Standard Features
1. Diesel driven, deck mounted power pack

2. Operator console mounted to the deck to operate engine, drilling functions, 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 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
Identification of Major Components
NOTE: Pictures shown are for reference only.

1 Single rod loader 6 Fuel tanks
2 Console 7 Auxiliary hoist
3 Operator platform 8 Main hoist
4 Rear jack 9 Rod box
5 Batteries 10 Hydraulic reservoir

1 Tower 5 Fuel tank
2 Helper platform 6 Chassis
3 Fuel tank 7 Auxiliary hoist
4 Front jack

1 Main hoist 5 Tool box
2 Leveling jack 6 Cooler package
3 Mud pump (if equipped) 7 Water injection
4 DHD lubricator 8 Receiver tank

1 Receiver 6 Rod spinner (if equipped)
2 Control console 7 Single rod loader (if equipped)
3 Table 8 Rotary head
4 Operator platform 9 Swivel and yoke
5 Helper platform

Section 2 - Safety

T3W Instruction Manual Safety
2.1 Safety First
General Information
This information is intended as a guide for trained and qualified personnel who are aware of the
dangers involved in handling potentially hazardous equipment. It is not intended to contain a complete
list of all safety precautions which should be observed by personnel using this equipment.
Before you operate, maintain, or in any other way use this drill:
• READ and STUDY the Safety First manual, Safety Decal manual, and this Instruction
manual.
• Know how to safely use the drill controls and what you must do for safe maintenance. Failure
to obey instructions or heed warnings could result in injury or death.
Those who operate, maintain, and work on equipment must be competent.
The maintenance and service of this equipment involves risks both to personnel and equipment and
must be performed only by qualified personnel exercising due care.
Personnel engaged in the operation, maintenance, or servicing of this equipment are urged to become
familiar with First Aid theory and practices.
During operation of this equipment, local safety and fire protection standards must be observed.
This safety summary includes general safety precautions and instructions that must be understood
and applied during operation and maintenance to make sure personnel safety and protection of
equipment. Before performing any task, the DANGERs, WARNINGs, CAUTIONs, NOTICEs, and
NOTEs included in that task must be reviewed and understood.
Warnings and Cautions
WARNINGs and CAUTIONs are used in this manual to highlight operating or maintenance
procedures, practices, conditions, or statements which are considered essential to the protection of
personnel or equipment. WARNINGs and CAUTIONs immediately precede the step or procedure to
which they apply. NOTICEs and NOTEs are used in this manual to highlight operating or maintenance

Safety T3W Instruction Manual
procedures, practices, conditions, or statements which are not essential to the protection of personnel
or equipment.
! 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.
! 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.
! 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
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.
NOTE: A 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.

2.2 Equipment Safety Decals
1. Laminated Safety Manual: quantity of

one located on side of operator console.
Table 2-1: Safety Decal List
Decal Message Location
Caution: Excessive Hydraulic Hydraulic Reservoir: 1 per tank,

Oil fluid level gauge side
Warning: Hot Pressurized Fluid Cooler Housing: 1 per engine

cooler top near fill cap
Warning: High Pressure Receiver Tank: 1 per left side of

sight glass. 1 on top of receiver
tank
Warning: Rotating Parts Engine Assembly/Coupling

Guard: 1 per plate
Warning: Rotating Shaft Engine Assembly/Coupling

Guard: 1 per plate

Safety T3W Instruction Manual
Table 2-1: Safety Decal List (Continued)
Warning: Rotating Fan Blade Cooler (Fan Side): 2 per cooler
Warning: Combustible Gas Deck Battery Box: 1 per battery

box
Truck Battery Box: 1 per box
Danger: Riding Rotary Head Rotary Head: 1 per rotary head
Warning: Don’t Modify or Alter Cab: 1 per cab as part of console

decal
Danger: Hazardous Voltage Cab: 1 per cab console
Warning: High Pressure Air Receiver Tank: 1 per right side of

sight glass. 1 on top of receiver
tank

Table 2-1: Safety Decal List (Continued)
Danger: Don’t Climb Tower Tower Bottom: 2 per bottom of

tower, 1 per tower side
Warning: Falling Tower Tower Raising Cylinder: 1 per

cab side cylinder. 1 per non-cab
side cylinder
Warning: Falling Drill Pipe Hydraulic Reservoir: 2 located on

each side. Sliding breakout
wrench: 1
Hazardous Voltage Console: 1
Notice: Using Non-Approved Hydraulic Reservoir: 1 located on

Hydraulic Oil top of reservoir
Notice: Hydraulic Failure Hydraulic Tank: 1 per hydraulic

tank on the non-cab side
Notice: Starting Cold Engine Tower Rest: 1
Notice: Electrical Damage Battery Box: 1 per truck battery

box
Battery Box: 1 per deck engine

battery box

Section 3 - Specifications

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 inches diameter (508 mm) (depending on carousel option),
is clear all the way up the tower.
Due to the design of the drill, the T3W can be mounted on several different truck frames.The
standard carrier used on a 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 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 drilling (DHD).
The T3W incorporates four frame mounted leveling jacks to keep the drill level and stable while
drilling. The tower 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 tower
is raised and lowered by two hydraulic cylinders.
The drill pipe carousel is contained in the tower in a fixed position and indexed in both
directions from the console by the hydraulic motor. The carousel holds nine 3.5 inch x 20 foot
(89 mm x 6.1 m) drill pipe or seven 4.5 inch x 20 foot (114 mm 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 tower.
In conjunction with the retractable rotary head, a 12,000 pound (5,443 kg) standard draw
works is available for 40K drills and an 18,000 pound (8,165 kg) standard draw works is
available for 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 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 40,000 lbf (177.93 kN) or 70,000 lbf (311.38 kN) depending
on the drill configuration.
The standard spur gear drive tophead provides 5,500 foot-pounds (7,458 N·m) of torque at
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
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 pieces of 4.5 inch (11.4 cm.) O.D. x 20
foot (6.1 m) long drill pipe or nine pieces of 3.5 inch (89 mm) O.D. x 20 foot (6.1 m) 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.
! 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 tower position and orientation of the drill, surface stability (bearing
strength), and wind conditions.
! WARNING
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.
! WARNING
Do not move or transport the T3W Waterwell drill with the tower in the
raised (up) position.
! WARNING
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 inch (114 mm) x 20 feet (6.1 m) or Nine 3.5 inch” (89
mm) x 20 feet (6.1 m) Pipe
7. Drill Pipe Rack for (24) 3.5 inch (89 mm) or (15) 4.5 inch (114 mm) 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.

! 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 tower.
Carrier
The initial production 40K T3W Waterwell drill was 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 door storage pocket on the drill, to determine the exact configuration of your carrier.
Table 1: Navistar Truck
Model 7600 Standard 6X4 Truck Chassis

Model Description Navistar Model 7600
Gross Vehicle Weight Rating 66,000 lb (29,937.6 kg)
Wheelbase 232 in (589.2 cm); Cab to Axle 164.9 inches (418.8
cm); Axle to Frame 59 in (149.8 cm)
254 ins (645 cm); Cab to Axle 186.9 in (474.7 cm;
Axle to Frame 59 in (149.8 cm)
Diesel Engine Caterpillar C13 ACERT, 50 state, 380 HP (283 kW)
@ 2,100 rpm, 1450 lb/ft torque @ 1,200 rpm, 2,100
rpm governed speed; 395 peak HP (max) and with
electronic controls and ADEM A4E4 ECM.
Manual Transmission Fuller FR0-14210C, 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 in 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 in x 3.892 in x 0.312 in; (274.6 mm x
98.9 mm x 8.0 mm); 480.0 in(12,192 mm) maximum
OAL.
The current T3W Waterwell drill is mounted on an International Workstar 7600 SBA, 6X4. You
must look at your carrier manuals, located in the driver door storage pocket on the drill, to
determine the exact configuration of your carrier.
Table 2: Workstar Truck
Model 7600 Workstar SBA 6X4 Truck Chassis

Model Description Workstar Model 7600 SBA, 6 x 4
Gross Vehicle Weight Rating
Wheelbase 232 in (589.2 cm); Cab to Axle 164.9 in (418.8 cm);
Axle to Frame 59 in 149.8 cm)
254 in (645 cm); Cab to Axle 186.9 in (474.7 cm);
Axle to Frame 59 in (149.8 cm)


Diesel Engine Caterpillar C13 ACERT, 380 HP (283 kW) @ 2,100
RPM, 1,450 lb/ft torque @ 1,200 rpm, 2,100 rpm
governed speed; 395 peak HP max (294 kW) with
Caterpillar C13 ACERT, 410 HP (305 kW) @ 2,100
rpm, 1,550 lb/ft torque @ 1,200 rpm, 2,100 rpm
governed speed; 425 peak HP max. (316 kW) with
Cummins ISM-400 Non EGR Export, 400 HP (298
kW) @ 1,800 rpm, 2,100 rpm governed speed; 1450
lb/ft torque @ 1,200 RPM; 400 peak HP (298 kW)
max
Manual Transmission Fuller FR0-14210C, 10 speed manual; with
overdrive, with air shift.
Fuller FR0-15210C, 10 speed manual; with
overdrive, with air shift, with internal lube oil pump.
Fuller RTO(F)-16908LL, 10 speed manual; Double
LO with overdrive, International lube pump and with
air shift.
with Kwik-Adjust (manual) feature,1,700 lb/ft torque
capacity.
Axle, Front Non-Driving Dana spicer I-220W Wide Track, I-Beam type,
22,000 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
Rubber fender extensions
Chrome stationary grill
Bug screen, front end; mounted behind grille
Front end tilting, fiberglass, with three piece
construction; for 2007 emissions
Front Tire (2) 425/65R22.5, Unisteel G286A (Goodyear) 470
Rev/Mile, Load Range L, 20 Ply


Rear Tire (8) 11R22.5 G164 RTD M+S (Goodyear) 499 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.
Suspension, Front Spring parabolic, taper leaf; 22,000 lb. capacity; and
with rubber auxiliary springs, with shocks.
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.
Brake System Air dual system for straight truck applications.
Air brake ABS (Bendix Antilock Brake system), full
vehicle wheel control system (4 channel).
Air Compressor: (CAT C270) 16.1 cfm capacity
Brakes Front, air cam 16.5 in x 6 in, includes 24 sq in long
stroke chambers.
Rear, air cam 16.5 in x 7.0 in; includes MGM TR3030
long stroke brake chamber and heavy duty spring
actuated parking brake.
Drain valve (berg) manual; with pull chain, for air tank
Air dryer (Bendix AD-9) with heater
Brake Package Front (Dana Spicer) ES-165-6) air, cam type,
extended service; size 16.5 in x 6 in, includes
automatic slack adjusters.
Rear (Dana Spicer) ES-165-7) air, cam type,
Steering Wheel 2-spoke, 18-in diameter, black
Steering Gear (2) Sheppard M-100/HD94, dual power
Electrical System 12 volt, standard equipment
Alternator Delco Remy 22-S1, 12-volt 100 amp. capacity; with
pad mounting.
Starting Motor Delco Remy 39MT, 12-volt; gear reduced, with
thermal over-crank protection.
Cigar Lighter Includes ash cup


Battery System (International) maintenance free, (3) 12-volt
1950CCA total.
Battery Box Steel, with fiberglass lid; 35 in back of cab, mounted
left side perpendicular to frame rail.
Horn Air, black, single trumpet, air solenoid operated,
mounted behind bumper on right rail.
Wiring Body builder wiring back of standard cab at left frame
or under extended or crew cab at left frame; includes
sealed connectors for tail/amber turn/marker/backup
/accessory power/ground and sealed connector for
stop/turn.
Circuit Breakers Manual reset (main panel) SAE Type lll with trip
indicators, replaces all fuses except for 5-amp fuses.
Radiator Aluminum; cross flow, front to back series system,
1,469 sq in, with 1,172 sq in charge air cooler.
Block Heater Engine (Phillips) 120 volt/1500 watt.
Fan Drive Horton Drivemaster, automatic on/off type control,
with normally closed temperature control.
Emission Compliance Federal Does not comply with California clean air regulations.
Suspension/Rear Axle Identity for Meritor (Rockwell) tandem rear axles with
bar-pin beam attachment type suspensions.
Tow Loop Front
Frame Rails Heat treated alloy steel (120,000 psi yield); 10.125 in
x 3.580 in x 0.312 in (257.2 mm x 90.9 mm x 8.0
mm); 480.0 in (12,192) maximum oal.
IP Cluster Display On board diagnostics display of fault codes in gauge
cluster
Air Conditioner (International Blend Air) with integral heater and
defroster
Fresh air filter for HVAC
Storage Pocket Door molded plastic, full width; mounted on
passenger door
Cab Rear Suspension Air bag type

The initial production 70K T3W Waterwell drill was mounted on a Paystar 5600i, 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 3: Paystar Truck
Model 5600i 6X4 Truck Chassis

Model Description Paystar Model 5600I, 6X4
Wheelbase 254 in (645 cm); Cab to Axle 192.0 in (487.68 cm);
Axle to Frame 68 in (172.72 cm).
Diesel Engine Caterpillar C13 ACERT, 50 state, 380 HP @ 2,100
governed speed; 395 peak HP (max) and with
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.
Range G, 14 Ply.
Suspension, Rear, Tandem Hendrickson RT-463, Walking Beam Type 54 in Axle
Spacing; 46,000 lb capacity with bronze center
bushings.
yield); 12.934 in x 3.687 in x 0.312 in x 415.5 OAL;
(328.5 mm x 93.6 mm x 7.9 mm x 10,553.7 mm)
OAL.

The current production 70K T3W Waterwell drill is mounted on a Paystar 5600 SBA, 6X4. 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 4: Paystar Truck
Model 5600 Paystar SBA 6X4 Truck Chassis

Model Description Paystar Model 5600 SBA, 6 x 4
Gross Vehicle Weight Rating
Diesel Engine Caterpillar C13 ACERT, 380 HP (283 kW) @ 2,100
governed speed; 395 peak HP max. (294 kW) with
Cummins ISM-400 Non EGR Export, 400 HP (298
kW) @ 1,800 rpm, 2,100 rpm governed speed; 1,450
lb/ft torque @ 1,200 rpm; 400 peak HP (298 kW)
max.
Manual Transmission Fuller FR0-14210C, 10-speed manual; with
overdrive, with air shift
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 International I-220S I-Beam type, 22,000 lb capacity.
Axle, Rear, Tandem Meritor RT-46-160 Single Reduction, 46,000 lb
Differential in Rear-Rear Axle and 200 Wheel Ends,
Gear Ratio: 4.89.
Cab Conventional
Bumper, front chrome plated steel; swept back 40
degrees
(Whisper Cab) Daycab interior noise reduction
package
Bug screen, front end; mounted behind grille
Front end tilting, fiberglass, with stationary grille
Single piece windshield


Front Tire (2) 425/65R22.5, Unisteel G286A (Goodyear) 470
Rev/Mile, Load Range L, 20 Ply
Rear Tire (8) 11R22.5 G164 RTD M+S (Goodyear) 499 Rev/
Mile, Load Range G, 14 Ply
Suspension, Rear, Tandem Hendrickson RT-463, Walking Beam Type 54-in Axle
Spacing; 46,000 lb capacity with bronze center
bushings
Suspension, Front Spring multileaf, shackle type; 23,000 lb capacity;
less shock absorbers
yield); 12.934 in x 3.687 in x 0.312 in x 415.5 in OAL
(32.8 cm x 9.3 cm x 0.79 cm x 1055.3 cm OAL)
Brake System Air dual system for straight truck applications
Air brake ABS (Bendix Antilock Brake system), full
vehicle wheel control system (4 channel)
Brakes Front, air cam S-Cam; 16.5 in x 6 in; includes 24 sq.
in. long stroke chambers
Rear, air cam S-Cam; 16.5 in x 7.0 in; includes 30 sq
in MGM spring-actuated parking brake chambers
Air dryer (Bendix AD-9) with heater, standard location
Brake Package Front (Dana Spicer) ES-165-6) air, cam type,
Rear (Dana Spicer) ES-165-7 air, cam type,
Steering Gear (2) Sheppard M-110/M-801, dual power
Electrical System 12 volt, standard equipment
Alternator Delco Remy 22-S1, 12-volt 100 amp. capacity; with
pad mounting
Starting Motor Delco Remy 39MT, 12-volt; gear reduced, with
thermal over-crank protection
Running Light (2) Daytime
Radiator Aluminum; crimped, cross flow, 2 row parallel
system, 1052 sq in, with 537 sq in charge air cooler
Block Heater: Engine (Phillips) 120 volt/1,500 watt


Fan Drive Horton Drivemaster, automatic on/off type control,
with normally closed temperature control
Emission Compliance Federal Does not comply with California clean air regulations
Suspension/Rear Axle Identity for Meritor (Rockwell) tandem rear axles with
bar-pin beam attachment type suspensions
Tow Loop Front
Frame Rails Heat treated alloy steel (110,000 psi yield); 12.250 in
x 3.375 in x 0.375 in x 389.4 in OAL (31.1 cm x 8.5
cm x 0.95 cm x 989 cm OAL)
Air Conditioner (International Blend Air) with integral heater and
defroster
Fresh air filter for HVAC
Air Cleaner Dual element; heavy duty with restriction gauge in
cab and vacuator
Differential Locking (Meritor) driver controlled Main Locking
Differential; in forward rear axle
Fuel Tank Non-polished aluminum, 24 in (60.9 cm) diameter,
100 gal (378 L) capacity mounted right side under
cab
Fuel tank straps bright finish stainless steel
Radio International AM/FM premium stereo with CD player,
with 3 second antishock and MP3 compatible,
weatherband, clock with alarm, with multiple coaxial
speakers
Speaker, auxiliary, CB radio with jack for CB;
mounted left side above driver door
Antenna base (1) dual function, for CB and
entertainment radio, with splitter, lead-in and dual
function antenna; mounted on left mirror

The initial production 70K T3W Waterwell drill was available on a Paystar 5600i, 6X6 truck
chassis. You must look at your carrier manuals, located in the driver door storage pocket on
the drill, to determine the exact configuration of your truck carrier.
Table 5: Paystar 5600i 6X6 Truck
Model 5600i 6X6 Truck Chassis

Model Description Paystar 5600i 6X6
Diesel Engine Caterpillar C15 Export, 435 HP @ 2,100 rpm, 1550
lb/ft torque @ 1,200 rpm, 2,100 rpm governed speed;
450 peak HP (max).
overdrive, with air shift, with internal lube oil pump
cast angle spring; ceramic, 15.5-in diameter, soft
capacity.
Axle, Front Driving Meritor MX-23-160, Single Reduction, 23,000 lb
capacity with S-Cam brakes and hub piloted wheel
mounting
Axle, Rear, Tandem Meritor RT-46-160, Single Reduction, 46,000 lb
Differential in Rear-Rear Axle and 200 Wheel Ends
Gear Ratio: 5.38
Cab Conventional
Range G, 14 Ply
Suspension, Rear, Tandem Hendrickson RT-463, Walking Beam Type 54-in Axle
Spacing; 46,000-lb capacity with bronze center
bushings
yield); 12.934 in x 3.687 in x 0.312 in x 415.5 OAL;
(328.5 mm x 93.6 mm x 7.9 mm 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 door storage pocket on the drill, to determine
the exact configuration of your truck carrier.
Table 6: Peterbilt Truck
Peterbuilt Model 365 Truck

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 lb (2,267.9 kg)
Chassis Front Axle Load 22000 lb (9,979 kg)
Rear Axle Load 46000 lb (20,865 kg)
Gross Carrier Weight 68000 lb (30,844.28 kg)
Wheelbase 254 in (6,456.6 mm)
Front Axle to BOC 68.9 in (1,750 mm)
Cab to Axle 185.1 in (4,701.54 mm)
Cab to EOF 244.1 in (6,200.1 mm)
Frame / Equipment 11-5/8” Steel Rails, Steel Xmbrs, To 444 in, 3/8 in Rail
Thickness. 10-3/4 in x 3/8 in 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 in
bolt circle
Taper Leaf Springs with Shocks 23,000 lb
Power Steering TRW TAS85 Dual for use with 16,000 lb
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 lb 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 in height, 7 in dia,
chrome plated stl standpipe.
Transmission and Clutch Fuller FR015210C 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 in 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 Alm
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 lb (18,143.6 kg)
Chassis Front Axle Load 22,000 lb (9,979 kg)
*
Rear Axle Load 48,000 lb (21,790.58 kg)
Gross Carrier Weight 50,040 lb (22,697.76 kg)
Wheelbase 262 in (6,654.8 mm)
Front Axle to BOC 76.8 in (1,950.72 mm)
Cab to Axle 185.2 in (4,704 mm)
Cab to EOF 244.2 in (6,202.6 mm)


Frame / Equipment 11-5/8 in Steel Rails, Steel Xmbrs, To 444 in 3/8 in Rail
Thickness. 10-3/4 in x 3/8 in Full Steel Liner. Peterbilt
Front Wheel Mudflaps.
Front Axles / Equipment Dana Spicer D2200F 22,000 lb, 3.5 in 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 in height, 7 in dia,
chrome plated stl standpipe.
Transmission and Clutch Fuller FR018210C 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 in x
0.180 wall tubing.
Eaton Fuller 15.5 inch Clutch, Easy Pedal VCTPlus,
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 Whl, pilot mount
RR: Accur 28408 STL Inner/Alcoa 883640 Outer Alm
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.
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 side door.
Powerpack
The T3W consists of a special truck frame which supports the power pack assembly (engine
/ compressor / hydraulic pump drive), the combined cooler package, drill tower assembly and
four leveling jacks.
The power pack (or power train) consists of a diesel engine directly coupled to an air
compressor through a clutch or in/out box on one end and a hydraulic pump drive on the other
end. This complete power pack assembly is mounted to the rig frame. The in-line drive train
configuration maximizes mechanical efficiency.
A heavy duty engine/muffler is provided to reduce engine noise emission. Separate two stage
dry type engine and air compressor air cleaners have quick release dust drop covers, as
standard, for easy maintenance.
Coolers are provided for the hydraulic oil, compressor oil, diesel engine coolant and air to air
aftercooler. All coolers are mounted side by side in one package and each section can be
individually removed for easy maintenance. The engine cooling package is rated for 125°F
(52°C) ambient at sea level. Low oil pressure, low coolant level, high water temperature or high
compressor temperature will shut down the engine.
Table 7: Power Pack Selections
Power Pack 1 (900 cfm @ 350 psi)

Deck Engine CAT C15 Diesel engine, 475 hp (354 kW) @ 1,800 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) @ 1,800 rpm
Compressor IR HR2.5 Over/Under screw compressor, 1070 cfm LPS
Flow with in/out box option.
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
Table 8: Deck Engine
Make / Model CAT C15, 475 HP (354 kW) @ 1,800 rpm

CAT C15, 580 HP (432.5 kW) @ 1,800 rpm
Engine Cooling Package Rated at 125 °F (52 °C) ambient at sea level
Exhaust System Silenced for reduced noise levels
Engine Silencer Aluminized steel
Fuel Capacity 160 gal (605 L)
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
Air compressors used on the T3W Waterwell 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 air cleaner,
electronic air regulation and full instrumentation and controls. The lubrication system includes
an oil cooler, bypass valve, oil filter, oil pump and combination air receiver and oil separator
tank. A safety shutdown system is provided for high discharge air temperature.
The oil pump allows the operator to close the intake valve when no air is required. This greatly
reduces the engine load which saves fuel and facilitates weather starting.
Table 9: Compressor
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 @ 2,413 kPa)
1070 cfm @ 350 psi, (30.3 m3/min @ 2,413 kPa)

Pressure Range 120 psi to 350 psi (827 kPa to 2413 kPa)
Operational RPM 1800 RPM
Receiver Capacity 28.5 gal (107.8 L)
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.
Table 10: Cooling Package
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 in blade
Cooling Fan Variable Controlled. The fan only runs as fast as
needed to maintain optimal fluid temperature.
Function Cools hydraulic oil, compressor oil and engine
coolant

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
Table 11: Hydraulic Reservoir
System Capacity 100 gal (378.5 L)

Filtration Three 3-micron in-tank return filters and one 10 micron case
drain filter.
Quantity/Location Located on helper 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 to 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 two basic configurations
for the 40K drill and two basic configurations for the 70K drill.
1. 40K Model with no Mud Pump.
2. 40K Model with Mud Pump.

3. 70K Model without Mud Pump.
4. 70K Model with Mud Pump.

Hydraulic Pumps
Rotation Pump
Table 12: Rotation Pump
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 (118.8 cc), 2,500 rpm, 78.5 gpm (297 L/min)
Function Supplies oil to the rotary head motors.
Main Pump
Table 13: Feed Pump
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), 2,500 rpm, 95.8 gpm (362.6 L/min)
Function Supplies oil to the main manifold.
Fan Pump
Table 14: Fan Pump
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 (70K Only)

On T3W Models with 70K pulldown, an Auxiliary pump is used to provide additional oil to the
main valve.
Table 15: Auxiliary Pump
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 (40K Only)

On T3W Models with 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 16: Mud Pump (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 (70K Only)

On T3W Models with 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 17: Mud Pump (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 and Pressure Control.
Function Supplies oil to the mud pump option.
Motors
Rotary Head Motor
Table 18: Rotary Head Motor
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 19: Fan Motor
Quantity One
Type Hydraulic Motor, Uni-Directional
Displacement Fixed displacement, 6.0 in3/rev (1,100 rpm)
Function Cooler Package Fan Motor
Carousel Motor
Table 20: Carousel Motor
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 21: Mud Pump Option Motor
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 22: Rod Spinner (Option) Motor
Quantity and 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 23: Hydraulic Leveling Jacks
Type Hydraulic cylinder with double holding valves

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

Tower Raising Cylinders

The tower is raised and lowered by two hydraulic cylinders. Tower pinning is a manual
operation.
Table 24: Tower Raising Cylinders
Quantity/Type Two, Hydraulic Cylinder

Bore x Stroke x Diameter 5 in x 36 in x 3 in (127 mm x 914.4 mm x 76 mm
Function Raise and lower the tower
Feed Cylinder
1. The T3W Water Well with the 40K tower drill uses a single hydraulic cylinder
cable feed system.
2. The feed system on the 70K tower 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 25: Feed Cylinder
Type Hydraulic Cylinder

Quantity 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)
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 26: Retract Table Cylinder
Quantity/Type One, Hydraulic Cylinder

Bore x Stroke x Diameter 3.5 in x 10 in x 1.75 in (89 mm x 254 mm x 44.5 mm)
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 27: Breakout Wrench Cylinder
Quantity/Type One, Hydraulic Cylinder

Bore x Stroke x Diameter 3.5 in x 10 in x 1.5 in (89 mm x 254 mm x 38 mm)
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 28: Jib Boom Swing Cylinder
Quantity/Type One, Hydraulic

Bore x Stroke x Diameter 3 in x 14.125 in x 1.5 in (76.2 mm x 358.7 mm x 38 mm)
Function Swings drill pipe over carousel when loading and
unloading drill pipe
Jib Arm Extend Cylinder
Table 29: Jib Boom Extend Cylinder
Quantity/Type One, Hydraulic

Bore x Stroke x Diameter 3 in x 14.125 in x 1.5 in (76.2 mm x 358.7 mm x 38 mm)
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 30: Bottom Holding Wrench Air Cylinder
Quantity/Type One, Air Cylinder

Size 2 in x 5 in x 1.0625 in (50.8 mm x 203 mm x 27 mm)
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 31: Upper Holding Wrench Air Cylinder
Quantity/Type One, Air Cylinder

Size 4 in x 6 in x 1.75 in (101.6 mm x 152 mm x 44.45 mm)
Function Engages drill pipe flats when loading and unloading carousel.
Tower
General Information
The tower 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 tower support the feed
cables. The tower 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 tower 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 32: Tower
T3W 40K T3W 70K

Tower Construction Welded cold finished steel tubing
Capacity 45,000 lb (20,412 kg) 75,000 lb (34,820 kg)
Length 35 ft 6 in (10,820 mm main chords)
Head Travel 27 ft 4 in (8,330 mm)
Width 36 in (914 mm)
Depth 28 in (711 mm)
Retract Channels Pneumatic foot pedal control at platform
Table Retractable table with swing out front

Swivel
Table 33: Swivel
Hose Lower
Tower Type
Connection Connection
40K 40 RM Swivel 3” NPT 3.5” IF Pin
70K 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-inch (76 mm) swivel and air piping.
Table 34: Rotary Head
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 5,500 ft·lb (7,458 N·m) @ 145 rpm, Single speed rotary head
Swivel/Piping 3 in (76 mm) air piping with 3 in (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 6,250 ft·lb (8,475 N·m) @ 134 rpm, two speed rotary head
Single Speed High Torque Rotary Head

(Two) 15 in3/rev (254 cm3/rev)

Torque 8,000 ft·lb (10,848 N·m) @ 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 5,500 ft·lb (7458 N·m) @ 145 rpm, Two speed rotary head
Second Speed 4,000 ft·lb (5424 N·m) @ 195 rpm
Two Speed Heavy Duty Rotary Head

(Two) 12.5 in3/rev (204.9 cm3/rev)

Torque 6,250 ft·lb (8,475 N·m) @ 134 rpm, Two speed rotary head
Second Speed 4,650 ft·lb (6,310 N·m) @ 180 rpm

2 Speed High Torque Rotary Head

(Two) 15 in3/rev (254 cm3/rev)

Torque 8000 ft·lb (10,848 N·m) @ 105 rpm, Two speed rotary head
Second Speed 5500 ft·lb (7458 N·m) @ 145 rpm
Drill Pipe Carousel

The drill pipe carousel is contained in the tower 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.
Table 35: Carousel
Location Fixed position inside tower

Carousel Indexing Hydraulic, forward and reverse
Capacity Nine (9) 3.5 in x 20 ft (89 mm x 6.1m) drill pipe
Seven (7) 4.5 in x 20 ft (114 mm x 6.1m) drill pipe
Dual Wall Carousel Seven (7) 4.625 in x 20 ft (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 inches (406.4 mm) of
casing.
Table 36: Retract Table
Retract Hydraulic Cylinder: 3.5 in x10 in x1.75 in (89 mm x 254 mm x

44.5 mm)
Table Base Two half plates. Rear half retracts and front half is hinged to
swing out to an opening up to 20 in (508 mm), depending on
carousel option.
Bottom Holding An air operated wrench fits either 3.5 in (89 mm) or 4.5 in (114
Wrench mm) 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 (114 mm) O.D. diameter
drill pipe.
Feed System
1. The 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 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.

Table 37: Feed
40K 70K
Type Single Cylinder, Cable Feed Double Cylinders, Cable Feed
No. of Cylinders One Two
Hyd. Cylinders 5 in bore x 165.5 in stroke x 3.5 in 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 in / 22 mm cable
Pulldown 25,000 lbf (111.21 kN) 30,000 lbf (133.45 kN)
Pullback 40,000 lbf (177.93 kN) 70,000 lbf (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 tower ensure maximum performance and increase the
available pullback power.

Winch
Table 38: Main Winch
Type Hydraulic motor, bi-directional, single line, bare drum.

Description 12,000 lb (5,443 kg): Fixed displacement 6.4 in3/rev motor, Line
speed of 120 ft/min (37 m/min) first wrap.
18,000 lb (8,165 kg): Fixed displacement 7.63 in3/rev motor,

Line speed of 165 ft/min (50 m/min) first wrap.
30,000 lb (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 39: Auxiliary Winch
2,000 lb (High
Specifications 4,000 lb
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 (89 mm) drill pipe
or twelve 4.5 inch (114 mm) 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.
Tool Box
The tool box is mounted under the cooler package and below the deck. Construction is all steel
with locking hatches.
Table 40: Tool Box
Width 58 in (1473.2 mm) wide

Height 23.8 in (604.52 mm) high
Depth 24 in (609.6 mm) deep
Door Assembly Swings open 90° from closed position

Operator’s Console and Platforms
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 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
manufacturer 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 41: Water Injection
Type Size Capacity Pressure Foam

CAT 12 GPM 0-12 gpm (0-45 L/min) 550 psi Optional foam
(3,792 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
(5,170 kPa)
John Bean 25 GPM 0-25 gpm (95 L/min) maximum
John Bean 35 GPM 0-35 gpm (0-132) L/min) 480 psi
(3,309 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 42: Mud Pump
Type Capacity
3 x 4 Centrifugal Mud Pump. 300 gpm (1,136 lpm) @ 145 psi (1,000 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 lpm) @ 310 psi (2,137 kPa)
Mounted behind the truck cab.
7.5 x 10 Duplex Mud Pump. 300 gpm (1,136) L/min) @ 400 psi (2,758
Mounted behind the truck cab. kPa)
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 43: Pipe Spinner
Pipe Size 3.5 in (89 mm) 4.5 in (114 mm)

Design Type Hydraulic motor / pneumatic cylinder design
Torque 80 ft·lb (284.7 N·m) 80 ft·lb (284.7 N·m)
RPM 395 395
Range 3.125 in to 3.5 in (79.375 4.125 in to 4.5 in (104.775
mm x 88.9 mm) mm x 114.3 mm)
Location Mounted on rear bumper next to retract table
Drill Pipe
Table 44: Drill Pipe
Size Connections Flats

3.5 in (89 mm) OD x 20 ft 2-3/8 in (60 mm) IF box up/ 2-3/4 in (70 mm) wrench
(6.1 m) long external flush: pin down connections. flats on box end of drill pipe
approx. 240 lb (109 kg)
4.5 in (114 mm) OD x 20 ft 2-7/8 in (73 mm) IF box up/ 3-1/5 in (89 mm) wrench
(6.1 m) long external flush: pin down connections. flats on box end of drill pipe
approx. 345 lb (156 kg)
Standard Tools and Accessories
1. Rod Wiper, Hoist Plug for drill pipe, Drill pipe centralizer bushings, Breakout
Wrench, Feed Cable Socket Wrench, Fire Extinguisher, Road Hazard Kit, Rod
Handling Sling, Control Panel Cover
2. Three CD ROM serial Parts manual and Safety Manual, Operation and
Maintenance manual; Three serial number paper Parts manuals and three
paper Safety, Operation and Maintenance Manuals.

Options
1. Mud Pumps, Floating Spindle Sub, 6x6 Heavy Duty Trucks, Pipe Spinner,
Sand Reel, Water Injection, Deck Engine Starting Aid, Single Pipe Loader,
Service Hoist, Down-hole Injection Lube, High Pressure Air Piping.
Dimensions
Table 45: T3W Dimensions
232 Wheel Base 254 Wheel Base

Description
Inch mm Inch mm
A Height - Overall, Tower Up 516.50 13119 516.50 13119
B Length - Overall, Tower Up 366.00 9296 401.7 10203
C Length - Overall, Tower Down 452.00 11481 452.3 11488
D Width - Across Outside of Front Tires 94.00 2388
E Length - Jack Center to Jack Center 219.00 5563 240.4 6119
F Height - Jack to Ground, Drill End 21.00 533
G Height - Mainframe to Ground 44.00 1118 44.00 1118
H Height - Overall, Tower Down, Drill End 151.50 3848 151.2 3840
J Width = Inside Rear Tires 45.9 1168 47.9 1217
K Width - Mid-Jack Centers 47.00 1194 47.00 1194
L Width - Rear Jack Centers 80.50 2045 80.50 2045
M Width - Overall 96.00 2438 97.1 2466
N Width - Wheel 24.00 610
Width - Outside Front Tires 100.9 2563
Q Height - Ground to Top of Cab 115.5 2934 115.3 2929
R Height - Overall, Tower Down, Non Drill 160.00 4064 159.8 4059
End
T Rotary Head Travel 330.00 8382 330.00 8382
U Cab Width 96.00 2438 96.00 2438
V Width - Mainframe, Drill End 95.00 2413 95.00 2413
W Width - Across Outside of Rear Tires 94.01 2388 96.2 2443

232 Wheel Base 254 Wheel Base

Description
Inch mm Inch mm
Y Length - Mainframe 216.00 5486
Z Width - Tower, Crown 51.50 1308 51.50 1308
AA Depth - Tower Side 29.50 749 29.5 749
BB Height - Mid-Jack to Ground 16.60 419
DD Length - Front Bumper to Mid-Jack 113.00 2870 116.00 2946
EE Length - Tower Support Clevis to Tower 48.5 1232
Rear
Length - Tower Pin to Bottom of Tower 48.8 1240
FF Length - Front Bumper to Tower Support 332.00 8433
Clevis
Length - Bumper to Tower Pin 356.8 9063
GG Length - Tower 439.50 11163 440.00 11176
JJ Height - Ground to Cooler 139.00 3531 139.00 3531
PP Width - Tower Edge to Hose Tray 66.00 1676 69.4 1763
QQ Height - Ground to Drill Table 48.50 1232 47.8 1214
RR Length - Rod Box 214.50 5448 214.50 5448
SS Length - Between Centers of Rear 54.00 1372
Wheels
WW Wheel Base 232.00 5893 254.00 6452
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/
Distributors 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 CMT
USA Customer Center, 3700 E.68th Ave., Commerce City, CO 80022.


Section 4 - Controls

T3W Instruction Manual Section 4 - Controls
OPERATING CONTROLS
General Information
! WARNING
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 controls and instruments, read
and understand Section 4 - Operating Controls & Instruments.
! WARNING
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.

Section 4 - Controls T3W Instruction Manual
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.
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 console.
Figure 1 : Operator Console
1 Drill string air on/off control
2 Downhole air pressure gauge
3 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 III
engines, are identified below reading clockwise from the receiver pressure gauge.

Figure 2 : Upper Console
1 Circuit breakers 13 Lights
2 Tachometer 14 Throttle
3 Emergency engine shutdown 15 Filter bypass
4 Fuel gauge 16 ECM
5 Interstage pressure gauge 17 Feed pressure gauge
6 Oil pressure gauge 18 Drill string vent
7 Discharge temp gauge 19 Rotation pressure gauge
8 Water temp gauge 20 Flow control know On/Off
9 Powerview diagnostics viewer 21 EARS diagnostic light
10 Start button 22 Compressor On/Off switch
11 On/Off key switch 23 Maximum pressure control knob
12 Ether button 24 Receiver pressure gauge
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
Make sure 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 Shutdown 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 Troubleshooting
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 Deck Engine ON/OFF key switch is a two position (On/Off) key operated switch that turns
on all electrical power to the deck engine and controls stopping and run operations.
The deck engine ON/OFF 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 Start button energizes the starter motor and engages the starter motor solenoid
to crank the engine for startup. Press the engine start button to start the engine. Once the
engine starts, release the engine starter button 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 an option for some deck engine applications.
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
1,200 rpm and a high idle of 1,800 rpm. The engine should always be run at low idle for 5
minutes before shutdown. This allows the turbocharger to cool down.
NOTICE
Make sure 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 7 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. Refer to Section 7 Compressor for the
Electronic Air Regulation System (EARS) description and information.
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 panel are identified below
reading clockwise from the Rotation Controller.
Figure 3 : Middle Console
1 Rotation 7 Mud pump volume
2 2-speed head 8 Slide wrench
3 Torque limit 9 Water injection
4 Slow speed 10 Jib hoist
5 Fast speed 11 DHD lube
6 Feed pressure 12 Foam
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.
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). There is a regen button on top of the fast
feed control. Pushing the regen button will direct more oil into the feed cylinder(s) to raise the
rotary head even faster.
NOTICE
The regen button will not lower the rotary head faster than the normal fast
feed speed.
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
(slow) 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 the downhole hammer drill, 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 counterclockwise.
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, Tower Raise control, Left Front Leveling Jack control, Right Front Leveling
Jack control, Left Side (Helper side) Drill End Leveling Jack control, Right Side (Operator
console side) Drill End Leveling Jack control, and the Drill Bubble Level.
Figure 4 : Lower Console
1 Main winch control 6 Rod spinner
2 Sand reel option 7 Retract table
3 Bubble level 8 Breakout wrench
4 Leveling jacks 9 Carousel index
5 Tower raise
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 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 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 counterclockwise 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.
Tower Raising
The Tower Raising valve spool is used to raise and lower tower. Raise the tower by pulling the
control up. Lower the tower by pushing the control down.
! DANGER
Always check for electrical power lines before raising the tower.
NOTICE
Feather the tower raising valve spool handle when the tower approaches

the vertical position. Do not slam the tower against the 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 level at all times.
Drill Bubble Level

The Drill Bubble Level gauge is used when leveling the drill in both directions. The tower 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.
Figure 5 : Foot Pedal Controls
1 Operator folding platform
2 Powerhead retract
3 Upper breakout wrench

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 tower 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 the casing into the
well, and for transport.

Helper Controls
Figure 6 : Helper Controls
1 Jib boom
2 Main hoist
3 Sand reel (option)
Jib Boom Control
1. The helper side Jib Boom control is used as a swing control to swing the jib
boom, mounted on top of tower, 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 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 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 DHDs. 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 to do actual drilling,
but are needed to perform functions that aid in the drilling procedures.
In/Out Box Actuation Control

The In/Out box is an option with the 1070 cfm compressor.
Figure 7 : In/Out Box
The In/Out Box Actuation control engages and disengages the compressor 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.
! CAUTION
Stop engine before engaging or disengaging the In/Out Actuator with the
compressor.
Service Pressure Regulator

A pressure regulator and a ball valve are connected to the main air discharge pipe to
accommodate tools and equipment that use air power.
Figure 8 : Pressure Regulator
1 Ball valve
2 Pressure gauge
3 Regulator
The pressure regulator is used to lower the high operating pressure to the tool operating
pressure, usually around 100 psi. The ball valve is there to reduce the load on the regulator
when it is not being used.
NOTICE
Do not operate the service air pressure at normal discharge pressure,

since most air tools are rated for no more than 100 psi.

Proportional Vent Valve and Actuator
Figure 9 : Proportional Vent Valve and Actuator
1 Proportional Vent Valve
2 Actuator
The proportional vent valve and actuator is controlled by the electronic controller. It can
release air from the receiver tank. The air is vented to atmosphere through an air silencer.
Receiver Tank Oil Level Gauge

The receiver tank contains the lubricating oil for the compressor. The oil is removed from the
air by centrifugal force, gravity, velocity and filtration.
Figure 10 : Receiver Tank Oil Level Gauge
1 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 maintained at the proper
level. Failure to maintain this level will result in the malfunction of the hydraulic system,
overheating of circuit components and the destruction of hydraulic pumps and motors.
Figure 11 : Hydraulic Oil Gauge
1 Oil level sight gauge
2 Oil temp gauge
Hydraulic Oil Temperature Gauge

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

The air filter indicator measures the restriction of the air cleaner and alerts the operator when
filter replacement is required.

Figure 12 : Air Cleaner Indicator
Fuel Tank Filler Cap
Figure 13 : Deck Engine Fuel Filler Cap
The fuel filler cap is located is located above the fuel tank mounted under the truck deck. The
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 tower is raised
(vertical position), the lube level should be halfway on the sight gauge in the front gearbox
cover.

Figure 14 : Tophead Gear Box 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.
Figure 15 : 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.
! 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 - Operation

T3W Instruction Manual Section 5 - Operation
OPERATING SAFETY
Safe Operations
Introduction
! WARNING

drill.
! WARNING
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.
! WARNING
and understand Section 4 - Operating Controls and instruments before
you operate or perform any maintenance, service or repairs on the drill.
! WARNING
Unexpected drill motion or moving parts can cut or crush. Shut down the

Section 5 - Operation 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 judgment 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

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.
! WARNING
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.
! 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.

! WARNING
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 cables 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 Section 6 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, tower 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 Areas
Keep operator’s areas clean! Clean windshields, mirrors and all lights. Check that all lights
function.
Make sure the operator 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 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.
! WARNING
! CAUTION
Never operate the engine with the oil level below the L (low) mark or
above the “H” (high) mark.

Truck Engine Coolant Level
! 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.
! WARNING
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 (0.48 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.

Deck Engine Coolant Level

Check engine coolant level on the radiator. The level should be maintained so fluid can be
seen in the high level sight glass and maintained above the low level sight glass. If the coolant
falls below the low level sight glass, the low level sensor will shut off the engine.
If the coolant level is low, refer to the instructions given in the Maintenance Procedures section
of Section 6 MAINTENANCE.
! WARNING
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.

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.
! WARNING
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.
! WARNING
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 with the drill turned off.
! WARNING

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.

! WARNING
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.
! WARNING
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. Check the oil level with the gearbox dipstick.
The oil level must be up to the FULL level on the dipstick. Refer to Maintenance Procedures
section of Section 6 MAINTENANCE.
! 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.

1. The oil level with all hydraulic cylinders retracted, tower down, jacks up and
rotary tophead 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.
! 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.
! 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. Loosen
this bleeder to drain moisture from the tank. Tighten the bleeder when the moisture has been
drained.
Operator 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.

! 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.
! WARNING
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
! 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.
! 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
! 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 and 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.
! WARNING
Read and understand Section 2-2 “Safety Precautions and Guidelines”

drill.
! WARNING
If you are not experienced with the drill’s controls and instruments, read
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.
! 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.
! WARNING
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
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).
! 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.
! 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.
! 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.
! 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.
! 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 original
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 temperature. After
starting a cold engine, increase the engine speed (rpm) slowly to provide adequate lubrication
to the bearings and to allow the oil pressure to stabilize.
! 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

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
1,000 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.
! WARNING
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.
! 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.

! CAUTION
Do not expose the engine to corrosive chemicals. Corrosive chemicals

can damage the engine.
! 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.
! 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.
! CAUTION
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 A/C 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 to 32 °C (32 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 to 54 °C (-25 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.
! WARNING
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
area while the engine is running.

Start Procedure
1 Engine shutdown
2 Ignition switch
3 Start button

1. Move all levers, switches, controls, etc. to the OFF, Neutral, or minimum flow
position.
2. The Engine Shutdown 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.
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.
! WARNING
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.

OPERATION
General Information
! WARNING

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.
! WARNING
! WARNING
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.

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 (1,200 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 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 = 1,200 rpm

b. Engine Water Temperature Gauge: 125 to 165 °F (51 to 74 °C).

10. Transfer the air pressure from the deck engine compressor to the operator
console by turning the air transfer valve to a horizontal position.
1 Air transfer valve
Leveling the Drill
! WARNING
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.
! WARNING
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.

3. Increase engine speed to 1800 RPM maximum with throttle control lever.
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.
1 Bubble level
2 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 tower is plumb when the drill level bubble is centered.

Raising the Tower
! DANGER
Before raising the tower, make sure there are no overhead electrical
power lines in the immediate vicinity.
1 Bubble level
2 Tower Raise
! WARNING
Check all hoses and cables to be sure they are free and clear. Check the
tower for any tools or loose objects before raising the tower.
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 tower.
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.

4. Remove the tower anchor bolts from the tower foot rests located on the main
frame and store them in the table as shown below.
1 Tower foot rest
2 Tower anchor bolt storage
3 Tower foot rest
5. Locate the tower raising control lever. (Raise the tower by pulling the control
lever up. Lower the tower by pushing the control lever down.)
NOTICE: Recheck hoses and cables making sure they do not snag or bind
during raising.
6. Raise the tower until it is in the vertical position. Before the tower approaches
the vertical position, slowly move the control to its center position (or feather the
control) to allow the tower to position without impact. Do not slam tower
against stops.
7. When the tower is raised, bolt it down to the tower foot rests with the bolts
removed in step 4. If not bolted down, any stress or pressure will warp the
tower and cause severe damage.
! CAUTION
Never drill with anchor bolts unfastened.
8. Recheck to make sure the drill is still level.

9. Check the overpressure controls before drilling.
Rotary Head Retract
1. The rotary head should be in the retract (inner track) position. Move the drill
feed control to UP position until the rotary head moves up and out of the retract
position. The retract gates will open and close automatically when going out of

retract.
2. Move the rotary head fast feed control to DOWN position and bring the rotary
head to the bottom of the tower.
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. 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.
Overpressure 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 overpressure control has been added to the feed circuits.

! WARNING
The overpressure control does not relieve the operator from the
responsibility of having control of the drill at all times. While the
overpressure 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:
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 tower.
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 tower 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 tower,
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.
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 tower 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.
1. Increase engine speed to 1,800 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.
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 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.
1. Decrease the engine speed to idle by turning the engine throttle to the left
(counterclockwise).
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).
4. Turn the ON-OFF 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 1,800 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.
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.

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.
! 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 before you operate or perform

any maintenance, service or repairs on the drill.
! WARNING
and understand Section 4 - Controls.
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 Drill String Assembly (Continued)
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 stabilizer, 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.

! WARNING
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.
3. Retract the table. Then open front table section and lower the stabilizer through
opening.
4. 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.
! WARNING
Do not let the centralizer bushing drop into the drilled hole.
5. Put 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.

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.
10. Bring rotary head out of retract and feed it down the tower until it is just above
stabilizer. To feed the rotary head down the tower, 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.

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.
! WARNING

aids provided to facilitate component lifting operations.
! WARNING

drill.
! WARNING
Unexpected drill motion or moving parts can cut or crush. If you are not
experienced with the drill controls and instruments, read and understand
Section 4 - Operating Controls & Instruments.

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.
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.

6. Extend the table wrench onto the flats. Extend the table wrench by pulling the
table wrench control towards the operator.
7. Turn off the water injection, if equipped. Deactivate water injection pump by
turning the control knob counter clockwise.
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.
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 tower.
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.
! WARNING

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.
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 tower 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.
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 tower 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.
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.
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.
! 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.
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.
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.
9. Extend the breakout cylinder to loosen the chuck.

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.
! 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.
! CAUTION
Watch the upper tool joint when breaking out.
! WARNING
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 tower
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.

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 tower 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 tower 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 tower.
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 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 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.
! WARNING

! WARNING
! WARNING

! WARNING

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.


DHD Drill String Assembly (continued)

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.
! WARNING
the lifting bail and the stabilizer pin end threads before moving the
stabilizer.
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.
! WARNING
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.
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.
10. Bring rotary head out of retract and feed down the tower until it is just above
stabilizer. To feed the rotary head down the tower, 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.

! WARNING
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
tower.
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./
230ml) of Rock Drill Oil into the drill backhead to lubricate it before
starting the DHD. Follow actual manufacturer lubrication instructions
when using DHD hammers.
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.
! 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.

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.
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.
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.

! 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.
! 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 tower 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.

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.
! 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).
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.
! 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.

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
NEUTRA” 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.
! WARNING
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.

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 (Cat Pump Only)

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.
! 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
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.
When using the DHD for the first time, pour one cup (8 oz/230ml) of Rock Drill Oil into the drill
backhead to lubricate it before starting the DHD.
NOTICE: Follow manufacturer 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 1,800 rpm.
3. Turn on the compressor. Adjust air volume (flow control) to the desired setting.
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.
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 to 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 manufacturer 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.

! WARNING

Do not wear loose fitting clothing that can become caught in rotation components.
Mud/Rotary Drill String Tools and Accessories

The following illustration shows a typical drill string suited for mud/rotary drilling.

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.
1. Change the main tower air hose from the air standpipe over to the mud
standpipe.
! WARNING
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.
4. Fill the mud source with water.
! 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.
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.
! WARNING
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.
! 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.

! 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 tower 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 clamping 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.

SHUTDOWN and DRIVE AWAY
Shutdown Procedures
NOTE: See section 4 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 tower. 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 tower, inspect for proper overhead clearance and for any
obstruction or tool left on the drill or tower.
9. Lower the tower.
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 tower 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 tower 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 manufacturer 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.
! WARNING
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 tower and place in retract position.

3. Swing the pipe holder option (if used) into the closed position.
4. Remove the tower 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 tower onto the tower rest.
Feather the tower raise/lower control lever as the tower approaches the
towertower rest so it doesn’t hit with excessive force. Never slam the tower 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 operator 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.
! WARNING
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.
! WARNING
Use the following recommendations to properly perform the towing

procedure.
! WARNING
Be sure to block the wheels of the drill and reapply the emergency brake
system before disconnecting from the towing vehicle.

! CAUTION
Maximum towing speed = 35 mph (60 km/h).
! 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

T3W Instruction Manual Section 6- Maintenance
6-1 MAINTENANCE SAFETY
Maintenance 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.
! WARNING
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.
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.
! WARNING
and understand the OPERATING CONTROLS & INSTRUMENTS section of
this manual.

Section 6 - Maintenance T3W Instruction Manual
If there is any doubt about the safe operating procedure of the drill, Stop! Review the
information supplied with the drill, ask your supervisor or contact your nearest Drilling
Solutions representative for assistance.
Make sure all new employees read and understand the decals in the Decal Safety Manual
mounted on the drill. Never remove the Decal Safety Manual. Replace the manual if it
becomes lost or illegible.
! WARNING
Most accidents involving product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing
potentially dangerous situations before trouble occurs. Some of the potential 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 correctly 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.

Burn Prevention
1. Do not touch any part of an operating engine or its components.

2. Allow the engine to cool before any repair or maintenance is performed.
3. Relieve all pressure in air, oil, fuel or cooling systems before any lines, fittings
or related items are disconnected or removed.
Coolant
1. Use caution when removing filler cap, grease fittings, pressure taps, breathers
or drain plugs.
a. At engine operating temperature, the engine coolant is hot and under

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.
4. Cooling system additive (conditioner) contains alkali. To prevent personal
injury, avoid contact with the skin and eyes and do not drink.
Oils
1. Hot oil and components can cause personal injury. Do not allow hot oil or any
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
skin and eyes. Wash hands after touching batteries and connectors. Use of
gloves is recommended. Batteries give off flammable fumes which can
explode. Ensure there is proper ventilation for batteries which are located in an
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 flammable
vapor mixture of hydrogen and oxygen to explode.
Fire or Explosion Prevention
1. Fire may result from lubricating oil or fuel sprayed on hot surfaces 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 unauthorized
persons. Store all oily rags or other flammable material in a protective container
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 operating.
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 Operation
section of this manual for specific starting instructions.

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 installed if a drill must be started
to make adjustments or checks. To help prevent an accident caused by rotating
parts, work carefully around them.
3. Do not disable or bypass automatic shutoff circuits. They are provided to
prevent personal injury and drill damage.
4. Never start an engine with the governor linkage disconnected.
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 maintenance 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 inspect 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 Procedure”
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 harmful to
your health. Always start and operate the engine in a well ventilated area and,
if in an enclosed area, vent the exhaust to the outside.

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
grid heater will ignite vapors, which can cause severe engine damage,
personal injury or death.
Engine Stopping
1. Stop the engine according to the Engine Stopping instructions in the Operation
Section to avoid overheating and accelerated wear of the engine components.
2. Only use the emergency stop button in an emergency. Do Not start the drill
until the problem is resolved.
3. On initial startup or overhaul, be prepared to stop the engine should an
overspeed condition occur. This may be accomplished by cutting the fuel and
air supply to the engine.
Maintenance Information
To prevent minor irregularities from developing into serious conditions, several other services
or checks are recommended for the same intervals as the periodic lubrication. The purpose of
these services or checks is to ensure the uninterrupted and safe operation of the drill by
revealing the need for adjustment caused by normal wear.
Prior to conducting any maintenance work, ensure that the following instructions are
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
cleaning solution before servicing to prevent dirt from entering while performing
the service.

When there is a need for service personnel to work on the drill in the working area or
danger zone and this involves activation of one or several drill functions, such work
shall only be done under the following conditions:
1. There shall always be two people present: both being fully instructed 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 emergency 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 supervisor 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.

6-2 MAINTENANCE SCHEDULE
Schedule Information
The maintenance schedule shows those items requiring regular service and the interval at
which they should be performed. A regular service program should be geared to the items
listed under each interval. These intervals are based on average operating conditions. In the
event of extremely severe, dusty or wet operating conditions, more frequent maintenance than
specified may be necessary.
NOTE: Refer to the manufacturer Operation and Maintenance manual for

the maintenance schedules and service maintenance procedures for the
deck engine.

the maintenance schedules and service maintenance procedures for the
Carrier Vehicle.
Before each consecutive interval is performed, all of the maintenance requirements from the
previous interval must also be performed.
Table 1: Maintenance as Required
Description Action Lubrication

Compressor Air Cleaner Check - Air Cleaner See Parts List
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
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 (Cat) 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 (Cat engine) 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 Gear Oil
Level
Grease Rotary Head Exxon Mobil Ronex Extra
Swivel & Yoke Assembly Heavy Duty Moly 2
Grease Upper Rotary
Head Bearing
Tower Pivot Pins: 5 shots of grease into each MPG-EPS Grease
grease fitting See 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 (Cat) Check - Engine Oil Level. CAT DEO-ULS (15W40)


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 (Cat engine). Clean ELC concentrate and
Cooling Fins. demineralized water, or
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 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
Feed Cables Torque Verification on
Feed Cable Clamps


Deck Engine (Cat) 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
Truck Engine (Cat) 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
Compressor Air Hose and Inspect Hoses, Tighten See Section 7 Dixon Boss
Coupling Clamps Coupling Clamp Bolts. Clamp Installation and
Section 7 Victaulic Rigid
Coupling Installation.

Hydraulic Reservoir Sample Hydraulic Fluid. ISO AW32
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
Main Winch Check - Oil Level Exxon Sparton 150 or
equivalent AGMA 4EP
Gear Oil
Tighten - Winch Mounting
Bolts
Clean and Add Corrosion See Instructions
Protection to Cables and
Ropes
Auxiliary Winch Change Auxiliary Winch Exxon Sparton 150 or
Oil equivalent AGMA 4EP
Gear Oil
Table 7: Maintenance at 1,000 Hours

Receiver Tank Change Compressor Oil XHP605 (high Pressure)
Hydraulics Replace Main Return Oil See Filter Elements and
Filters Kits Chart
Replace Case Drain Oil
Filter
Replace Hydraulic Tank
Breather
Rotary Head Change - Rotary Head Oil SAE 80W90 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 manufacturer Service
Clearance Manual
Receiver Tank Change Receiver See Filter Elements and
Separator Element Kits Chart
Replace Discharge Hose See Parts List. See
and Hose Clamps Section 7 Dixon Boss
Clamp Installation and
Section 7 Victaulic Rigid
Coupling Installation.

Cooling System Drain and Flush Engine Caterpillar engines use a
Cooling System. Replenish 50/50 Mix of Caterpillar
Coolant. See manufacturer ELC concentrate and
Service Manual demineralized water, or
ELC 50/50 premix.

Hydraulic Reservoir Change Hydraulic Oil ISO AW32
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 manufacturer Operation and Maintenance manuals for

the maintenance schedules and procedures for the carrier engine and
carrier vehicle.
NOTE: Refer to the manufacturer 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.
NOTE: Before each consecutive interval is performed, all maintenance

from the previous interval must be performed.
Table 11: 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

Description Action
PM Level 1 - Every 48,000 km (30,000 miles) or 15,520 L (4,100 US gal) 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
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 L (33,000 US gal) of
Fuel or 4,000 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

Description Action
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
Every 966,000 km (600,000 miles) or 6 Years
Alternator: Inspect
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 manufacturer 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 12: 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: Check
Engine Air Cleaner Service Indicator: Inspect
Engine Oil Level: Check
(Fuel) Primary Filter/Water Separator: Drain
Walk Around Inspection: Walk Around Inspection

Description Action
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
Initial 500 Hours (for New Systems, Refilled Systems and Converted Systems)
Every 500 Service Hours
Belts Inspect / Adjust / Replace
Turbocharger Inspect
Water Pump Inspect
Every 3,000 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
Driven Equipment Check
Cooling System Coolant (ELC) Change
Every 14,400 L (3750 US gal) of Fuel or 250 Service Hours or 1 Year
Battery Electrolyte Level Check
Electronics Grounding Stud Inspect / Clean / Tighten
Engine Crankcase Breather Clean
Engine Oil Sample Obtain
Primary Fuel/Water Separator Element Replace
Secondary Fuel Filter Replace

Description Action
Hoses and Clamps Inspect / Replace
Radiator Clean
Every 114,000 L (30,000 US gal) of Fuel or 3,000 Service Hours
After cooler Core Clean / Test
Crankshaft Vibration Damper Inspect
Engine Clean
Engine Mounts Inspect
Engine Speed / Timing Sensors Check / Clean / Calibrate
Engine Valve Rotors Inspect
Fan Drive Bearing Lubricate
Overhaul Considerations Check Fuel and Oil Consumption
Overhaul
Fan Drive Bearing Replace

the maintenance schedules and procedures for the deck engine.

6-3 REFILL CAPACITIES/LUBRICANTS/FUEL
General Information
Lubrication is an essential part of preventive maintenance, affecting to a great extent the
useful life of the unit. Periodic lubrication of the moving 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 shows those items requiring regular service
and the interval at which they should be performed. Details concerning fuel, oil and other
lubricants follow the lube chart. A regular service program should be geared to the items listed
under each interval. These intervals are based on average 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 lubricants are not made here due to regional
availability, operating conditions and the continual development of improved products. Where
questions arise, refer to the component manufacturer’s manual and a reliable supplier.
All oil levels are to be checked with the drill parked 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 otherwise 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 formation of rust. An anti-seize compound may be
used if rust has not formed. Otherwise, the component 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.
NOTE: To prevent minor irregularities from developing 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
the service.
2. Lubricants must be at operating temperature when draining.
3. During regular lubrication service, visually check the entire unit with regard to

capscrews, nuts and bolts being properly secured.

4. Spot check several capscrews and nuts for proper torque. If any are found
loose, a more thorough investigation must be made.
5. If a defect is detected which requires special maintenance service, stop the drill
operation until the defect has been corrected. If necessary, contact the local
Drilling Solutions distributor for assistance.
Lubrication Table
Periodic lubrication requirements are listed in the following Lubrication Chart. These
requirements include lubricant checks and greasing designated areas of the drill.
Table 13: 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 Oil (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 in (114.3
mm) from top of tank (high) to 5.5
in (139.7 mm) from top of tank
(low).
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


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 tower horizontal, remove oil
Gear Box level plug. Oil should be at bottom
of level plug.
Refill Capacities
The following fluid capacities are provided for servicing personnel who must perform drill
maintenance in remote locations where complete shop facilities and resources are not
available. These capacities will give the servicing personnel an approximation of the fluid
capacities of the components to be serviced. Always ensure that the specified method of
checking for accurate fluid levels is used.
Table 14: Approximate Refill Capacities
Component Lubrication Approximate Quantity

Hydraulic Reservoir ISO AW32 100 gal (378.5 L)
Receiver Tank XHP605 28.5 gal (107.8 L)
Rotary Head SAE80W90 Gear Oil 3 qt (2.8 L)
Pump Drive Gearbox 80W90 Gear Oil 1.125 gal (4.25 L)
12K Main Winch Exxon Sparton 150 or 6 pt (2.8 L)
equivalent AGMA 4EP
18K Main Winch Gear Oil, ISO VG 150 9 pt (4.2 L)
30K Main Winch 15 pt (7.09 L)
3K Sand Reel SAE90 Lubricating Oil 3.2 pt (1.5 L)
4K Service Winch SAE 90 Lubricating Oil 2.3 pt (1.1 L)
CAT Deck Engine (C15) CAT DEO-ULS 15W40 40 qt (38 L)
CAT Truck Engine (C13) CAT DEO-ULS 15W40 42 qt (40 L)
CAT Deck Engine Coolant 50/50 mix of Caterpillar 25 gal (94.6 L)
Extended Life Coolant
CAT Truck Engine Coolant (ELC) concentrate and Refer to OEM manual.
demineralized water, or
ELC 50/50 premix.
Fuel Tank (Deck Engine) No. 2-D S500 Diesel 150 gal (567.8 L)
Fuel Tank (Navistar 7600) No. 2-D S15 Diesel 50 gal (189 L)

Component Lubrication Approximate Quantity

Fuel Tank (Paystar 5600i) No. 2-D S15 Diesel 100 gal (379 L)
Fuel Tank (Peterbuilt) No. 2-D S15 Diesel One 60 gal (227 L) One 80
gal (302 L)
CAT 12 gpm Water CAT Pumps Special Multi- 40 oz (1.18 L)
Injection Pump Viscosity ISO68 oil.
CAT 25 gpm Water 84 oz (2.48 L)
Injection Pump
FMC John Bean 18 gpm SAE30 Texaco Meropa 64 oz (1.89 L)
Water Injection Pump 100 or SAE30 Shell Omala
100 oil.
FMC John Bean 25 gpm 64 oz (1.89 L)
Water Injection Pump
DHD Lubricator Tank Rock Drill Oil. Always 7 gal (26.5 L)
check with DHD OEM for
correct DHD lube oil.
Filter Elements and Kits

Table 15: Filter Elements and 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

Description Filter/Element Quantity Part No.

HR2.5 Compressor Filters Oil Filter 2 36860336
(900HR2.5 and
1070HR2.5 Receiver Tank Separator 1 57569758
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
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 coolant 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 following shows the
specifications:
Table 16: Hydraulic Oil
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-O Standards (4-11-78) and ISO
Viscosity Grade 32.
The following are approved oils for Parker Hydraulics Pump Division HF-O Standard.
Table 17: 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
Lubricant Oil & Grease
Extreme Pressure Multipurpose Lubricant

This gear lubricant is compounded to achieve high load carrying capacity and meet the
requirements of either API-GL-5 or MIL-L-2105C. Unless otherwise specified, SAE-90
viscosity oil may be used for year round service.
Table 18: Extreme Purpose Multipurpose Lubricant
Application Quantity Type

Rotary Head 1 gal (3.78 L) S.A.E. 80W90 Gear Oil
Planetary Drive Gearbox 4.5 qt (4.25 L) 80W90 Gear Oil
Carousel Speed Reducer 80W90 Gear Oil
3K Sand Reel 3.2 pt (1.5 L) SAE90 Lubricating Oil
4K Service Winch 2.3 pt (1.1 L) SAE90 Lubricating Oil
Low temperature usage is restricted as follows:

Table 19: 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)

Winch Lubricant
The following table represents the lubricant used in the 12K, 18K, and 30K main winch:
! WARNING
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-friction
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 contribute to
intermittent brake clutch slippage. Make certain that the gear oil viscosity
used in your winch is correct for your prevailing ambient temperature.
Table 20: Prevailing Ambient Temperature
Temperature Range Required Lubricant
-25 to 130 °F (-31.6 to 54.4 °C) Mobilgear SHC 150 or 220 Synthetic or
equivalent
10 to 80 °F (-12.2 to 26.6 °C) Exxon Sparton EP150 or equivalent
AGMA 4EP Gear Oil, ISO VG150
25 to 130 °F (-3.8 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) currently available oils. Consult your
oil supplier for other equivalent oils if required.
Table 21: 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
Water Injection Pump Lubricant

The required lubricating oil for water injection pumps is as follows:

Table 22: Water Injection Pump Lubricant
Manufacturer Required Lubricant

Cat Water Injection Pump CAT Pumps Special Multi-Viscosity ISO68
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 23: Compressor Fluids
Design Operating
Ambient Temperature Specification
Pressure
350 psi -10 to 125 °F (-23 to 52 °C) 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

The use of quality engine lubricating oils, combined with appropriate oil drain and filter change
intervals, is a critical factor in maintaining engine performance and durability.
NOTE: CAT DEO-ULS (Diesel Engine Oil-Ultralow Sulfur) multi-grade is

the preferred oil for use in CAT C13 and CAT C15 engines.
The proper SAE viscosity grade of oil is determined by the minimum ambient temperature
during cold engine startup and the maximum ambient temperature during engine operation.
If ambient temperature conditions at engine startup require the use of multigrade SAE 0W oil,
SAE 0W-40 viscosity grade is preferred over SAE 0W-30.
NOTE: Generally, use the highest oil viscosity that is available to meet the

requirement for the temperature at startup.
Table 24: SAE Viscosity
Engine Oil Viscosities for Ambient Temperatures

Ambient Temperature
Viscosity Grade Minimum Maximum
SAE 0W-30 -40 °C (-40 °F) 30 °C (86 °F)
SAE 0W-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 25: 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 recommended:

Table 26: Normal Operating Properties
Normal Operating Condition Consistency Grades

NLGI Number 0 Subzero fahrenheit (celsius) temperatures

Normal Operating Condition Consistency Grades

NLGI Number 1 0r Number 2 Ambient temperatures 0 to 100 °F (-17.8 to 38 °C)
NLGI Number 2 or Number 3 Temperatures over 100 °F (38 °C)
Multi-Purpose Grease
With the exception of the rotary head, the following grease can be used:
Table 27: 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-OH, Light Brown
NLG1 Grade: 2
Work Penetration, D17, 77°F (25°C): 265 to 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

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 28: Rotary Head Grease Specification
Description Specifications
Manufacturer: Exxon Mobil
Type: Ronex Extra Heavy Duty Moly 2
Quantity: 1 lb (0.45 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.

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 29: Minimum Acceptable Water Requirements
Property Maximum Limit

Chloride (Cl) 40 mg/L (2.4 grains/US gal)
Sulfate (SO4) 100 mg/L (5.9 grains/US gal)
Total Hardness 170 mg/L (10 grains/US gal)

Total Solids 340 mg/L (20 grain/US gal)
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

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 performance,
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 extended

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 instructions 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 Operation and Maintenance Manual Maintenance Interval
Schedule (Maintenance Section). To achieve this service life, the coolants must be properly
maintained. The maintenance program includes S-O-S coolant analysis.
Table 30: 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

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 microns absolute at the point at which
the fuel is dispensed into the vehicle.
NOTICE
Operating with fuels that do not meet Caterpillar 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 31: 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
Kinematic Viscosity, mm2/s at 40 °C (Min) 1.3 1.9 1.3 1.9

Grade Grade Grade Grade
Kinematic Viscosity, mm2/s at 40 °C (Min) 2.4 4.1 2.4 4.1
Ramsbottom carbon residue, on 10%,% 0.15 0.35 0.15 0.35

mass, max
Ash,% mass, max 0.01 0.01 0.01 0.01
0.10
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 50 No. 3 No. 3 No. 3 No. 3
°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 - -

6-4 MAINTENANCE AS REQUIRED
General Information
! WARNING

before you operate or perform any maintenance, service or repair on the
drill.
and understand Section 4 - Operating Controls.
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.

6. Never stop the drill on a slope or surface that is liable to collapse.
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 control panel.
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.
! WARNING
Airborne dust may be hazardous. Wear proper personal protective

equipment while handling air cleaners and elements.
! CAUTION
Raw, unfiltered air can cause engine or compressor damage. Never

service air cleaners while the drill is running.
Air Cleaner Indicators

Check the air cleaner visual restriction indicator before every shift, during every shift and after
every shift.
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.
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 manufacturer 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.
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).

! 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.
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.
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.

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:

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 (25.4 mm) 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.
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 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 SafetySignalTM 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 tower 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 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 tower feed installation for debris buildup around the sheaves.
3. Thoroughly wash all fittings, caps, plugs, etc. with a nonflammable, nontoxic
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
The pull down - pull back swivel yoke has provisions for connecting the two pull back feed
cables as well as the two pull down feed cables. The feed cables are adjustable for wear and
stretch. The lower feed (pull down) cables are adjusted at the cable anchor nuts located at the
pull down-pull back swivel yoke and the upper feed (pull back) cables are adjusted at the feed
cable anchor eyebolts located at the pull back cable anchor frame. Periodically, inspect the
feed system components for signs of wear and deterioration.

Adjusting the Feed Cables / Precautions / Details

The following instructions are written and provided by field technicians.
1. It is recommended that both pull down cables, or both pull back cables, are
replaced as sets.
2. As designed, the pull down-pull back swivel yoke should be maintained in a
horizontal or perpendicular position in reference to the tower in order to provide
proper swivel yoke roller alignment with the tower guide rails and the power
head / swivel yoke roller retract gates.
3. If the unit is equipped with high pressure rigid piping which is connected to the
pull down-pull back swivel yoke’s riser arm and the swivel inlet, this piping must
be removed before feed cable adjustment.
4. The power head/swivel yoke rollers should be at least 4 inches (101.6 mm)
above the retract gates when the feed cylinder stroke ends.
5. Before beginning the adjustment, ensure that a gap is maintained between the
power head/swivel yoke rollers and the powerhead/swivel yoke roller stops.
6. Ensure that the tower is supported in its transport position.
NOTE: The left side feed cable (driver’s side) adjusting nuts are used to
adjust the right (curb side) feed cable and, conversely, the right side feed
cable (curb side) adjusting nuts are used to adjust the left side (driver’s
side) feed cable.
7. Loosen the desired feed cable anchor’s adjusting nut jam nuts.
8. When adjusting the feed cable adjusting nuts, the cable should not be allowed
to turn along with the feed cable adjusting nuts.
9. Turn feed cable anchor’s adjusting nut sufficiently in order to obtain the desired
0.25 inch (6.35 mm) of feed cable sag at mid-span of the unsupported section
of the feed cable when the power head is at either end, but not contacting the
roller stops, of the tower.
10. In the event that the correct feed cable tension is obtained but the need arises
to raise or lower one side of the pull down-pull back swivel yoke, alternately
adjust (tightening one and loosening the other of the same side adjusting nuts)
the same number of turns (including fractional turns) in order that the feed cable
tension is not changed.
11. Re-check deflection of the pull back cables (upper feed cables) and readjust if
necessary.
12. Tighten jam nuts against the anchor nuts.
13. If one side of the feed system leads the other when raising and lowering the
rotary head, stop operation immediately and investigate the cause.

Cable and 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 broken wires in a wire rope lay length, or three
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 broken wires in a wire rope lay length, or four
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 tower, 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 wire rope broken down. 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 wires from
same strand within the lay length, it should be replaced according to ASME standards.

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 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.
1. Nuts should always be retightened after the initial load has been applied.
2. A termination made in accordance with the following instructions and using the
number of clips shown has an approximate 80% efficiency rating. This rating is
based upon the catalog breaking strength of wire rope. If a pulley is used in
place of a thimble for turning back the rope, add one additional clip.
3. The number of clips shown is based upon using right regular or Lang lay wire
rope, 6 x 19 Class or 6 x 37 Class, fiber core or IWRC, IPS or XIPS.

4. The number of clips shown also applies to right lay wire rope, 8 x 19 Class, fiber
core, IPS, sizes 1-1/2 inch and smaller; and right regular lay wire rope, 18 x 7
Class, fiber core. IPS and XIPS, sizes 1-3/4 inch and smaller.
5. The important things are using proper thimble size, number of clamps and size,
and installing them properly. See Wire Rope Clamp chart.
Table 32: Correct Usage of Wire Rope Clips
Amount of Rope
Minimum Number Torque in Foot-
Clip Size Inches to Turn Back in
of Clips Pounds
Inches
Dimensions are in inches and are approximate

1/8 2 3-1/4 -
3/16 2 3-3/4 -
1/4 2 4-3/4 15
5/16 2 5-1/2 30
3/8 2 6-1/2 45
7/16 2 7 65
1/2 3 11-1/2 65
9/16 3 12 95
5/8 3 12 95
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

Amount of Rope
Minimum Number Torque in Foot-
Clip Size Inches to Turn Back in
of Clips Pounds
Inches
3 10 106 1200
Wire Rope Installation

Unless a revolving stand is available, we recommend unwinding the cable coil prior to
installing on winch drum. This prevents the cable from becoming twisted during the winding
operation.
! WARNING
The cable clamp is not designed to hold the full load alone. NEVER
attempt to lift a load with less than five wraps of cable on the drum.
Take the free end of the wire rope and insert it through 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 (10 mm and 11 mm) wire rope by inserting
the wedge large end first. You may anchor 1/2 inch and 9/16 inch (13 mm and 14 mm) wire
rope by inserting the wedge small end first.
1. Wind cable onto the drum.
a. Leather gloves should be used when handling winch cable.

b. The cable winds in on TOP of the winch drum. Care should be taken to wind
the cable on the winch drum as evenly and as tight as possible.
2. Always use two persons when winding the cable onto the winch drum; one
person to operate the controls and the other to guide the cable from a safe
distance to obtain as level a winding job as possible.

3. When winding winch cable on the winch drum, never attempt to maintain
tension by allowing winch cable to slip through hands. Always use “hand-over-
hand” technique.
Notes:
1. Check feed cable tightness only when the rotary head is in the retracted
position. The cables become tighter when the rotary head is in the retract
position. Over tightened cables will unnecessarily wear the tower sheaves and
bearings.
2. New cables will stretch and seat in new cable anchor ends.
3. Suggest for regular maintenance adjustment to remove the slack but do not
tension cables excessively as it only makes it more difficult to feather the feed
system when making or breaking a drill pipe joint.
4. Feed cables not tensioned excessively will assist the operator to make up and
detach drill pipe joints with minimal drill pipe thread damage. Some customers
have installed a telescoping spindle adapter for additional protection.
5. Cables stretch under load. This is normal. Do not tighten the cables because
they are loose in a deep hole. Only check adjustment with NO LOAD on the
head.
6. Tighten the jam nuts securely. Cables rotate and have been known to unscrew
the improperly secured nuts right off the adjusters.
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.
! WARNING
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.

! WARNING
been relieved from the system. Completely relieve pressure before
removing filler plug, drain valve, fittings or receiver cover.
3. Remove the bolts from the receiver tank cover and remove the cover.
4. Pull the separator element from the receiver tank.
5. Inspect the element for failure mode.

6. Discard the used element in accordance with local guidelines.
7. Clean any old gasket material from the receiver tank or cover before installing
the new receiver element.
8. Remove the new receiver element from box and insert the new receiver
element into the receiver tank. Ensure the scavenge holes in the receiver
element are located properly. There will be several holes at the bottom of the
receiver element.
9. When installing the new element, make sure that the gasket is equipped with a
staple in the gasket on the element flange. Do not remove the staple.

10. Reattach the front cover and tighten the bolts to recommended torque per
Section 6 Torque Specifications.
11. After startup, check for any leaks at operating temperatures.
Fuel Systems
Maintain the fuel tanks at a high level to minimize water condensation inside the tanks. This is
best accomplished by filling the fuel tanks at the end of each shift or day. The fuel tanks should
be filled when the fuel indicator on the fuel gauge for the fuel tank moves below the 1/4 tank
mark.
1. Deck Engine Fuel Tank - Periodically check the fuel level and fill to full with
No.2-D S500 (LSD) Diesel Fuel. Refer to Refill Capacities / Lubricants / Fuel
for recommended distillate diesel 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 Refill Capacities / Lubricants / Fuel
for recommended distillate diesel fuel.

6-5 MAINTENANCE (8-10 Hours)
Overpressure Control System Test

The T3W feed system provides more than enough feed capability to lift the drill by overfeeding
the bit. To reduce the possibility of tipping the 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.
! WARNING
The overpressure 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 make sure the jacks are 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 1 inch (25.4 mm) 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.
3. Raise and lock the tower.
4. Lower the empty rotary head and stall the rotary head at the bottom of the tower
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.
Air Cleaners
The following are detailed instructions for performing routine maintenance procedures on the
compressor air cleaner. Note: See manufacturer service and maintenance manuals for
maintenance information on the carrier air cleaner.
! CAUTION
Raw, unfiltered air can cause engine and compressor damage. Never
service the air cleaners while the engine is running.
Air Cleaner Indicators
1. Check the air cleaner visual restriction indicator before every shift, during every
shift and after every shift.
2. Clean and inspect the engine and compressor air cleaners visual restriction
indicators. They should be GREEN. If the indicators show RED, indicating a
plugged air cleaner, clean or replace the filter elements.
3. After servicing the element, reset the restriction indicator to GREEN when the
element is replaced in the air cleaner housing.
4. The 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 cleaner connections and ducts for leaks before every shift, during every shift and
after every shift. Ensure all connections between the air cleaners, air compressor and engine
inlets 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.
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 replace 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.
Deck Engine
Engine Oil Level

Check the engine oil level daily by viewing the dipstick. Perform this maintenance with the
engine shut off.
! WARNING
Hot oil or components can burn. Hot oil and hot components can cause
personal injury. Do not allow hot oil or hot components to contact the
skin.
1. The drill must be on a level, stable surface when checking the oil level to be
sure the measurement is correct.
2. 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.
3. Pull out the dipstick (oil level gauge), wipe it clean with a lint free dry cloth and
push the dipstick back in.
4. Pull out the dipstick again and check the oil level on the dipstick.
5. Maintain the oil level between the ADD (low) mark and FULL (high) mark on the
oil level gauge (dipstick). Do not fill the crankcase above the HIGH mark.

! CAUTION
Never operate the engine with the oil level below the low (L) mark or
above the high (H) mark.
6. Remove the oil filler cap and add oil, if necessary. (Refer to the Lubricant
Specifications in this section for details on engine oil.)
7. Clean the oil filler cap and reinstall.
8. Repeat process and check oil level again after engine has run for about 1
minute.
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 Maintenance section.
Adjust the belt tension in order to minimize belt slippage. Belt slippage will decrease the life of
the belts. If the belts are too loose, the belts will vibrate. 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
! WARNING
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 immediately.
NOTICE
Use a suitable container to catch any fuel that might spill. Clean up any
spilled fuel immediately.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly clean the area
around a fuel system component that will be disconnected. Fit a suitable
cover over disconnected fuel system component.
The bowl should be monitored daily for signs of water. If water is present, drain the water from
the bowl.
1. Open drain. The drain is a self-ventilated drain. Catch the draining water in a
suitable container. Dispose of the water properly.
2. Close drain.

NOTICE
The water separator is under suction during normal engine operation.

Ensure that the drain valve is tightened securely to help prevent air from
entering the fuel system.
Cooling System
Radiator Coolant Level

The coolant level must be checked daily as part of the 8 hour routine maintenance procedure.
Check the coolant level when the engine is stopped and cool. Ensure the coolers are not too
hot to touch.
If the cooler is equipped with a sight glass, maintain the coolant level in the sight glass. Some
truck engine radiators have a surge tank with a coolant level mark on it. Maintain the coolant
level to the correct mark by adding coolant mixture, if necessary.
Add Coolant Mixture
! WARNING
skin and eyes. Always shut down the engine and allow it to cool down
before removing the radiator cap. Remove the cap slowly to relieve
pressure. Avoid contact with steam or escaping fluid.

! WARNING
Do not remove the radiator cap from the cooler(s) while the engine is hot.
Wait until the temperature is below 120 °F (50 °C) before removing the
pressure cap. Failure to do so can result in personal injury from heated
coolant spray or steam. Remove the filler cap slowly to relieve coolant
system pressure.
! CAUTION
Do not add cold coolant to a hot engine. Engine castings can be

damaged. Allow the engine to cool to below 120 °F (50 °C) before adding
coolant.
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.
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 hydrometers can give an
incorrect reading.
! 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 in order to relieve pressure, then
remove the cap. Do not allow coolant to splash out.
2. Start and run the engine with the filler cap removed. Allow the coolant to warm
up, the coolant level to stabilize and the thermostat to open.
3. Visually check the coolant level again.
4. Add coolant mixture, if necessary, to bring coolant level to the desired full level
marks or between the sight gauges. Refer to Section 6-3 Refill Capacities /
Lubricants / Fuel, Coolant Specifications for recommended coolant.
5. Check the condition of the filler cap gasket. If the gasket is damaged, discard
the old filler cap and install a new one. If the cap does not hold the correct
pressure, replace the cap.
6. With the engine running, look for coolant leaks. Check for proper operating
temperature.
Clean Radiator(s) and Oil Coolers

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

ensure that appropriate protective clothing is worn to protect eyes and
exposed parts of the body. Maximum air pressure at the nozzle must be
less than 30 psi (205 kPa) for cleaning purposes.
NOTICE
Do not use caustic solutions on the coolers as they may degrade the fin
material and cause a leak.

Pressurized air is the preferred method for removing loose debris. Direct the air in the opposite
direction of the fan’s air flow. Hold the nozzle approximately 0.25 inch (6 mm) 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. Thoroughly 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. Repeat 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 important 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 nozzle 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 purchasing fuel which contains water, or water may
contaminate the fuel in storage at the service location. 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 water goes beyond them, the water will gall the
injector body and score the fuel pump body and gears.

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

The fuel system hoses and fittings must have their tightness checked on a regular basis. The
following steps will help keep the fuel system functioning satisfactorily:
1. Let no contamination (dirt or water) enter the tank filler opening.

2. The fuel for the diesel engine must be of good quality (No. 2-D S500 LSD for
deck engine and No. 2-D S15 ULSD for truck engine) and should be obtained
from a reliable supplier.
3. Have a clean fuel nozzle and loading area where vehicle fuel tank is filled.
4. Have fuel tanks filled at the end of each shift before parking. Be sure the vent
in the fuel cap is open. Do not fill fuel tank above bottom of the filler neck.
5. Replace filters on a regular basis.
6. Keep all fuel system hoses and fittings tight.
Maintain fuel tank(s) 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 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. Select the proper grade of fuel in accordance
with the information in 6.3 Refill Capacities / Lubricants / Fuel.
! WARNING
extinguish all open flames, and do not smoke while filling the fuel tanks.
Always wipe up any spilled fuel immediately.
1. Check the fuel levels by reading the fuel level gauges located on the cab
dashboard and operator’s control console.
2. Never allow fuel tanks to completely empty, otherwise the entire fuel system will
require bleeding.
3. When fuel is added, clean the fill cap area and open the fuel filler cap.

4. Fill tank with the correct grade of fuel. Refer to 6.3 Refill Capacities/Lubricants/
Fuel for more details.
Receiver Separator
The receiver tank contains the lubricating oil for the compressor. The oil is removed from the
air by centrifugal force, gravity, velocity and filtration. The receiver 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.
1 Oil fill
2 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 pressure from receiver tank.
! WARNING
Do not attempt to open the filler plug, any drain plugs or the drain valve
before making sure all air pressure has been relieved from the system.
High pressure can cause severe injury or death.
4. Add fresh, clean synthetic oil (filtered through a 10-micron filter) through the fill
cap area to bring the oil to the correct full level.
! CAUTION
Over filling the receiver tank can cause oil carry-over into the drill string.
5. High pressure compressors (350 psi) must use XHP605 oil. For details on
compressor oil, refer to Compressor Fluids in section 6-3 Refill Capacities/
Lubricants/Fuel Specifications.
Drain Water from Receiver Tank

Water condenses and must be drained daily from the bottom of the receiver tank. If water is
allowed to condense into the compressor oil, the bearing life will be considerably reduced.
! WARNING

pressure before removing filler plug, drain valve, fittings or receiver
cover.
1. Locate and open the receiver tank drain valve and allow any of the
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 hydraulic reservoir oil level must be checked daily as part of the 8 hour routine
maintenance procedure.
NOTICE

clean, contaminant free system is extremely important for proper drill
function. Take extra care when working around or on the hydraulic
system to ensure its complete cleanliness. When operating, the oil level
must be between the maximum and minimum levels.
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 necessary, through the hand fill pump.
1 Hydraulic oil level gauge
2 Hand pump (fill)
3 Hydraulic oil temp gauge
The following procedure is proper for checking the hydraulic oil level in the reservoir. If the
hydraulic oil level is low, add hydraulic oil through the hand fill pump.
! CAUTION
Excessive hydraulic oil can rupture the hydraulic tank and cause injury
or property damage. Do not fill hydraulic tank with cylinders extended.
Retract all cylinders and fill tank to indicated level.

1. Level the drill.

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 (tower 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 running AND
also when the engine is stopped. There must be oil showing 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 immediately and call for
service assistance to investigate the cause of oil loss.
4. If necessary, add fresh, clean (filtered through a 5-micron filter) anti-wear

hydraulic oil through the hand fill pump to bring tank level to the FULL level on
the sight gauge. Refer to Refill Capacities/Lubricants/Fuel for details on
hydraulic oil.
5. During operation, monitor the hydraulic oil temperature gauge located under
the hydraulic oil level sight gauge.
Drain Water from Hydraulic Tank

Two moisture bleeder valves located on the bottom of the hydraulic tank are used to drain off
any moisture accumulated in the hydraulic tank. Release moisture from the hydraulic tank
daily, at shift change or every 10 hours of drill operation.
Moisture bleeder valve (right side under tank)

Moisture bleeder valve (left side under tank)

1. Place a container under the moisture bleeder valve that will be drained to
contain the escaping fluid.
2. Turn the petcock on the left moisture bleeder valve until water starts flowing.
3. When oil start to flow out, tighten the petcock.
4. Make sure there are no leaks around the moisture bleeder valve.
5. Repeat step 1 through step 4 to the other moisture bleeder valve.
6. Dispose of all accumulation in accordance with local regulations.
Rotary Tophead
Check the rotary head daily. Perform this maintenance with the tower up and the rotary head
at the bottom of the tower.
! WARNING
Riding the rotary head can cause severe injury or death. Do not ride the
rotary head.
! WARNING
Climbing a raised tower can cause severe injury or death. Do not climb a
raised tower.
! WARNING
Falling tower can cause severe injury or death. Ensure all locking pins are
in locked position.
! WARNING
Rotating shafts or drill string can cause severe injury or death. Do not
service the rotary head with the drill string in motion.

NOTICE
If a problem is found during a visual inspection, DO NOT use the drill until
the problem is corrected.
Rotary Head Oil Level
1. Move the drill to a stable, level surface.

2. Raise the tower and bolt the tower to the tower foot rests with the tower anchor
bolts.
3. If necessary, remove the drill pipe in the rotary head and lower the rotary head
to the bottom of the tower.
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 visible near the center of the sight
glass located on the side of the rotary head.
If the fluid level is low, add fluid using the following procedure:
1. The drill must be level. The tower must be raised and the rotary head must be
at the bottom of the tower.
2. Clean the area around the fill plug and remove the fill plug.
3. Add SAE 80W90 oil through the fill port until the oil level is visible in the center
of the sight glass. Refer to Refill Capacities/Lubricants/Fuel for details on
hydraulic oil.
4. Once the proper oil level is reached, replace the fill plug and tighten.

Rotary Head Swivel, Yoke and Rollers

Visually inspect the drill for leakage, damage or wear daily, at shift change, or at every 10
hours of operation.\
NOTICE
If a problem is found during a visual inspection, DO NOT USE THE DRILL

until the problem is corrected.
After the drill has been running for one hour, lubricate the bearings through the grease point
in the lower portion of the bearing housing, while the spindle is rotating. Lubricate the packing
every 3 to 4 hours through the grease point in the packing box (the mud pump, if equipped,
must be off). Lubricate the rotary head rollers through the grease points in each roller.
Lubrication
The following grease procedures must be carried out as part of the 10 hour or daily routine

maintenance schedule.
Tower Pivot Pins
1. Shut down engine.

2. Apply grease gun pressure to the tower 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 carousel 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 tower and two more large feed cable sheaves at the
bottom of the tower. In addition, there are two draw works sheaves and two jib boom sheaves
located at the top of the tower.
1. Lower the tower 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 grease nipple or until all of the
old grease has been purged out and new grease appears.
5. Wipe off excess grease.
6. It is particularly important that the lower feed cable sheaves at the bottom of the
tower be kept clean. Allowing cuttings to build up on these sheaves could result
in a failure of the sheave itself or in the cable.
Cylinders
Grease the cylinders on the drill daily. A typical cylinder will have a grease fitting at both the
rod end and the cylinder end of the cylinder. Both need lubricated. A typical T3W will have two
tower raise cylinders, four leveling jacks cylinders with grease points on each jack cylinder
can, one jib boom swing cylinder, one jib boom extend cylinder, one or two feed cylinder(s),
one table retract cylinder, one breakout wrench cylinder, one upper breakout (air) wrench and
one table (sliding) wrench air cylinder.

1. Lower the tower into the horizontal position.

3. Use a manlift, if necessary. Do not climb on tower.
4. Clean all grease nipples on the cylinders.
5. Inject five shots of MPG-EP2 grease into each grease nipple.
Rotary Tophead, Swivel and Rollers

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 a visual inspection, DO NOT RUN THE

ROTARY HEAD until the problem is fixed.
1. Move the drill to a stable, level surface. Raise the tower and bolt it down.
2. If necessary, remove the drill pipe in the rotary head and lower the rotary head
and swivel yoke to the bottom of the tower.
3. Clean all the grease nipples on the swivel yoke assembly and guide rollers.
Breakout (Holding) Wrenches

The upper and lower breakout (holding) wrench grease points require 5 pumps of grease daily,
at shift change, or every 10 hours of drill operation.
1. The lower breakout holding wrench has two grease points in the sliding portion
of the wrench and two grease points at the pivot points of the wrench.
2. The upper breakout holding wrench has only one grease point at its pivot.

Chain/Pipe Wrench
1. Clean all the grease nipples on the chain/pipe wrench assembly.

Gearbox Drive Shaft

The following grease procedure must be carried out as part of the 10 hour or daily routine
maintenance schedule.
! WARNING
Shut down engine and remove ignition key from ignition switch. Rotating
shaft can cause injury or death. Do not operate with 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 button (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 excessive grease.
Retract Gate Arms

There are four retract gate arms located at the top of the tower.
1. Lower the tower into the horizontal position.


3. Use a manlift, if necessary. Do not climb on tower.

4. Clean all grease nipples on the retract gate arms.
5. Pump 5 shots of grease into the grease fitting on each of the 4 retract gates
daily, at shift change, or every 10 hours of drill operation.
7. Verify the locking collar on each retract gate is tight. A loose locking collar will
allow the retract gate to move into the path of the rotary head and cause
extensive damage to the feed system.
Mud Pump Grease Points

The number of grease points will vary depending on which mud pump is installed on the drill.
There are grease points on the mud piping valves, for the mud pump shaft seal, for the mud
pump bull gear shaft and for the pump jack shaft (input shaft).
1. Clean all the grease nipples on the mud pump assembly.

2. Pump 5 shots of grease into the grease fittings.
Rod Holder Option

If necessary, raise the tower and lock the tower in the vertical position.
1. Shut down engine.

2. Clean all the grease nipples on the rod holder.
3. Pump 5 shots of grease into each grease fitting on the rod holder.
Jib Hoist/Boom
The jib hoist/jib boom grease points require 5 pumps of grease daily, at shift change, or every
10 hours of drill operation. NOTE: Use a manlift to grease the fittings located at the top of
the tower 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. 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 hours
of drill operation. There are five grease points located on the sand reel, shafts and levers. In
addition, there are two (one each) grease points on the sand reel sheaves at the top of the
tower.
1. Clean all the grease nipples.

2. Pump 5 shots of grease into the grease fittings.
4. Lower the tower to the horizontal position and use a manlift to grease the sand
reel sheaves at the top of the tower.
DHD Lubricator
DHDs (Down Hole Drill) 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.
The DHD lubricator must always be used whenever the DHD is being operated. Use the
correct oil for the DHD and the season. Make sure there is sufficient DHD oil in the lubricator
to lubricate the DHD during each shift.
1. A sight glass on the side of the lubricator shows the amount of oil in the DHD
lubricator tank.

NOTICE
Use only approved DHD oil to obtain maximum life from the DHD.
2. Add approved DHD Oil through the fill plug on top of the container. Oil can be
added while the drill is running, if necessary.
NOTICE
Make sure all dirt and cuttings are removed around the fill cap.
Truck
Refer to the manufacturer service and maintenance manuals for specific information on
maintenance for the truck, truck transmission and the truck cooling system.
Truck Engine
Maintain the engine oil level between the ADD and FULL marks on the dipstick. Refer to the
manufacturer service and maintenance manuals for specific information on engine lubricating
oil.
Truck Transmission
maintenance for the truck transmission.
Truck Power Steering

maintenance for the truck power steering unit.
Truck Cooling System

maintenance for the truck cooling system.
Housekeeping
The complete drill must be given a weekly cleaning. Daily cleaning will be required if material
is adhering to the tower or truck working parts.

1. Make sure the inside of 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 operator’s platform.
2. Check the tower feed installation for debris buildup around the sheaves.
3. Thoroughly wash all fittings, caps, plugs, etc. with a nonflammable, nontoxic
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 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.

6-6 MAINTENANCE (50 Hours or Weekly)
General Information
! WARNING

drill.
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.

crushing risk.

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.
! WARNING
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.
! WARNING
Battery fumes can ignite and explode. Do not smoke when observing
battery fluid level.
Electrolyte Level
1. Remove filler caps. Maintain electrolyte level to bottom on fill plug openings.
! WARNING
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 ounce (29.5 ml) of water per cell per
week.
3. Specific gravity should be 1.225 g/cm3 or above.
4. Do not over fill. Over filling can cause poor performance or early failure.
Battery Terminals
Keep the batteries clean and the connections tight.
1. Loosen and remove cable clamps from all battery terminals.

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 lubricant, petroleum jelly or
MPGM grease.
Winch/Sand Reel Cable

The following must be carried out as part of the 50 hour routine maintenance schedule.
! WARNING
Do not climb a raised tower. Climbing a raised tower can cause severe
injury or death. Lower the tower to the horizontal position to service the
winch and sand reel.
! WARNING
Never lift or transport personnel with the winches. Do not use the winch
in any manner of operation which may endanger any individual.
! WARNING
Cable clamps are not designed to hold rated winch load. At least five
wraps of cable must remain on the drum at all times.
! CAUTION
Stay at least 10 feet (3.048 cm) away from cable while it is under tension.
Cable should be inspected whenever unwound and replaced when
broken strands are noted.
Wire Rope
Wire ropes, including their anchorage and other load carrying components of the traveling
block and winch system, e.g. sheave bearings, rope sheaves and drill hooks shall be checked
at least once a week.
Wire rope used in drilling operations becomes unusable because of wear and wire breakage
and should be 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 drills 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 the basis of experience.
1. Replace when four randomly distributed broken wires are found in one lay.
2. Replace when the wire rope shows wear of one third (1/3) 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.
Refer to Cable and Wire Rope information in 6.4 Maintenance As Required for additional
information on wire rope and wire rope clamps.
Periodic Inspection
1. Inspect rigging, winch and hydraulic hoses at the beginning of each work shift.
Defects should be corrected immediately.
2. Be certain that at least five full wraps 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. Wear should not exceed 1/16 inch (1.59
mm).
Cat Water Injection Pump

Change the initial water injection pump oil after the first 50 hours of operation. Thereafter,
water injection pump oil change maintenance must be carried out as part of the 500 hour
routine maintenance schedule and every 500 hours thereafter.
! WARNING
The water injection pump oil should be at operating 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 appears 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 check for any leaks.
Pump Drive Gearbox
Oil Leaks
Inspect the hydraulic pump drive gearbox for leaks as part of the 50 hour maintenance
schedule. Follow the steps shown below.
1. Look for signs of oil on the case and around the bottom of the case.
2. If there are signs of oil leakage, clean the outside of the case and around the
bottom. Verify signs of oil are from the case and not another source.
3. If a leak is verified, contact maintenance and take corrective action.
Check Oil Level

The type of service and the operating conditions will determine the maintenance interval.
However, it is recommended that the oil level be checked as part of the 50 hour routine
maintenance schedule. At the same time, check for oil leaks. Because the lubricant system is
the heart of the unit, it is especially important that the oil be kept clean.

! WARNING
Hot oil or components can burn. Oil must be at normal operating

temperature when draining. Avoid contact with hot oil or components. Do
not allow used oil to drain into the ground. Dispose of properly.
NOTICE
The oil in the pump drive gearbox should be changed whenever the oil
shows any traces of dirt or the effects of high temperature, evidenced by
discoloration or strong odor.
! CAUTION
Do not add or check the oil level with the engine 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 dipstick 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.
Winch (Auxiliary)
There are two different sizes of (auxiliary) winches available on the T3W. A regular program
of preventive maintenance for the auxiliary winch will minimize the need for emergency
servicing and insure long life and trouble free service. All service intervals are specified for
operating hours of the drill.
NOTICE
The service intervals that are suggested will optimize component service
life. The intervals may be gradually increased or decreased after gaining
experience with a particular lubricant and the recommendations of an
independent oil analysis.
The gear oil should be changed after the first 50 hours of operation, then every 500 operating
hours or 12 months, whichever occurs first. The gear oil must be changed to remove wear
particles that impede the reliable and safe operation of the brake clutch and erode bearings,
gears and seals. Failure to change gear oil at these suggested minimum intervals may
contribute to intermittent brake slippage which could result in property damage, severe
The gear oil should also be changed whenever the ambient temperature changes significantly
and an oil from a different temperature range would be more appropriate. Oil viscosity with
regard to ambient temperature is critical to reliable brake operation. Make certain that the gear
viscosity used in your winch is correct for your prevailing ambient temperature. Failure to use
the proper type and viscosity of planetary gear oil may contribute to brake slippage which
could result in property damage, severe personal injury or death.
For normal operating temperatures, use SAE 90 lubricating oil. Refer to Section 6-3 Refill
Capacities/Lubricants/Fuels for further recommended oil specifications.
! WARNING
winch.

! WARNING
Never lift or transport personnel with the winch. Do not use the winch in
any manner of operation which may endanger any individual.
! CAUTION
Stay at least 10 feet (3.048 m) away from cable while it is under tension.
4K Winch (PL5)

3. Shut off the engine.
4. There are two fill and 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.
6. Place a container with a capacity of at least 1 gallon (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 and drain port until oil is level with the fill and drain port. 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 4K winch is
2.3 pints (1.1 liters). 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
100 hours of operation, then every 500 operating hours or 6 months, whichever occurs first.
3K Winch (M8 Sand Reel High Rope Capacity)

4. Place a container with a capacity of at least 1gallon (3.7 liters) under the drain
5. Use an Allen wrench to remove the drain plug and allow the oil to drain
smoothly into the suitable container.
6. Using a suitable hose or funnel, refill the housing with SAE90 lubricating oil
through the breather relief valve and filler port until oil is level with the level port.
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
3K winch is 3.2 pints (1.5 liters). Refer to section 6.3 Refill Capacities/
Lubricants/Fuel for further recommended oil specifications.
7. Clean and install the oil level plug.
8. Clean and install the breather relief valve. Do not paint over the breather relief
valve or replace it with a solid plug.

guidelines.

6-7 MAINTENANCE (100 Hours)
General Information
! WARNING

drill.

crushing risk.

Winch (Main)
There are three different sizes of (main) winches available on the T3W, along with two different
sizes of auxiliary winches which will be described later.
A regular program of preventive maintenance for the winch will minimize the need for
emergency servicing and insure long life and trouble free service. All service intervals are
specified for operating hours of the drill.
NOTICE
The service intervals that are suggested will optimize component service
life. The intervals may be gradually increased or decreased after gaining
experience with a particular lubricant and the recommendations of an
independent oil analysis.
The gear oil should be changed after the first 100 hours of operation, then every 1,000
operating hours or 6 months, whichever occurs first. The gear oil must be changed to remove
wear particles that impede the reliable and safe operation of the brake clutch and erode
bearings, gears and seals. Failure to change gear oil at these suggested minimum intervals
may contribute to intermittent brake slippage which could result in property damage, severe
Required lubricant for these (main) winches is Exxon Sparton 150 or equivalent AGMA 4EP
gear oil. Refer to Section 6-3 Refill Capacities/Lubricants/Fuels for further recommended oil
specifications.
! WARNING
winch.

! WARNING
Never lift or transport personnel with the winch. Do not use the winch in
any manner of operation which may endanger any individual.
! CAUTION
Stay at least 10 feet (3.048 m) away from cable while it is under tension.
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 anchor pocket and manually rotate
the drum in the direction to hoist a load until the drain holes are aligned.
5. Place a container with a capacity of at least 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 housing with Exxon Sparton 150 or
equivalent AGMA 4EP, ISO VG 150 gear oil through the fill hole until oil is level

with the bottom of the fill/level hole. 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 12K winch is 6 pints (2.8 liters). Refer to section
6.3 Refill Capacities/Lubricants/Fuel for further recommended oil
specifications.
10. Clean and install the fill/level plug.
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 replace it with a solid plug.
18K 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 anchor pocket and manually rotate
the drum in the direction to hoist a load until the drain holes are aligned.
5. Place a container with a capacity of at least 2 gallons (7.57 liters) under the
drain point to collect the used oil.
6. Use an Allen wrench to remove the fill and drain plug through the pipe.
7. Remove the drain plug, insert a suction drain tube and allow the oil to drain
9. To fill with oil, install a short piece of 1-inch pipe in the larger threads of the drain
hole. If necessary, insert a bar into the anchor pocket and manually rotate the
drum in the direction to hoist a load until the fill and drain port is in the 12:00
o’clock position.

10. Using a suitable hose or funnel, refill the housing with Exxon Sparton 150 or
equivalent AGMA 4EP, ISO VG 150 gear oil through the fill hole until oil is in
the middle 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 18K winch is 9 pints (4.2 liters). Refer to section
6.3 Refill Capacities/Lubricants/Fuel for further recommended oil
specifications.
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 replace it with a solid plug.
30K Winch

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 suitable container with a capacity
of at least 3 gallons (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.
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 AGMA 4EP, ISO VG 150 gear

oil through the drain/fill hole until oil is in the middle 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 liters). Install the plug securely after refilling gear
cavity. Refer to section 6.3 Refill Capacities/Lubricants/Fuel for further
recommended oil specifications.
6. Remove the vent relief plug located in the brake 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.
one hundred (100) hours of operation, then every five hundred (500) operating hours or six (6)
months, whichever occurs first.
John Bean Water Injection Pump

Change the initial water injection pump oil after the first 100 hours of operation. Thereafter,
water injection pump oil change maintenance must be carried out every 750 hours.
! WARNING


Change Initial Oil
1. Position the drill on a stable, level surface.

5. 18 gpm and 25 gpm Water Injection Pumps - Refill the oil through the oil 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.
6. 35 gpm Water Injection Pumps - Refill the oil through the oil fill port
(approximately 2 quarts 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.
7. Clean and install fill plug and level plug (35 gpm water injection pumps).
Feed Cable Clamps

Clamp Manufacturer Recommendation: “It is necessary to inspect the feed cable clamps for
wear and torque.”
Check the feed cable clamp bolts for torque verification after the first 100 working hours, at
250 working hours, and every 250 working hours after that.

Clamp Assembly Instruction and Adjustments
1. T3W Drills with 70K Feed System
a. 70K Drills use 7/8 inch feed cable clamps (#58062985) for both pullback
and pulldown cables. Torque to 225 ft·lb each.
2. T3W Drills with 40K Feed System
a. 40K Drills use 7/8 inch feed cable clamps (#58062985) for the pullback
cables only. Torque to 225 ft·lb each.
b. 40K Drills use 3/4 inch feed cable clamps (#56793599) for the pulldown
cables only. Torque to 130 ft·lb each.
Tightening torque values are based upon threads being clean, dry and free of lubrication.
1. Apply the first clamp as close to the thimble as possible.

2. Use calibrated torque wrench to tighten evenly. Alternate from one nut to the
other until reaching the above mentioned torques.
3. Apply the rest of the clamps evenly spaced, as shown. Follow the same
procedure for tightening.
4. Ensure that the last clamp is at least one base width from dead end of rope.
5. Upper cable clamp spacing may be adjusted to maintain adequate clearance
between clamps and traveling sheaves.
6. Use safety wire 2”(50.8 mm) wide to bind the dead end with the live rope.

General Information
! WARNING

drill.
Do not wear oil stained or damaged garments.
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
maintenance on the drill.
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.
crushing risk.
controls are at stop, neutral or off position.

Deck Engine Oil and Filter Change
! WARNING
NOTICE
Oil must be at normal operating temperatures when draining.
Do not drain the oil when the engine is cold. As oil cools, suspended waste particles settle on
the bottom of the oil pan.The waste particles are not removed with the draining cold oil. Drain
the crankcase with the engine stopped and the oil warm. This draining method allows the
waste particles that are suspended in the oil to be drained properly.
Failure to follow this recommended procedure will cause the waste particles being recirculated
through the engine lubrication system with the new oil. Refer to the OEM Engine Manual for
additional information.
Drain the Engine Oil
1. Position the drill on a stable, level surface and shut off engine. Wait at least 5
minutes after shutting off engine to drain the oil. This allows time for the oil to
drain into the oil pan.
2. Ensure oil is warm by viewing water temperature gauge. The temperature
should not exceed 140 °F (60 °C) before draining oil.
3. Place container, with a capacity of at least 20 gallons (75 liters), under the drain
point. Use one of the following methods to drain the engine crankcase oil.
a. If the engine is equipped with a drain valve, turn the drain valve
counterclockwise in order to drain the oil. After the oil has drained, turn the
drain valve knob clockwise in order to close the drain valve.
b. If the engine is not equipped with a drain valve, remove the oil drain plug in
order to allow the oil to drain. If the engine is equipped with a shallow sump,
remove the bottom oil drain plugs from both ends of the oil pan.
4. After the oil has drained, the oil drain plug(s) should be cleaned and installed.
5. Recycle or dispose of used oil in an environmentally responsible manner.

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 aluminum parts, brass parts or
bronze parts of the engine. Parts that may be affected include the following
items: main bearings, rod bearings, turbocharger bearings and cylinder heads.
Due to normal wear and friction, it is not uncommon to find small amounts of
debris in the oil filter. Consult your Caterpillar dealer 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.
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. Contaminated 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.

Fill the Engine Crankcase
1. Remove the oil filler cap. Refer to section 6-3 Refill Capacities / Lubricants /
Fuel for more information. Fill the crankcase with the proper amount of engine
oil.
NOTICE
Under filling or over filling the crankcase with oil can cause engine
damage.
NOTICE
To prevent crankcase bearing damage, crank the engine with the fuel
OFF. This will fill the oil filters before starting the engine. Do not crank the
engine for more than 30 seconds.
2. Start the engine and run the engine at LOW IDLE for two minutes. Perform this
procedure in order to ensure that the lubrication system has oil and that the oil
filters are filled. Inspect the oil filter for oil leaks.
3. Stop the engine and allow the oil to drain back to the sump for a minimum of
ten minutes.
4. Remove the oil level gauge in order to check the oil level. Maintain the oil level
between the ADD and FUL” marks on the oil level gauge.
Deck Engine Fuel System Filters
Replace Primary Filter (Water Separator) Element

Water in the fuel can cause the engine to run rough. Water in the fuel may cause an electronic
unit injector to fail. If the fuel has been contaminated with water, the element should be
changed before the regularly scheduled interval.
The primary filter/water separator also provides filtration in order to help extend the life of the
secondary fuel filter. The element should be changed regularly. If a vacuum gauge is installed,
the primary filter/water separator should be changed at 50 to 70 kPa (15 to 20 inches Hg).

Replace the Element
! WARNING

cause a fire.
1. Close the main fuel supply valve.

2. Remove element from the element mounting base while bowl is attached.
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 O-ring from the gland of the bowl. Clean the following components:
bowl, O-ring and Mounting Base. Inspect the O-ring for damage and for
deterioration. Replace the O-ring, if necessary.
5. Lubricate the O-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 diesel 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 engine 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.
Replace Fuel System Secondary Filter
! WARNING

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 immediately.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly clean the area
around a fuel system component that will be disconnected. Fit a suitable
cover over any disconnected fuel system components.
NOTICE
Use a suitable container to catch any fuel that might spill. Clean up any
spilled fuel immediately.
1. Stop the engine. Turn the ignition switch to the OFF position or disconnect the
battery. Refer to the Engine OEM Operation and Maintenance Manual “Battery
or Battery Cable - Disconnect” topic (Maintenance Section) for more
information. Shut off the fuel supply valve (if equipped).
2. It may be necessary to relieve residual fuel pressure from the fuel system

before the fuel filter is removed. Wait for one to five minutes until the fuel
pressure has lowered. Use a suitable container in order to catch any fuel that
may spill.
3. Remove the used fuel filter and discard the used fuel filter.
4. Clean the gasket sealing surface of the fuel filter base. Ensure that all of the old
gasket is removed.
5. Apply clean diesel fuel to the new filter gasket.
NOTICE
Do not fill the secondary fuel filter with fuel before installing. The fuel
would not be filtered and could be contaminated. Contaminated fuel will
cause accelerated wear to fuel system parts.
NOTICE
In order to maximize fuel system life and prevent premature wear out from
abrasive particles in the fuel, a two micron high efficiency fuel filter is
required for all Caterpillar Electronic Unit Injectors.
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 engine will need to be purged of air. Refer to
the Engine OEM Operation and Maintenance Manual, Fuel System - Prime
topic (Maintenance Section) for more information.
Cooling System Coolant Sample
NOTICE
Obtain a Coolant Sample (Level 1) if the coolant 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/Coolant).
3. Commercial heavy-duty coolant/antifreeze.

Table 33: 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 meet the CAT EC-1 specification
for engine coolant.
2. The Level 2 Coolant Analysis should be performed sooner if a problem is
suspected or identified. Refer to Level 1 Sample 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 contaminate may cause a false analysis and an incorrect
interpretation that could lead to concerns by both dealers and customers.
NOTE: Note: Level 1 results may indicate a need for Level 2 Analysis.
Obtain the sample of the coolant as close as possible to the recommended sampling interval.
In order to receive the full effect of S-O-S analysis, you must establish a consistent trend of
data. In order to establish a pertinent history of data, perform consistent samplings that are
evenly spaced.
Use the following guidelines for proper sampling of the coolant:
1. Complete the information on the label for the sampling bottle before you begin
to take the sample.
2. Obtain coolant samples directly from the coolant sample port. You should not
obtain the samples from any other location.
3. Keep the lids on empty sampling bottles until you are ready to collect the
sample.
4. Place the sample in the mailing tube immediately after obtaining the sample in
order to avoid contamination.
5. Never collect samples from expansion bottles.
6. Never collect samples from the drain for a system.

7. Submit the sample for Level 1 analysis (or Level 2 analysis if necessary).
For additional information about coolant analysis, refer to the engine OEM Operation and
Maintenance Manual, Refill Capacities and Recommendations topic or consult your Caterpillar
dealer.
Cooling System Supplemental Coolant Additive (SCA)

This maintenance procedure is required for conventional coolants such as DEAC and for
mixtures of water and SCA. This maintenance is not required for cooling systems that are
filled with Caterpillar Extended Life Coolant (ELC).
! WARNING
Cooling system coolant additive contains alkali. To help prevent personal

injury, avoid contact with the skin and eyes. Do not drink cooling system
coolant additive.
Note: Caterpillar recommends an S-O-S coolant analysis (Level 1).
Coolant/Antifreeze and SCA
NOTICE
Do not exceed the recommended six percent supplemental coolant

additive concentration.
Test the concentration of the SCA with the Cat 8T-5296 Coolant Conditioner Test Kit.
Water and SCA
NOTICE
Do not exceed the recommended eight percent supplemental coolant

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 coolant.

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 order 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 INDICATOR SOLUTION B to the mixing bottle.
Move the bottle in a circular motion in order to mix the solution.
5. Add 1 drop of NITRITE TEST SOLUTION 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 results.
Table 34: Test Results
Number of
Concentration of SCA Maintenance Required
Drops
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
! 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.
NOTE: Always dispose of fluids according to local regulations.
2. If necessary, drain some coolant in order to allow space for the addition of the
SCA.

NOTICE
Excessive supplemental coolant additive concentration can form

deposits on the higher temperature surfaces of the cooling system,
reducing the engine’s heat transfer characteristics. Reduced heat
transfer could cause cracking of the cylinder head and other high
temperature components.
Excessive supplemental coolant additive concentration could also result

in blockage of the heat exchanger, overheating, and/or accelerated wear
of the water pump seal.
Do not exceed the recommended amount of supplemental coolant

3. Add the proper amount of SCA. For the proper amount of SCA, refer to the
engine OEM Operation and Maintenance Manual, Refill Capacities and
Recommendations topic. The proper concentration of SCA depends on the
type of coolant that is used. For the proper concentration of SCA, refer to the
engine OEM Operation and Maintenance manual, Refill Capacities and
Recommendations topic or consult your Caterpillar dealer.
4. Clean the cooling system filler cap. Install the cooling system filler cap.
Engine Belts (Inspection)

Inspect the alternator belt (deck engine and truck engine) and fan drive belts (truck engine) for
wear and for cracking. Replace the belts if the belts are not in good condition.
Check the belt tension according to the information in the engine OEM Service Manual,
Specifications.
Slippage of loose belts can reduce the efficiency of the driven components. Vibration of loose
belts can cause unnecessary wear on the following components:
1. Belts
2. Pulleys
3. Bearings
If the belts are too tight, unnecessary stress is placed on the components. This reduces the
service life of the components.
Engine Belts (Replacement)

For applications that require multiple drive belts, replace the drive belts in matched sets.
Replacing one drive belt of a matched set will cause the new drive belt to carry more load
because the older drive belts are stretched. The additional load on the new drive belt could
cause the new drive belt to fail.

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 tension 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 tension.
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 tension again after 30
minutes of engine operation at the rated rpm.
Truck Maintenance
Truck Engine
Refer to the actual manufacturer’s service and maintenance manuals for specific information
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 manual for the correct
procedure to perform this maintenance.
2. Change the engine oil filter(s) when changing the engine oil. Follow engine
manufacturer’s recommendations.
3. Change the fuel filter(s) when changing the engine 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 engine manual.
6. Check the engine belt(s) tension at this time. Refer to the engine manual.
Truck Transmission
on maintenance for the truck transmission.
1. Check the truck transmission oil level every 250 operating hours. Add oil if
necessary. Refer to the actual manufacturer’s service manual for the procedure
and for the type of transmission fluid used in your vehicle.
Truck Power Steering

on maintenance for the truck power steering system.
1. Check the truck power steering fluid level every 250 operating hours. Add oil id
necessary. Refer to the actual manufacturer’s service manual for the procedure
and for the type of power steering fluid used in your vehicle.
Truck Differentials
maintenance for the truck differentials.
1. Check the gear oil level in the truck differentials every 250 operating hours. Fill
to oil level plug if needed. Refer to the actual manufacturer’s service manual for
the procedure and for the type of gear oil used in the differentials.
Drive Lines and U-Joints

To insure proper lubrication of all bearing assemblies on the truck universal joints, it is
essential that the lubricant be added until it appears at all journal cross bearing seals.
! WARNING
Shut down engine and remove ignition key from ignition switch. Rotating
shaft can cause severe injury or death. Do not operate with the guard
removed.
NOTE: Do not assume that the bearing cavities have been filled with
lubricant unless flow is noticed around all bearing seals.
1. Apply grease gun pressure to lubrication fitting until fresh grease appears at the

pressure relief hole in the welch plug at the sleeve end of the spline. When
grease appears, cover the pressure relief hole with finger and continue to apply
pressure until fresh grease appears at the sleeve yoke seal.
Compressor Air Hose and Clamps

Two types of hose couplings are used on the air hoses. A maintenance inspection must be
performed every 250 operating hours or monthly, whichever occurs first, on both types of
coupling clamps.
Dixon Hose Couplings (Boss Clamps)
1. Periodic Coupling (clamping) bolts tightening is necessary due to “Cold-Flow”

present in all rubber hoses. Tighten to recommended torque value listed on
BOSS CLAMPS chart in Section 7 Dixon Boss Clamps Selection and
Installation instructions.
2. Examine and change out worn air hoses and weakened Boss clamps. If hoses
are to be changed out, change the Boss clamps also. Boss clamps hold the

hose connections under a large amount of pressure. Boss clamps (including

nuts and bolts) are for single use only. Do not reuse. Once removed, discard.
Refer to the Dixon Boss Clamp Selection and Installation instructions shown in Section 7 for
the proper way to select and install Dixon Hose Couplings (Boss Clamps).
Victaulic Hose Couplings
1. Always inspect each joint to ensure that the hose couplings are properly
installed. Undersized or oversized fittings, shallow grooves, eccentric grooves,
bolt pad gaps, etc. are unacceptable.
2. Hose couplings must be properly assembled with the bolt pads in firm, metal-
to-metal contact.
3. The housing’s keys must be fully engaged in both grooves.
4. The gasket must be slightly compressed, which adds to the strength of the seal.
Refer to the HNBR Hose/Victaulic Coupling Installation instructions shown in Section 7 for
further information regarding Victaulic Hose Couplings.

General Information
! WARNING

drill.
crushing risk.

Hydraulic Reservoir
Atlas Copco recommends including a hydraulic fluid sample test as part of every 500 hour
routine maintenance program. When hydraulic fluid has reached maximum service life based
on regular sampling, testing and recording fluid characteristics, the fluid must be changed.
Follow the procedure below to sample the hydraulic oil.
NOTICE

clean, contaminant free system is extremely important to the machine’s
system to ensure its cleanliness.
! WARNING
Oil must be at normal operating temperature when draining. Hot oil or

components can burn. Avoid contact with hot oil or components.
1. Obtain the appropriate fluid sampling materials.

2. The engine must be off.
3. The hydraulic fluid temperature must be below 120 °F (48.8 °C).
4. The sample must come from the drain manifold.
5. Send the sample to an approved laboratory for analysis.
6. Record the laboratory results for determination of action or for trending data.
Hydraulic Fluid Condition Limits

The following is for mineral based and synthetic fluids, excluding automatic transmission
fluids. Sample fluid from the return manifold every 500 operating hours. Change the fluid if any
of the following conditions occur:
1. Viscosity increases by 16% or decreases by 10% (compared to new fluid)*.

2. Total Acid Number (TAN) increases by 2.5 or more (compared to new fluid)*.
3. Water content exceeds 0.1% (1,000 ppm).
4. The fluid becomes contaminated with any other unfiltered contaminant such as
glycol, fuel, etc.
* Oxidation of the fluid is usually indicated by an increase in viscosity and an

increase in TAN. If the fluid shows a TAN increase of 2.5 or more, and
especially if it corresponds to a viscosity increase of over 16%, the hydraulic
fluid should be changed.
Notes:
a. High concentrations of soluble metals as indicated by a spectrochemical

analysis do not necessarily indicate a deterioration of the fluid.
b. A high particle count does not necessarily indicate deterioration of the fluid.
A filter bypass alarm or particle count exceeding ISO 18/15 indicates the
need for a filter change.
Compressor
The following compressor system maintenance must be carried out as part of the 500 hour
routine maintenance schedule.
! WARNING
Hot compressor oil or components can burn. Avoid contact with hot oil
or components. Do not allow used compressor oil to drain into the
ground. Dispose of used compressor oil properly.
! WARNING
Do not attempt to remove any plugs or open the drain valve before
making sure all air pressure has been relieved from the compressor
system.
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 pieces and parts of the thermostat, that
could damage the pump. The metal strainer should be removed, cleaned and reinstalled every
500 hours.

1 Compressor oil strainer
2 Compressor oil filters
1. Thoroughly clean the entire area around the compressor oil strainer.
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 Filters

The following compressor oil filter maintenance must be carried out as part of the 500 hour
routine maintenance schedule.
1 Compressor oil strainer
2 Compressor oil filters

! WARNING
Hot compressor oil or components can burn. Avoid contact with hot
compressor oil or components. Do not let used oil drain into the ground.
Dispose of properly.
1. Thoroughly clean and wipe all the external dirt and oil from the filter housing
and the head area to minimize contamination from entering the system.
2. Place a container under the oil filters to collect any oil escaping during filter
removal and to prevent any oil spill from contaminating the ground.
3. Unscrew the used filters using a filter wrench. Discard the used filters in
accordance with local guidelines.
4. Clean the sealing surface of the filter mounting base. Make sure the entire old
gasket is removed.
5. Fill the new filters with clean compressor oil and lubricate the o-ring seal with
clean oil.
6. Screw the new oil filters on until the gasket contacts the base. Tighten the filters
3/4 of a turn more by hand. Do not over tighten. Use the rotation index marks,
on the filters, as a guide for proper tightening.
7. After startup, check the oil filters for any leaks at operating temperatures.
Pump Drive Gearbox

The type of service and the operating conditions will determine the maintenance interval.
However, it is recommended that the pump drive gearbox oil be changed after the first 50
hours of operation, then at every 1,000 operating hours. Because the lubricant system is the
heart of the unit, it is especially important that the oil be kept clean.
! WARNING
components. Oil must be at normal operating temperature when draining.
Do not allow used oil to drain into the ground. Dispose of properly.
NOTE: The oil in the pump drive gearbox should be changed whenever
the oil shows traces of dirt or the effects of high temperature, evidenced
by discoloration or strong odor.

Change Pump Drive Gearbox Oil
1. Move the drill to a stable, level surface and shut off the engine.
2. Place a container with a capacity of at least 2 gallons (7.5 liters) 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 metal 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. Install the drain plug.
8. Refill the pump drive gearbox through the breather/fill port with SAE80W90
gear oil until the oil level reaches the full mark on the dipstick (approximately
1.125 gallons/4.25 liters). Do not over fill. This will result in the overheating
and possible malfunction 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 thereafter.

! WARNING

1. Position the drill on stable, level surface.

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.
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.

! WARNING

1. Position the drill on stable, level surface.

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 quarts 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).
Main Winch
There are three different sizes of (main) winches available on the T3W. The main winch oil
level should be checked every 500 hours or 3 months of operation, whichever comes first.

12K Winch

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.
18K Winch

3. To check the oil level, view the oil level sight glass located in the center on the
non-motor end of the drum. Maintain the lubricant level in the gear housing to
the middle of the oil level sight glass. 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.

30K Winch

3. To check the oil level, view the oil level sight glass located in the motor end of
the drum. Maintain the lubricant level in the gear housing to the middle of the
oil level sight glass. 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.
Mounting Bolts
Tighten all winch base mounting bolts to recommended torque after the first 100 hours of
operation, then every 500 operating hours or 3 months of operation, whichever comes first.
Refer to 6-14 Torque Specifications.
Cable/Rope Corrosion Lubricant

Corrosion protection of the wire rope and cable should be included in the maintenance
schedule. Cables should be cleaned with a wire brush and solvent and coated with corrosion
protection 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 Manufacturing Company)
The corrosion protection 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 available 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.
! WARNING
winch.
4K Winch (PL5)
The instruction for changing the lubricating oil in the 4K winch are shown in Section 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,
Maintenance (50 Hours or Weekly).
Mounting Bolts
operation, then every 500 operating hours or 6 months, whichever occurs first.

6-10 MAINTENANCE (1,000 Hours)
General Information
! WARNING

drill.
crushing risk.

Receiver Tank
Under normal operating conditions, the compressor oil must be changed every 1000 hours as
part of a routine maintenance program.
! DANGER
opening drain valve, removing filler plug, fittings or receiver cover.
! 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.
2 Oil fill
3 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 gallons (151 liters) 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 gallons (107.9 liters). See Section 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
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
Section Refill Capacities/Lubricants/Fuel Specifications.
NOTICE

clean contaminant free system is extremely important to the machine’s
Hydraulic Oil Filters

It is important to monitor the Filter Bypass Indicator Light, located on the upper operator
console panel under the Emergency Engine Shutdown button, during drilling operations.
When the filter bypass indicator light is on, the return filter elements require replacement.
Under normal operating conditions, these filters are replaced whenever the hydraulic oil is
changed or at the regular 1000 hour service interval.

There are three hydraulic return oil filters and one hydraulic case drain oil filter on the drill.
The system main return filters are in-tank filters located in the hydraulic tank and available for
servicing at the top of the tank. The main return flow to the tank passes through these filters
and into the hydraulic tank.
The case drain filter is located on the side of the hydraulic tank next to the hydraulic oil fill hand
pump and filters case drain oil prior to return into the hydraulic tank.
! WARNING
Do not attempt to service the filters before making sure all the hydraulic
pressure has been relieved from the system.
NOTICE
Care must be taken to ensure that fluids are contained during any
inspection or work that is performed on these components. Follow all
local and federal regulations concerning the handling of hydraulic fluid.
Main Return Filters

When the filter bypass light indicates that element servicing is required, or when the regular
1,000 hour service interval is reached, proceed in the following manner.
1 Hydraulic tank main return

filters
1. Make sure that a container is provided to put the dirty filter elements in. Do not
allow used oil to drain into the ground.
2. Remove the six bolts and lock washers from the three return filters top covers
and carefully remove each cover and bypass valve located under each cover.
3. Lift the elements out and away from the housing quickly. Do not allow dirty oil
from the filter elements to drain from the element into the housing.
4. Make sure all of the old gasket seal is retained in the element and removed
from the filter housing.
5. Inspect the new filter and gaskets for damage. Do not use a damaged filter.

Inspect o-rings for serviceable condition. If damaged, replace O-rings.

6. Install new filter elements and the bypass valves.
7. Replace the covers and install the bolts.
8. Replace all hydraulic oil filters every time the hydraulic oil is changed.
9. Operate the drill and check for leaks.
Case Drain Filter

The case drain filter is located on the side of the hydraulic tank next to the hydraulic oil fill hand
pump. When the filter bypass light indicates that filter element servicing is required, or when
the regular 1,000 hour service interval is reached, proceed in the following manner:
1 Hydraulic hand pump
2 Hydraulic sight glass
3 Hydraulic case drain filter
4 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 components. Do not allow used oil
to drain into the ground. Dispose of used oil properly.
2. Wipe all the external dirt and oil from the filter housing and the head area to
minimize contamination from entering the system.
3. Place a container under the oil filter to prevent any oil spill from contaminating
the ground.
4. Carefully remove the spin-on filter by turning the filter housing in a counter
clockwise direction.

5. Empty the oil from the filter housing into a drain container. Remove element
6. Discard the old element in accordance with any local guidelines.
7. Clean the filter housing and filter head with an approved cleaning solvent.
8. Lubricate the new filter gasket with clean, fresh oil and install the new filter onto
the filter head.
9. Turn the filter in a clockwise direction to tighten. Hand tighten and follow the
tightening instructions on the filter.
10. Pressurize the hydraulic system and check for leaks.
11. Check the oil level in the hydraulic reservoir and add oil if necessary following
the procedures previously mentioned.
Hydraulic Tank Breather

The hydraulic tank pressurized breather filter/relief valve should be kept clean. It must not
become plugged or saturated with oil.
1. Thoroughly clean the area around the hydraulic tank breather filter to prevent
dirt from entering the breather filter port.
2. Remove the breather filter from the hydraulic tank port. Until the breather filter
is installed, cover the breather port to ensure that no contamination can get into
the tank housing.
1 Pressurized breather filter,

relief valve, 40-micron
3. Clean and install or replace and install the breather filter into the breather tank
port and tighten firmly by hand.
Rotary Tophead
Change the rotary tophead oil as part of the 1,000 hour routine maintenance schedule.

! WARNING
Riding the rotary head can cause severe injury or death. Do not ride the
rotary head.
! WARNING
Climbing a raised tower can cause severe injury or death. Do not climb
raised tower.
! WARNING
A falling tower can cause severe injury or death. Make sure all locking
pins are in a locked position.
! WARNING
Rotating shafts or a rotating drill string can cause severe injury or death.
Do not service the rotary head with the drill string in motion.

Rotary Tophead Oil
1 Sight level gauge
2 Filler/breather
3 Drain plug - Remove 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 tower.
2. If necessary, remove the drill pipe in the rotary tophead and lower the rotary
tophead to the bottom of the tower.
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.
5. Place a container with a capacity of at least 2 gallon (7.5 liters) under the rotary
tophead drain point.
! CAUTION
Take care to prevent any contamination from entering the fill port.
6. Clean around the breather/fill port area to prevent debris from entering the
rotary tophead housing during the oil change.
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 housing 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 80W90 gear oil until
the fluid is in the center of the fluid level sight glass (about 3 quarts/2.8 liters).
11. Clean and install the fill plug.
12. After startup, check the rotary head for any leaks while at operating
temperature.
Pump Drive Gearbox

It is recommended that the pump drive gearbox oil be changed as part of the 1,000 hour
routine maintenance schedule. Because the lubricant system is the heart of the unit, it is
especially important that the oil be kept clean. NOTE: The oil in the pump drive gearbox
should be changed whenever the oil shows traces of dirt or the effects of high
temperature, evidenced by discoloration or strong odor.
Follow the instructions previously shown under Maintenance (500 Hours).
Main Winch
A regular program of preventive maintenance for the winch and sand reel will minimize the
need for emergency servicing and insure long life and trouble free service. All service intervals
are specified for operating hours of the drill.
The gear oil should be changed after the first 100 hours of operation, then every 1,000
operating hours or 6 months, whichever occurs first. The gear oil must be changed to remove
wear particles that impede the reliable and safe operation of the brake clutch and erode
bearings, gears and seals. Failure to change gear oil at these suggested minimum intervals
may contribute to intermittent brake slippage which could result in property damage, severe

Refer to Maintenance (100 Hours) for the procedure and instructions to change oil in the winch
and sand reel.
Mounting Bolts
operation, then every 1,000 operating hours or 6 months, whichever occurs first.
Table 35: Winch Mounting Bolt Torque
Thread Condition Torque

Dry Thread 205 to 220 ft·lb (278 to 280 N·m)
Lubed Thread 158 to 170 ft·lb (214 to 230.5 N·m)

The following water injection pump maintenance must be carried out as part of the 500 hour
routine maintenance schedule and every 1,000 hours thereafter.
Refer to Maintenance (500 Hours) for the procedure and instructions to change oil in the water
injection pump.
Carousel
Carousel Gearbox
Change the carousel gearbox oil every 1,000 operating hours. Follow the instructions shown
below.
1. Move the drill to a stable, level surface. Raise the tower and pin it in the vertical
position.
2. Operate the carousel to warm the gearbox.
3. Lower the tower to the horizontal position. Shut off the engine.

4. Place a container with a capacity of at least 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.

General Information
! WARNING

drill.
Always wear the correct safety gear while working on or around the drill. This includes an
crushing risk.

Engine
Engine Valves
Refer to the manufacturer 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.
! 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.

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 2,000 hours.
1. Park the drill on stable, level surface and shut down engine. Allow time for the
drill to cool.
! WARNING
opening the drain valve or removing the filler plug, fittings or removing
the receiver cover.
! WARNING
components.

2. Relieve all air pressure in receiver tank.
1 Cover
2 Separator element
3 Vertical receiver tank
3. Remove bolts from cover of the receiver tank, then remove the cover.
4. Pull the separator element from the tank.
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 and hose coupling clamps between the compressor and
the receiver tank should be replaced every 2 compressor oil changes or once every 2,000
hours, whichever 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.

General Information
! WARNING

drill.
Always wear the correct safety gear while working on or around the drill. This includes an
crushing risk.

Engine Coolant
The coolant system of any engine should be drained and flushed out after 3,000 operating
hours or 2 years of service. Unless the coolant has a corrosion preventive in it, rust and scale
will eventually clog up the system. Any effective commercial flushing agent should be used at
least once or twice a year to ensure against buildup.
Clean the cooling system and flush the cooling system 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 coolant 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 system 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 system cleaners that are approved for
Cummins engines. Contact your nearest Cummins dealer or refer to your
Cummins Operation and Maintenance manual for specifics.
NOTE: Inspect the water pump and the water temperature regulator after
the cooling system has been drained. This is a good opportunity to
replace the water pump, the water temperature regulator, thermostat and
the hoses if necessary.
! WARNING
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.

skin and eyes. Avoid all contact with steam or escaping fluid.
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.
4. Loosen the cooling system filler cap slowly in order to relieve any pressure.
Remove the cooling system filler cap when draining the system to ensure
proper draining.
5. Open the drain valve and allow the radiator coolant to drain into the container.
At the same time, drain the engine block. Remove the drain plug from the water
pump housing if required. Refer to the engine manufacturer Service and
Maintenance manuals for the recommended procedures.
NOTICE
Engine coolant must be disposed of in a responsible manner. Please

consult the local environmental agency for recommended disposal
guidelines.
Flush Cooling System
1. Flush the cooling system with clean water in order to remove any debris.
NOTICE
Any debris or contamination in the cooling system will seriously risk

damage to the components being cooled. The cooling system must be
free of debris and contamination.
NOTE: Refer to the engine manufacturer Service and Maintenance

manuals for recommended flushing procedures
2. Clean and install the drain plugs and/or close the drain valves.

Fill the Cooling System
1. Refill the radiator with a 50-50 mixture of the engine manufacturer’s

recommended antifreeze and quality water. Install the correct coolant filter (if
required).
2. When refilling the cooling system, refer to the engine manufacturer Operation
and Maintenance instruction manual.

Hydraulic Reservoir
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 Refill Capacities/Lubricants/Fuel Specifications.
NOTICE

clean contaminant free system is extremely important to the machine’s
Change Hydraulic Oil

Change the hydraulic tank oil (and filters) after any major hydraulic system repair. Also, when
hydraulic fluid has reached maximum service life based on regular sampling, testing and
recording fluid characteristics, the fluid must be changed. If the hydraulic oil has not been
changed before 5,000 operating hours or three years, whichever comes first, change the
hydraulic oil (and filters).
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.
! WARNING
Hydraulic oil must be at normal operating temperature when draining. Hot

oil or components can burn. Avoid contact with hot oil or components.

3. Ensure that a container with a capacity of at least 100 gallons (378.5 liters) is
placed under the drain point to collect used oil. Do not allow used oil to drain
into the ground.
4. Remove the six bolts and lock washers from the three return filters’ top covers
and carefully remove each cover and bypass valve located under each cover.
5. Lift the elements out and away from the housing quickly. Do not allow dirty oil
from the filter elements to drain from the element into the housing.
6. Make sure all of the old gasket seal is retained in the element and removed
7. Now open the drain valve located under the hydraulic tank and allow the oil to
drain from the hydraulic tank.
8. Close the drain valve.
9. Dispose of the used oil in accordance with local guidelines.
10. Inspect the new filter and gaskets for damage. Do not use a damaged filter.
Inspect o-rings for serviceable condition. If damaged, 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.
NOTE: Any contamination entering the hydraulic 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 hydraulic supply (drum, tank, etc.).
15. Start pumping and refill the tank with clean, filtered 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 Refill Capacities/Lubricants/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 gauge:
a. The oil level with all cylinders retracted (tower down and leveling jacks up)
should be even with the mark on the hydraulic reservoir 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 showing on the gauge at all
times. Add oil to bring to levels defined above.
18. After completing all scheduled service (hydraulic oil change and changing all
in-tank return filters), start the engine and check for leaks.
19. During operation, monitor the hydraulic oil level sight gauge and hydraulic
temperature gauge located on the side of the hydraulic oil reservoir.

NOTE: If no oil is showing on the oil level gauge, stop the engine
immediately and call for service assistance to investigate the cause of oil
loss.

6-14 Torque Specifications

Bolt Head Markings
Fasteners should be replaced with the same grade or a higher grade. If higher grade fasteners
are used, these should only be tightened to the strength of the original grade fastener.
The head of Grade 5 bolts are marked with three short lines. The head of a Grade 8 bolts are
marked with six short lines.
Figure 6-1: SAE Bolt Head Markings
Grade 5
Grade 8
Figure 6-2: Metric Bolt Head Markings
Do not use these values if a different torque value or tightening procedure is listed for a specific
application. Torque values listed are for general use only. All values are suggested maximum
with dry plated hardware.
NOTE: 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 torques for the various size bolts used
by Drilling Solutions. Proper torque specifications should be used at all times.
NOTE: 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 hydraulic lock giving a false torque reading.
Suggested Torque for SAE Bolts

The following tables list suggested assembly torque values for SAE Grade 5 and Grade 8 bolts
in ft·lb and N·m .
Table 36: Suggested Torque in ft·lb for SAE Bolts
SAE Grade 5 Tightening SAE Grade 8 Tightening

Torque Torque
Size
Dry Lube Dry Lube
1/4 - 20 NC 8 6 12 9
1/4 - 28 NF 10 7 14 10
5/16 - 18 NC 17 13 25 18
5/16 - 24 NF 19 14 25 20
3/8 - 16 NC 30 23 45 35
3/8 - 24 NF 35 25 50 35
7/16 - 14 NC 50 35 70 55
7/16 - 20 NF 55 40 80 60
1/2 - 13 NC 75 55 110 80
1/2 - 20 NF 90 65 120 90
9/16 - 12 NC 110 80 150 110

9/16 - 18 NF 120 90 170 130
5/8 - 11 NC 150 110 220 170

5/8 - 18 NF 180 130 240 180
3/4 - 10 NC 260 200 380 280

3/4 - 16 NF 300 220 420 320
7/8 - 9NC 430 320 600 460

7/8 - 14 NF 470 360 660 500
1 - 8 NC 640 480 900 680

1 - 12 NF 710 530 1,000 740
1-1/8 - 7 NC 800 600 1,280 960

1-1/8 -12 NF 880 660 1,440 1,080

Table 36: Suggested Torque in ft·lb for SAE Bolts (Continued)

Torque Torque
Size
Dry Lube Dry Lube
1-1/4 - 7 NC 1,120 840 1,820 1,100
1-1/4 - 12 NF 1,240 920 2,000 1,500
1-3/8 - 6 NC 1,460 1,100 2,380 1,780

1-3/8 - 12NF 1,680 1,260 2,720 2,040
1-1/2 - 6 NC 1,940 1,460 3,160 2,360

1-1/2 - 12 NF 2,200 1,640 3,560 2,660
Table 37: Suggested Torque in Nm for SAE Bolts

Torque Torque
Size
Dry Lube Dry Lube
1/4 - 20 NC 11 8 16 12
1/4 - 28 NF 14 9 19 14
5/16 - 18 NC 23 18 34 24
5/16 - 24 NF 26 19 34 27
3/8 - 16 NC 41 31 61 47
3/8 - 24 NF 47 34 68 47
7/16 - 14 NC 68 47 95 75
7/16 - 20 NF 75 54 108 81
1/2 - 13 NC 102 75 149 108

1/2 - 20 NF 122 88 163 122
9/16 - 12 NC 149 108 203 149

9/16 - 18 NF 163 122 230 176
5/8 - 11 NC 203 149 298 230

5/8 - 18 NF 244 176 325 244
3/4 - 10 NC 353 271 515 380

3/4 - 16 NF 407 298 569 434
7/8 - 9NC 583 434 813 624

7/8 - 14 NF 637 488 895 678
1 - 8 NC 868 651 1,220 922

1 - 12 NF 963 719 1,356 1,003

Table 37: Suggested Torque in Nm for SAE Bolts (Continued)

Torque Torque
Size
Dry Lube Dry Lube
1-1/8 - 7 NC 1,085 813 1,735 1,302
1-1/8 -12 NF 1,193 895 1,952 1,464
1-1/4 - 7 NC 1,519 1,139 2,468 1,491

1-1/4 - 12 NF 1,681 1,247 2,712 2,034
1-3/8 - 6 NC 1,979 1,491 3,227 2,413

1-3/8 - 12NF 2,278 1,708 3,688 2,766
1-1/2 - 6 NC 2,630 1,979 4,284 3,200

1-1/2 - 12 NF 2,983 2,224 4,827 3,606
Suggested Torque for Metric Bolts

The following tables list suggested assembly torque values for Metric bolts in ft·lb and N·m.
Table 38: Suggested Torque in ft·lb for Metric Bolts
Class 12.9 (Socket

Class 8.8 Class 10.9
Head Cap Screw)
Size
Dry Lube Dry Lube Dry Lube
M6x1 8 6 11 8 13 9
M8x1.25 19 15 27 20 31 23
M8x1 21 16 29 22 — —
M10x1.5 39 29 53 40 62 47
M10x1.25 41 30 56 42 — —
M12x1.75 67 50 93 70 108 81
M12x1.25 73 55 101 76 — —
M14x2 107 80 148 111 173 130
M14x1.5 116 87 161 121 — —
M16x2 167 125 231 173 269 202
M16x1.5 177 133 245 184 — —
M20x2.5 325 244 450 337 525 394

Table 38: Suggested Torque in ft·lb for Metric Bolts (Continued)
Class 12.9 (Socket

Head Cap Screw)
Size
M20x1.5 361 271 500 375 — —
M24x3 562 422 778 583 908 681
M24x2 612 459 846 635 — —
M30x3.5 1,117 838 1,545 1,159 1,804 1,353
M30x2 1,237 928 1,711 1,283 — —
M36x4 1,952 1,464 2,701 2,026 3,154 2,366
M36x2 2,187 1,640 3,025 2,269 — —
M42x4.5 3,123 2,342 4,320 3,240 — —
M42x2 3,513 2,635 4,860 3,645 — —
M48x5 4,684 3,513 6,479 4,860 — —
M48x2 5,321 3,991 7,361 5,521 — —
Table 39: Suggested Torque in N·m for Metric Bolts
Class 12.9 (Socket

Head Cap Screw)
Size
M6x1 11 8 15 11 17 13
M8x1.25 26 20 37 27 42 32
M8x1 28 22 39 30 — —
M10x1.5 53 39 72 54 84 64
M10x1.25 56 41 76 60 — —
M12x1.75 91 68 126 95 146 110
M12x1.25 99 75 137 103 — —
M14x2 145 108 201 150 234 176
M14x1.5 157 118 218 164 — —
M16x2 226 169 313 235 365 274

Table 39: Suggested Torque in N·m for Metric Bolts (Continued)
Class 12.9 (Socket

Head Cap Screw)
Size
M16x1.5 240 180 332 249 — —
M20x2.5 440 331 610 457 712 534
M20x1.5 489 267 678 508 — —
M24x3 762 572 1,055 780 1,231 923
M24x2 830 622 1,147 861 — —
M30x3.5 1,514 1,136 2,095 1,571 2,446 1,834
M30x2 1,677 1,258 2,320 1,740 — —
M36x4 2,647 1,985 3,662 2,747 4,276 3,208
M36x2 2,965 2,223 4,101 3,076 — —
M42x4.5 4,232 3,175 5,857 4,393 — —
M42x2 4,763 3,573 6,589 4,942 — —
M48x5 6,351 4,763 8,784 6,889 — —
M48x2 7,214 5,411 9,980 7,485 — —

6-15 MAINTENANCE (40 RM Swivel)
40 RM Swivel

Swivel Information
Table 40: Technical Data
Static Load Capacity 140,000 lb (63,504 kg)

Rotating Load Capacity (100 rpm) 71,000 lb (32,205.6 kg)
Pulldown Load Capacity 22,000 lb (9,979.2 kg)
Hose Connection 3 in NPT Female
Lower Connection 3-1/2 in IF LH Pin (mod.) 3 in ID.
Fluid Passage Full 3 in
Bearings Lubrication (NLG2 Grease) (5) Angular Ball
Packing Lubrication (NLG2 Grease) Chevron V-Ring
Standard (416) Chevron Working Pressure 50 to 500 psi (3.45 to 24.5 bar)
Optional (417) Chevron Working Pressure 125 to 1,500 psi (8.63 to 103.5 bar)
Optional Rubber Ring 25 to 350 psi (1.73 to 24.15 bar)
Operation
The 40RM swivel is designed for use on the T3W Water Well drill.
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.

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 or three
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 40RM 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.

5. Loosen the #11 squarehead set screw located on the side of the gooseneck.
Unscrew about three or four 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 O-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. NOTE: 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 O-rings from the #9 packing gland.
8. Remove the #3 O-ring from the top of the #7 packing box.
9. Clean and inspect all parts. Never re-use packing and/or O-rings. Replace
all worn or damaged items.
Assemble the Packing Assembly
1. Install #5 O-ring in the #9 packing gland.

2. Install the #9 packing gland into #7 packing box with the top #3 O-ring groove
up.
3. Turn the #7 packing box over (#9 packing gland down) and install the five #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 O-ring and #4 packing gland O-ring.

9. Install the #16 washpipe O-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. NOTE: 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

Major repair should only be done with the swivel removed from the drill and in a safe work area.
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 #1 bolts with washers.
4. Remove the four #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. NOTE: This is a left
hand thread.
8. Remove the #19 retainer wire from the #23 bearing housing.
9. Slide the #23 bearing housing off the #22 bearings and remove. The #23
bearing housing should slide in a downward motion towards the 3-1/2 inch IF
LH pin tool joint.
10. Remove the four #25 set screws from the lower connection.
11. Secure the #28 lower connection and break the #21 bearing spindle loose. Do
not unscrew more than two to three threads.
12. Stand this assembly up (washpipe face on flat surface) and finish unscrewing
the #28 lower connection. Remove the lower connection.
13. Remove the #27 spindle thread seal from the #28 lower connection.
14. Remove the #26 thread seal O-ring, the five #22 bearings and #20 bearing
shield from the #21 bearing spindle.
15. Remove the two #15 housing seals from the #23 bearing housing.

16. Remove the #15 housing seal and the #18 shield seal from the #2 gooseneck.
17. Disassemble 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 O-rings.
Should you have any problems or require additional information, contact your local Atlas
Copco Drilling Solutions Distributor or Dealer.


Section 7 - Troubleshooting

T3W Instruction Manual Section 7 - Troubleshooting
7-1 INTRODUCTION
General Information
Always wear correct safety gear while working on or around 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.
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, operator observed problems,
pneumatic, mechanical/hydraulic and mechanical/Engine.
! WARNING
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 Electrical 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 Operator
Observed Problems Troubleshooting Chart.
The troubleshooting chart is limited to machine failure control operational problems which will
guide the operator to rectify the cause of the failure.

Section 7 - 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

7-2 ELECTRICAL
General Information
! WARNING

drill.
approved hard hat, safety glasses, steel toed shoes/boots, gloves, respirator and ear
4. Always perform safety checks prior to starting, operating or performing
maintenance when troubleshooting the drill
crushing risk.

Electrical System Information

The following information is provided to give an understanding of the electrical system and the
relation to the operator control panel that is described in Section 4 - Operating Controls. Note
there are wiring schematics shown at the end of this section which relate to the information
provided here.
The T3W Waterwell drill is an EPA compliant drill. As the EPA sets new standards to keep the
environment clean, the T3W30K, T3W40K, T3W55K and T3W70K drills are equipped with
Caterpillar C15 tier 3 engines as standard deck engines.
Engine
The CAT C15 electronic engines have the following characteristics: direct fuel injection,
electronic unit injection that is mechanically actuated, turbocharged and air-to-air after cooled
(ATAAC).
The electronic engine control system provides the following functions: electronic governing,
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
functioning and operating properly. In the event of a system component deviation from the
programmed limits, the operator will be alerted to the condition by a DIAGNOSTIC lamp that
is mounted on the control panel. There are three types of diagnostic codes: ACTIVE, LOGGED
and EVENT. These codes are logged and stored in the ECM (Electronic Control Module).
Electrical System Components

The electrical systems consists of five 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.

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 complete 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 alternator. 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 activates 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
Electrical 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 operating hours as part of
routine maintenance. Refer to Section 6 Maintenance at 50 Hours or Weekly.
Fusible Links
The three Fusible Links used on T3W drills are blue and are 9 inches (23 cm) long. There is a
ring connector on one end of each link. Fasten one (each) fusible link end ring connector to
each starter and fasten the third fusible link end ring connector to the alternator. The other end
of each fusible link is connected to the main hot wire #1 by a wire nut. The main hot wire (#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
The alternator is a 24V, 100 amp model. It is used to charge the batteries and provide current
to the electrical system and the night lights. Caterpillar recommends a scheduled inspection
of the alternator for loose connections and proper battery charging.
Key Switch
The key switch controls current to all the electric circuits on the drill. When it is turned on it
supplies power through Wire #7 to the Engine and Compressor starting circuit, and power
through Wire #6 to the Drill and Operating Lights circuit. The key switch also energizes the

ECM (Electronic Control Module). Refer to the Electric Schematics at the end of this section
for further information.
Circuit Breakers
A bank of five circuit breakers, located on the operator control panel, 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.
NOTICE
If there is a recurrence, call for service assistance to correct the cause of

the overload in the circuit.
Table 1: Circuit Breakers
Breaker 1 15 Amp Engine and Compressor Starting Circuit

Breaker 2 15 Amp Drill and Operating Lights
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
Pushbuttons
The pushbutton switch, located on the control console, enables the operator to start the engine
when the key switch is ON. This pushbutton 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 disconnects 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. R1B is a normally open

contact, connected physically, that becomes energized when R1 is energized. Even though
the schematic shows the elements in different places, they are actually made up of a single
device.
All shutdown devices are in the open mode during normal running conditions and are
connected to the R1 relay coil.
Should an abnormal condition occur in any of these circuits, the appropriate monitoring device
will close and cause R1 relay coil to become energized. When R1 coil is energized, it moves
the R1A contacts from a normally closed position to an open position. This interrupts the flow
to the Fuel Solenoid and shuts down the engine. It also cuts off current to the red light in the
Emergency Stop button.
If the engine was at high idle (1,800 rpm) when the shutdown occurred, the high pressure oil
switch may shut the engine down.

If the oil pressure remained higher than 10 psi, but lower than 27 psi, the engine would try to
restart at low idle. For this reason we added R1B. When current is interrupted to the fuel
solenoid, it must remain off until the engine stops. To insure this happens, R1B supplies
current to R1 coil continuously to keep it from cycling.
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 Shutdown

Pushing the emergency engine shutdown switch shuts off power to the fuel valve which stops
fuel flow and shuts the engine down. Turning 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.
Engine Electronics
The C15 Engine has a comprehensive, programmable Engine Monitoring System. The Engine
Control Module (ECM) has the ability to monitor the engine operating conditions. If any of the
engine parameters extend outside an allowable range, the ECM will initiate an immediate
action.
The following actions are available for engine monitoring control: WARNING, DERATE, and
SHUTDOWN. These engine monitoring modes have the ability to limit engine speed and/or
the engine power.
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 Coolant 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
available 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 described. For more
information about the gauge package, refer to the parts book information for your drill.
Gauges provide indications of engine performance. Make sure 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 significant change in the
readings. Consult your Atlas Copco distributor or CAT dealer for assistance.
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 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 and 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.
Warning / Derate / Shutdown
! 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.

! WARNING
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.
! WARNING
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

manufacturer Operation and Maintenance Manual.
Air Inlet Temperature Sensor
! WARNING
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 1,000 feet (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 ll 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 electronic problem
with an input or an output is detected, a diagnostic code is generated. This indicates the
specific problem with the circuitry.
Diagnostic codes are also generated when an abnormal engine operating condition is
detected. For example, a diagnostic code will be generated if the low oil pressure 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 following 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 intermittent
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 electronic control

module will continue flashing the flash code at five second intervals until the problem is
repaired.
Diagnostic Flash Code Retrieval

Problems with the electronic control system are reported via these types of codes: flash codes,
SPN/FMI codes, diagnostic codes and special event codes.
Table 2: Cross Reference for Diagnostic Codes
Diagnosti
Flash SPN(*1)/ c 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

Diagnosti
Description of Code
Code FMI Code Event
Code
21 678-03 41-03 8 Volt DC Supply short to +batt
678-04 41-04 8 Volt DC Supply short to ground
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

Diagnosti
Description of Code
Code FMI Code Event
Code
38 105-03 172-03 Intake Manifold Air Temp open/short to
+batt
105-04 172-04 Intake Manifold Air Temp short to ground
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

Diagnosti
Description of Code
Code FMI Code Event
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.

MurphyLink PowerView
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).

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 and red). It
has a wide temperature range of -40 to +185 °F (-40 to +85 °C), display viewing -40 to +167
°F (-40 to +75 °C), and increased environmental sealing to +/- 5 psi (±35 kPa).
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
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 button is touched to scroll through the screen either moving the
parameter selection toward the left or upward.

Right Arrow Key - The right arrow button 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
Electrical Installation
PowerView Unit Back View

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
1. Starting at the single or four engine parameter display, touch Menu.
2. The first seven items of the Main Menu will be displayed. Touching the arrow
buttons will scroll through the menu selection.
3. Touching the right arrow button will scroll down to reveal the last items of Main
Menu screen highlighting the next item down.

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.
Engine Configuration Data
1. Starting at the single or the four engine parameter display touch the Menu
button.
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.
3. Once the Engine Configuration menu has been highlighted touch the Select
button to view the engine configuration data.

4. Use the arrow buttons to scroll through the engine configuration data.
5. Touch the Menu button to return to the main menu.
6. Touch the Menu button to exit the Main menu and return to the engine
parameter display.
Stored Fault Codes
1. Starting at the single or the four engine parameter display touch the Menu
button.

through the menu until the Stored Fault Codes is highlighted.
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).
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.
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.

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.
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.
4. The display will return to the single or four parameter screen.
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

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.
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.
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.
6. The display will return to the single or four parameter display, but the display
will contain the flashing Active Fault warning icon.
7. Touching the Select button will re-display the hidden fault.
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.

Shutdown Codes
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.
4. The display will return to the single or four parameter display, but the display
will contain the flashing Shut Down icon.

5. Touching the Select button will re-display the hidden fault.
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.
Back Light Adjustment
1. Starting at the single or four engine parameter display touch the Menu button.
through the menu until the Adjust Backlight is highlighted.

3. Once the Adjust Backligh” menu has been highlighted, touch the Select button
to activate the Adjust Backlight function.
4. Use the arrow buttons to select the desired backlight intensity.
6. Touch the Menu button to exit the main menu and return to the engine
parameter display.

Contrast Adjustment
1. Starting at the single or four engine parameter display, touch the Menu button.
through the menu until Adjust Contrast is highlighted.
3. Once the Adjust Contrast menu item has been highlighted, touch the Select
button to activate the Adjust Contrast function.
4. Use the arrow buttons to select the desired backlight intensity.

parameter display.
Select Units
1. Starting at the single or four engine parameter display, touch the Menu button.
through the menu until the Select Units is highlighted.
3. Once the Select Units menu has been highlighted, touch the Select button to

access the Select Units function.
4. Use the arrows to highlight the desired units. English for Imperial units i.e. PSI,
°F, or Metric kPa, Metric Bar for IS units i.e. kPa, Bar, °C.
5. Touch the Select button to select the desired units or CANCEL to exit.

parameter display.
Setup 1-Up Display
1. Starting at the single engine parameter display, touch the Menu button.
through the menu until the Setup 1-Up Display is highlighted.
3. Once the Setup 1-Up Display menu item has been highlighted, touch the Select
button to access the “Setup 1-Up Display” function.
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.
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.

8. Touching the Select button will display a list of engine parameters.
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.

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.
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.
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.
17. Touch the Menu button to exit the main menu and return to engine parameter
display.
4-Up Display Setup
1. From the single or four engine parameter display, touch the Menu button.
through the menu until Setup 4-Up Display is highlighted.

3. Once the Setup 4-Up Display menu item has been highlighted, touch the Select
button to activate the Setup 4-Up Display menu.
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.
6. Use the arrow buttons to scroll through and highlight the desired engine
parameter.

7. Pressing the Select button will place the selected parameter in the pre-selected
4-Up Display Location.
8. Use the arrow buttons to select the next parameter display location.
9. Press the Select button to view the engine parameter list.
10. Use the arrow buttons to scroll to and highlight the desired parameter.

11. Pressing the Select button will place the selected parameter in the pre-selected
4-Up Display Location.
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.
14. Press the Menu button to exit the Main menu and return to engine parameter
display.

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.
2. The main menu will be displayed. Use the arrow buttons to scroll through the
menu until the Utilities is highlighted.
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.

4. Press the Select button to enter the Gages Data display.
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.
7. Use the arrow buttons to scroll to Remove All Gages. Then press Select to
highlight and enter the menu.
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

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 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.
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 electricity 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.

The Third part is the Key Switch and the Circuit Breakers that protect each separate circuit
and control the power to the whole system.
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.
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.
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.
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.

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

Schematics

7-3 OPERATOR OBSERVED PROBLEMS
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
understand Section 4 - Operating Controls.
Unexpected drill motion or moving parts can cut or crush. Shut down the engine before
working on the drill.
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: Troubleshooting 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 switch gage Replace Switch gage.
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.


(continued): Engine difficult Loose Connection Check and tighten
to start. Engine has poor between Terminal Strip and Terminal connections.
and irregular performance. Wiring Harness.
Using too high viscosity Use appropriate oil grade
oils in low ambient in winter.
temperature.
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 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 manufacturer
engine diagnostic ECM Operation Manual for
system. correct engine diagnostics.


Engine making excessive Engine oil level too high. Drain engine oil to correct
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.
Battery State - Ammeter Speed of alternator too low. Check drive belt tension.
indicates low or negative
value. Not changing due to Call for service to correct
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
Read and understand Section 2 - Safety 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
understand Section 4 - Controls.
Unexpected drill motion or moving parts can cut or crush. Shut down the engine before
working on the drill.
crushing risk.

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.
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 250 psi (17.25 bar) or
greater. All T3W high pressure compressors have discharge pressures of 350 psi (24.15 bar).
They are designated HR2.5 which describes the rotor sizes. The HR2.5 has two sets of rotors:
226 mm x 2/127.5 mm. The size of the rotors and their speed determine the inlet volume of
the air end. There are two sizes: 900 cfm and 1070 cfm.
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 systems 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 filtration. 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.
2 Oil fill
3 Drain valve
Oil Pump
The oil pump is a gear type pump, driven from the rear of one of the compressor rotors. It
operates whenever the compressor is turning. It is speed sensitive and pumps at rated volume
only when the compressor is at full rpm.
It acts as a normal pump when the oil is cold but becomes a restriction to maintain oil flow from
the receiver tank when the compressor is operating at normal pressure and temperature. This
prevents all the oil from being forced out of the receiver tank at once and flooding the
compressor rotors. There is no shaft seal in this pump since it is being lubricated by the same
oil it is pumping.

Strainer
A 40-mesh (150-micron) strainer is mounted just before the inlet to the oil pump as shown
above. It protects the pump and catches any foreign debris such as hose pieces and parts of
the thermostat that could damage the pump. The metal strainer should be removed, cleaned
and reinstalled every 500 hours.
Compressor Oil Cooler

The cooling package on the T3W with a Tier 3 engine is a side by side configuration with four
cores; the radiator cooler core, the hydraulic oil cooler core, the engine charge air cooler core
and the compressor oil cooler core.
The compressor oil cooler is a single pass unit. Hot oil enters from the bottom of the cooler
and cool oil exits out from the top. This prevents any air bubbles that may have been carried
along with the oil from being trapped in the top and creating a vapor barrier.
Temperature Bypass Valve

The temperature bypass 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.
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 thermostat 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 operation, 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
A 75 psi (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.
Oil Filter
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 oil. This oil is not
compatible with certain types of O-rings. Therefore, use “Viton” type O-rings in the air end
fittings and filters. The oil is also not compatible with other oils and should never be mixed with
other oil. These high pressure compressors use XHP605 oil. 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 purposes:
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 returning 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.
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
completely 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).
If the oil cooler becomes plugged and the differential pressure across the cooler builds up to
75 psi (5.17 bar), the relief valve opens and allows oil to bypass the cooler. It still flows from
(C to A) in the temperature bypass valve.
When the oil exits the temperature bypass valve, it passes through a 40-mesh (150:) screen
into the inlet of the oil pump. When the oil is cold or the receiver is operating at low pressure,
the pump performs as a regular pump by forcing oil into the compressor. But as the
temperature and pressure increase, the pump acts to prevent excess oil from getting into the
compressor and flooding it.
Before the oil reaches the pump, it passes through a 40-mesh,150-micron strainer that keeps
larger debris from reaching the pump.
After the oil passes the pump and before it gets to the compressor bearings, it passes through
two 10-micron filters and then flows through a metal manifold that sends oil to all areas of the
compressor. Each bearing has its own supply line. The balance of the oil goes into the low
pressure area of the rotors.
A 425 psi (29.33 bar) relief valve is located between the oil pump and the compressor and
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
Lubricating oil is forced through the air end to cool, seal and lubricate the rotors. When the oil
is pumped into the receiver separator tank, it must be separated from the air going down the
hole. This is accomplished in three steps.
1. The air/oil mixture enters the receiver through the inlet pipe and splashes
against the inner walls. This forces the majority of oil to fall to the bottom of the
tank and remain there.
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.
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 inch 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.
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.
The Electronic Air Regulation System consists of 14 general components. Some of the
components are only required on some of the applications.
1. Flow Sensor (Vacuum 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
The proportional butterfly valve and actuator is controlled by the MC2 electronic
controller. It regulates the air flow into the compressor from the 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
1 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
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
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 console
The Flow control knob is a variable voltage input into the electronic controller
(0.5 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 (0.5 to 4.5 VDC). 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
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
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 (low 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
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 1 - 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.

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
The system can detect various types of problems and flash out a code for the operator 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 conditions. 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 indicating 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).

10. The Hydraulic temperature sensor is indicating an electrical fault. (It is

indicating an out of range signal).
11. One of the four temperatures is too high.
Standard Test Conditions
1. EAR/EFR system is fully assembled with all connectors, actuators and sensors
connected and tight. The system has a limited number of parts that can easily
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.
4. Drills with the capability to select a drill mode should be pre-set to that mode.
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 counterclockwise).
9. Maximum air pressure knob set to minimum (fully counterclockwise).
10. The throttle valve should be open (if equipped).





Error Code Meaning and Diagnostic Information

The following is a listing of the diagnostic error codes along with the possible faults that could
cause the error.
1. Code 1 - The vacuum sensor input has been below 1.05 volts DC (2 psia) and
above 0.5 volts DC (psia) for more than 30 seconds. Possible non-rotating
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:
a. The butterfly valve is not opening and the vacuum has remained low for too
long.
Interface board terminals for vacuum sensor:
a. Terminal 46 - Vacuum Sensor Supply (20 to 30 volts DC).

b. Terminal 47 - Vacuum Sensor Ground.
c. Terminal 48 - Vacuum Sensor Signal.
The sensor supply voltage originates on the interface board. It goes off the
interface board at terminals 46, 49, 71,69.
2. Code 2 - The vacuum sensor input has been below 0.25 volts DC. Possible
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 to 30 volts DC).

b. Terminal 47 - Vacuum Sensor Ground.
c. Terminal 48 - Vacuum Sensor Signal.
interface board at terminals 46, 49, 71,69.

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 to 30 volts DC).

b. Terminal 50 - Pressure Sensor Ground.
c. Terminal 51 - Pressure Sensor Signal (0.48 to 0.51 volts DC).
The sensor supply voltage originates on the interface board 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 (counterclockwise 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).

5. Code 5 - The maximum pressure potentiometer input is below 0.25 volts DC or

greater than 5.75 volts DC. Possible causes include:
a. Damaged maximum pressure potentiometer.

b. Disconnected or damaged maximum pressure potentiometer wiring.
c. Low maximum pressure potentiometer supply voltage.
d. Shorted maximum pressure potentiometer wiring.
Interface board terminals for Maximum Pressure potentiometer:
a. Terminal 43 - Maximum Pressure Pot Supply (4.6 volts DC).

b. Terminal 44 - Maximum Pressure Pot Ground (0.4 volts DC).
c. Terminal 45 - Maximum Pressure Pot Signal (counterclockwise 0.4 Volts
DC, clockwise 4.6 volts DC).
Interface board terminals for the plus supply and ground used by the
potentiometer circuits:

b. Terminal 8 - Ground from controller (ground).
6. Code 6 - The controller is not receiving the data from the engine (J1939).
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 to 3 volts DC).

b. Terminal 35 - Data High (2 to 3 volts DC).
7. Code 7 - The regulated 5 volt supply the controller provides to the interface
board is below 4.8 volts DC or above 5.2 volts DC. (This voltage should be
measured from the ground on pin 8 of the interface board). Possible causes
include:
a. Short on interface board or wiring between controller and interface board.

b. Damaged controller.

Interface board terminals for the plus 5 volt supply and ground.

b. Terminal 8 - Ground from controller (ground)
8. Code 8 (TH60 drills) - The engine speed as reported 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 signal. Zero volts DC on a non

running drill and approximately XXX 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) temperature 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 sensor wiring.
c. Low COC temperature sensor supply voltage.
d. Shorted COC temperature sensor wiring.

Interface board terminals for COC temperature sensor:
a. Terminal 71 - COC Temperature Sensor Supply (20 to 30 Volts DC).

b. Terminal 75 - COC Temperature Sensor Ground.
c. Terminal 74 - COC Temperature Sensor Signal.
interface board at terminals 46, 49, 71, 69.
10. Code 10 - The hydraulic temperature sensor input is below 0.25 Volts DC or
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:
a. Terminal 69 - Hydraulic Temperature Sensor Supply (20-30 Volts DC).

b. Terminal 73 - Hydraulic Temperature Sensor Ground.
c. Terminal 70 - Hydraulic Temperature Sensor Signal.
interface board at terminals 46, 49, 71, 69.
11. Code 11 - One of the four temperatures monitored by the Electronic Fan
Regulation (EFR) systems has exceeded its maximum 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
1. Use a multi-meter to measure resistance between Terminal 32 and Terminal

78. The resistance should not be less than 20 ohms.
2. 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 counterclockwise rotation always opens the
valve. The actuator has six wires:
1. Clockwise Supply
2. Counterclockwise Ground
3. Clockwise Ground
4. Counterclockwise Supply
5. Heater Ground
6. Heater Supply
Actuator Test Box

To connect the actuator test box, simply uncouple existing 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 compressor 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.

! CAUTION
Opening the receiver tank vent valve too quickly while the compressor is
making high volumes of air can result in damage to the separator
elements.
Actuator Test Using an Actuator Test Box
Instructions:
1. Make sure the white line on the actuator indicator knob is lined up with the
scribed mark on the actuator. (This requires removing the indicator knob).
2. Install the actuator test box in series with the actuator to be tested.
3. Set the speed switch to fast.
4. Use the clock wise and counterclockwise switch to command the actuator and
observe the actuator response.
5. Set the speed switch to slow.
6. Use the clock wise and counterclockwise switch to command the actuator and
observe the actuator operation at slow speed.
Results:
1. The butterfly valve should move in the direction commanded by the switch.
2. The actuator should have free travel from horizontal with the long edge of the
actuator to perpendicular to the same edge. The actuator is stopped at the end
of travel by internal limit switches that can be heard as a faint click. The actuator
should not load up and stop.

3. The actuator should stop in the horizontal position after moving clock wise and
in perpendicular position after moving counterclockwise.
4. The actuator should move smoothly with a steady buzzing 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, possible 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, however, be corrected.
Use the schematic and connector pin diagrams to diagnose and correct.
b. The test box is wired incorrectly. Use the tester schematic and connector
pin diagrams to diagnose and correct.
2. If the actuator does not travel the full operating distance, 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 actuator. 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 mechanical 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 counterclockwise, 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/terminals until the pair with the
greatest resistance is found.
a. The resistance should correspond with the resistance marked 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 resistive 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.
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 applied 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

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 counterclockwise 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. Once the flow is reduced to
minimum flow, the pressure will rise to 20 psi (1.38 bar) above the maximum
pressure and the vent valve will begin to open and regulate the receiver tank to
20 psi (1.38 bar) above the maximum pressure. If the pressure raises too high,
this indicates a problem with the vent valve actuator or valve.
Control Logic
Compressor Related Problems

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 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


Excessive Oil Oil carryover through Check for high oil level in
Consumption discharge air hose separator
Check for plugged orifice in
scavenger line
Compressor Makes Air But Clogged air inlet filter Clean or replace filter
Volume Is Low elements
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 Oil Carryover symptoms (problem). above 300 psi (20.7 bar)
Into Service Air Products previously used
Oil Or Foam Out Of The were Mobil 626 and
Blowdown Valve During XHP505.
Shutdown

Electronic Fan Regulation System
The EFR (Electronic Fan Regulation) system is implemented in combination with the EAR
(Electronic Air Regulation) system. Many of the components of the EAR system are shared
with the EFR system.
Depending on the configuration, the electronic controller monitors the temperature from
different systems on the machine.
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 engines 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.

The controller is always working to reduce the fan speed to the minimum required to keep the
hottest system below the determined temperature set-point.
Additional System Components
The compressor discharge temperature sensor detects the temperature of the air/oil mix after
it exits the compressor and sends this information to the electronic controller.
The hydraulic temperature sensor detects the temperature of the hydraulic oil in the return
manifold and sends this information to the electronic controller.
The fan speed control valve is controlled by the electronic controller. It regulates the fan speed
over a fixed range. The valve reduces the fan speed as the current signal from controller
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 to fivehydraulic 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 70K model with a mud pump.
The hydraulic system consists of several circuits. Each circuit includes 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 rotation 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 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 Circuit.
The Main Manifold is used to supply oil to the main valve, 10-spool valve, 2-spool valve (40K
model), 3-spool valve (70K model), regen valves, remote valve, jib boom and jib arm, main
and auxiliary winches, and the hot oil shuttle manifold.

7-7 HYDRAULIC CIRCUITS
General Information
! WARNING
Read and understand Section 2 - Safety and the Safety First manual
drill.
If you are not experienced with the drill controls and instruments, you
must read and understand Section 4 - Controls.
approved hard hat, safety glasses, steel toed boots/shoes, gloves, respirator and ear
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, 3,750 psi
relief valve, 6,000 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.
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.
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 operates on both sides of center. The
pump output is controlled by the operator via the rotation controller located on 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 controller. When the
operator moves the control handle, the electric 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.

Some hot, dirty oil must be drained from the circuit and clean, cool oil must be put back into
the loop. This is done by the charge pump that is built into the rotation pump and a hot oil
shuttle valve. Cool, clean oil is pumped through the charge pump and into the make-up oil. A
relief valve in the charge pump outlet forces the clean oil into the make-up line and the same
volume that is allowed in is returned through the hot oil shuttle. The hot oil shuttle will exhaust
low pressure oil no matter which direction the rotation is in, and the charge pump will supply
make-up oil from either side.
On drills with a torque limit control, a sequence valve is added to the forward rotation line to
prevent the torque limit from dropping below 500 psi (3447 kPa).
Rotation Motors
There are two types of rotary heads used on the T3W Waterwell drill. One is a four motor,
single speed drive head and the other is a 4-motor, 2-speed drive head.
The four rotary head motors are fixed displacement motors and are bi-directional and thus can
be used either in forward or reverse rotation. Note that system pressure is limited to 4,500 psi
(31,027 kPa).
The schematic for the rotation motors is shown below. The main motor section is shown by
the circle with two triangles pointed inward from the two main ports. There are case drains on
each since they are piston motors.

The single speed standard rotary head uses four 9.9 cubic in/rev hydraulic rotation motors with
5,500 ft·lb (7,457 N·m) torque @ a rotation speed of 0 to 145 rpm.
The single speed heavy duty rotary head uses two 9.9 cubic in/rev hydraulic rotation motors
and two 12.5 cubic in/rev hydraulic rotation motors with 6,250 ft·lb (8,474 N·m) torque @ a
rotation speed of 134 rpm.
The single speed high torque rotary head uses two 12.5 cubic in/rev hydraulic rotation motors
and two 15 cubic in/rev hydraulic rotation motors with 8,000 ft·lb (10,847 N·m) torque @ a
rotation speed of 0 to 105 rpm.
The two speed standard rotary head uses four 9.9 cubic in./rev hydraulic rotation motors with
5,500 ft·lb (7,457 N·m) torque @ a rotation speed of 0 to 145 rpm. The second speed is 4,000
ft·lb (5,423 N·m) torque @ a rotation speed of 0 to 195 rpm.
The two speed heavy duty rotary head uses two 9.9 cu. in/rev hydraulic rotation motors and
two 12.5 cubic in/rev hydraulic rotation motors with 6250 ft·lbs (8,474 N·m) torque @ a rotation
speed of 134 rpm. The second speed is 4,650 ft·lb (6,305 N·m) torque @ a rotation speed of
0 to 180 rpm.
The two speed high torque rotary head uses two 12.5 cubic in/rev hydraulic rotation motors
and two 15 cubic in/rev hydraulic rotation motors with 8,000 ft·lb (10,847 N·m) torque @ a
rotation speed of 0 to 105 rpm. The second speed is 5,500 ft·lb (7,457 N·m) torque @ a
rotation speed of 0 to 145 rpm.
Main Manifold
Main Pump (40K, 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 (145 cc)
at 2,500 rpm. The main pump supplies oil to the main manifold as needed.
Auxiliary Pump (70K 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 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 (75
cc) at 2,500 rpm. The auxiliary pump supplies additional oil to the main manifold, as needed,
to supply the additional feed cylinder used on 70K drills.



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.
3. Raise and lock the derrick.
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.
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.

1. The 40K derrick uses one 5 inch diameter x 165.5 inch x 3.5 inch diameter rod
(127 mm x 4203.7 mm x 88.9 mm) cylinder.
2. The 70K derrick uses two 5 inch diameter x 165.5 inch x 3.5 inch diameter rod
(127 mm x 4203.7 mm x 88.9 mm) cylinders.
Fast Feed
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.
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.
Pressure to operate the jib boom swing and extend comes from the main manifold also.

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 in3/rev (60 cc) at 2,500 rpm. The cooler fan
pump supplies oil to the cooler fan motor.
Main Valve
40K Drills
The main manifold supplies oil to the two spool main valve on 40K T3W drills. The feed
cylinder is operated through one of the spool valve sections 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 2,500 psi relief valve.

70K Drills
The main manifold supplies oil to the three spool main valve on 70K T3W drills. The feed
cylinders are operated through spool valve section one and spool valve section two of the
three spool main valve that is mounted on the back side of the derrick support. The spools
have regenerative sections built in and are 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 cylinders in the down position only. The main
winch operates through the third spool valve of the three spool main valve that is mounted on
the back side of the derrick support. This spool section has a 2,500 psi relief valve.


10-Spool Valve
The main manifold and the main valve supplies oil to the 10-spool valve. Ten spool valve spool
sections 1 through 3 are shown below.

Ten Spool sections 4 through 6 are shown below.

Ten Spool sections 7 through 10 are shown below.

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/rev. 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 Option)

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 in3
/rev, 2,000 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 the 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 inch (146 mm) bore x 4.5 inch (114.3 mm)
x 36 inch (914 mm) stroke with a double pilot holding valve and an 18 inch (457 mm) jack pad.

Valve Section Eight (Leveling Jack)

This section operates the cab end, operator console side, leveling jack. The jack is mounted
directly behind the truck cab. The standard jack has a 5.75 inch (146 mm) bore x 4.5 inch
(114.3 mm) x 36 inch (914 mm) stroke with a double pilot holding valve and an 18 inch (457
mm) jack pad.
Valve Section Nine (Leveling Jack)

This section operates the drill end, rod box side, leveling jack. The jack is located on the side
of the deck behind the rear wheel. The standard jack has a 5.75 inch (146 mm) bore x 4.77
inch (113.5 mm) x 48 inch (1219 mm) stroke with a double pilot holding valve and an 18 inch
(457 mm) jack pad.
Valve Section Ten (Leveling Jack)

This section operates the drill end, operator’s console side, leveling jack. The jack is located
on the side of the deck behind the rear wheel. The standard jack has a 5.75 in. (146 mm) bore
x 4.47 in. (113.5 mm) x 48 in. (1219 mm) stroke with a double pilot holding valve and an 18 in.
(457 mm) jack pad.
Schematic Circuit Symbols
Cylinders
A representative cylinder symbol is shown below. This is a double acting, single rod 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 out of one end of
the cylinder tube.

Motors
Representative motor symbols are shown below. The circle may contain one triangle pointed
inward from one work port (unidirectional) or a triangle pointed inward from both ports
(bidirectional).
Motor B is fixed displacement. This means that speed may only be changed by changing the
motor supply flow. Motor A is bi-directional. Dotted lines leaving the circle show that the motor
case leakage is taken away from the motor externally.
Relief Valves
Relief valves are used in many locations in the auxiliary functions circuit. A representative
relief valve symbol is shown below.
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 spring 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 spring side of the main relief drops. This allows
the upper pilot pressure to overcome the combination of spring and lower pilot pressure and
the main relief opens, allowing full flow through the valve.

Restrictor Valves
Bypass type restrictor valves allow a restricted flow to the work load and divert any excess oil
to the valve bypass port.The water injection regulator is an example of this type of valve.
Check Valves
The check valve is a one-way valve of the hydraulic circuit. Flow into the spring end of the
valve forces the ball into its seat to block fluid flow (blocked flow direction). Flow into the seat
end of the valve pushes the ball out of its seat to permit fluid flow (free flow direction). The
check valve spring is typically preloaded at the factory to provide a preset, nonadjustable valve
opening pressure in the free flow direction.
Two-Way Valve
The two-way valve has a closed position and an open position that can be activated by a
plunger. In the normal position, the valve spring holds the valve closed so that oil cannot flow
from the P to the T port. When the plunger is pressed, however, the valve shifts and free flow
is allowed.

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 components in place.
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 opened, oil flows with very little restriction.
Filters and Manifolds

The filter (shown below) is represented by a square, 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 leaves through the outlet port. Contamination is
captured by the porous element within the housing.‘
An additional feature in certain filters is the visual 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 would 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 elements also keeps debris from getting into the
system since the elements do not 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.



Mud Pumps
There are three types of mud pumps used on the T3W. The primary components of a mud
pump system are the mud pump, mud pump hydraulic drive pump, mud pump motor, mud
pump control valve, mud pump gauge on standpipe, and a 0.30 inch diameter orifice.
Mud Pump Options
1. 3 x 4 Centrifugal Mud Pump - The 3 x 4 centrifugal mud pump is mounted in

a vertical position next to the non-drilling end leveling jack on the operator side
of the drill, behind the truck cab.
a. The 3 x 4 centrifugal mud pump has the capacity to deliver 300 gpm (1,136
L/min) @ 145 psi (1,000 kPa).
b. 40K - The hydraulic pump that supplies oil to the mud pump is mounted in
the upper center position on the 3-hole main hydraulic drive gearbox. 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 (60 cc), 39.6 gpm (149.9 liter/minute) @ 2,500
rpm.

c. 70K - 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 gearbox. 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 (60 cc),
39.6 gpm (149.9 liter/minute) @ 2,500 rpm.
d. The hydraulic motor used with the 3 x 4 centrifugal mud pump is a fixed
displacement, bi-directional motor with a displacement of 3.32 in3/rev.
2. 5 x 6 Duplex Mud Pump - The 5 x 6 duplex piston mud pump is mounted
behind the truck cab.

a. The 5 x 6 duplex piston mud pump has the capacity to deliver 150 gpm (568
L/min) @ 310 psi (2,137 kPa).
displacement of 3.66 in3/rev (60 cc), 39.6 gpm (149.9 liter/minute) @ 2,500
rpm.
d. The hydraulic motor used with the 5 x 6 duplex piston mud pump is a fixed
displacement, bi-directional motor with a displacement of 15 in3/rev.
3. 7.5 x 10 Centerline Mud Pump - The 7.5 x 10 Centerline mud pump is
mounted behind the truck cab
a. The 7.5 x 10 Centerline mud pump has the capacity to deliver 300 gpm
(1,136 L/min) @ 400 psi (2,758 kPa).

displacement of 4.58 in3/rev (75 cc), 49.6 gpm (187.74 liter/minute) @

2,500 rpm.

7.8 - Dixon Boss Clamp Installation Instructions
Torque Procedure For Dixon 4 Bolt Clamp With Atlas Copco Hose
Notes:
1. Periodic bolt re-tightening is necessary due to Cold-Flow present in all rubber

hoses.
2. Dixon Boss clamps (including nuts and bolts) are for a single use only! Once
removed, discard. Only use nuts and bolts that come with the clamps. Do not
replace hardware.
3. DO NOT USE AN IMPACT WRENCH.
Clamp and Hose Selection:
Refer to rig BOM for correct hose and clamps to use.
Process:
1. Install whip checks on hose and hard pipe for both ends of the hose.
2. Insert hose into stem.
3. Position the clamp gripping fingers behind the stem collar. See illustration
above.
4. Tighten the bolts by hand until there is equal thread engagement. DO NOT
USE AN IMPACT WRENCH
5. Set a calibrated torque wrench to the final torque value for the clamp.
6. Using the calibrated torque wrench to tighten bolts to required torque following
the procedure below:
NOTE: Torque values are based upon dry bolts. Lubricant on bolts will
adversely affect clamp performance.
3" ID clamps (2657546061 and 2658006735) should be torqued to 100 ft·lb using the
procedure below: (Note: Torque value for 3" Dixon clamps (2657546061 and 2658006735)
on Atlas Copco hose is lower then normal catalog torque specs. DO NOT torque
assemblies to 150 ft·lb.)
2.5" and 2" ID clamps (2656918832 and 2650743731) should be torqued to 60 ft lbs using the
procedure below:

6. Bolt tightening sequence (Figure 1):
a. Back bolt (nut 1), 1 full turn.

b. Front bolt (nut 2), 1 full turn.
c. Snug by hand, nuts on opposite side of bolts just tightened. (nut 3 and nut 4)
d. Opposite side back bolt (nut 3), 1 full turn.
e. Opposite side front bolt (nut 4), 1 full turn.
f. Snug by hand, nuts on opposite side of bolts just tightened. (nut 1 and nut 2)
g. Repeat "a" to "f" until all bolts are tightened to specified torque. Once the torque
value is reached on a bolt move to the next step in the tightening sequence.
NOTE: It is common for one bolt to reach torque before the others.
Continue sequence until all four bolts have reached torque in sequence.
7. Inspect results using Criteria for Sufficient Fit of a Boss Clamp (Figure 2):
a. Sufficient fit criteria provides inspection guidelines when the clamp has been
assembled in accordance with the torque procedure and all the bolts are
tightened to the correct torque.

b. Failure to adhere to these guidelines could produce poor clamp performance.

Minimum Range:
- 1/16" clearance between clamp halves (both sides for 4 bolt clamps).
Maximum Range:
- 1/16" interlock between gripping fingers and stem collar (all gripping fingers).
- 1/16" interlock between dovetail extensions. (all gripping fingers).
Torque Procedure For Dixon 6 Bolt Clamp With Atlas Copco Hose
Notes:
1. Periodic bolt re-tightening is necessary due to Cold-Flow present in all rubber

hoses.
2. Dixon Boss clamps (including nuts and bolts) are for a single use only! Once
removed, discard. Only use nuts and bolts that come with the clamps. Do not
replace hardware.
3. DO NOT USE AN IMPACT WRENCH.
Clamp and Hose Selection:
Refer to rig BOM for correct hose and clamps to use.
Process:
1. Install whip checks on hose and hard pipe for both ends of the hose.
2. Insert hose into stem.
3. Position the clamp gripping fingers behind the stem collar. See illustration
above.
4. Tighten the bolts by hand until there is equal thread engagement. DO NOT
USE AN IMPACT WRENCH
5. Set a calibrated torque wrench to the final torque value for the clamp.
6. Using the calibrated torque wrench to tighten bolts to required torque following
the procedure below:
NOTE: Torque values are based upon dry bolts. Lubricant on bolts will
adversely affect clamp performance.

4" ID clamps (2657823932) should be torqued to 200 ft·lb using the procedure below
6. Bolt tightening sequence (Figure 1):
a. Bolt 1 (nut 1), 1 full turn

b. Bolt 2 (nut 2), 1 full turn
c. Bolt 3 (nut 3), 1 full turn
d. Bolt 4 (nut 4), 1 full turn
e. Bolt 5 (nut 5), 1 full turn
f. Bolt 6 (nut 6), 1 full turn
g. Repeat "a" to "f" until all bolts are tightened to specified torque. Once the torque
value is reached on a bolt move to the next step in the tightening sequence.
NOTE: It is common for one bolt to reach torque before the others.
Continue sequence until all four bolts have reached torque in sequence.
7. Inspect results using Criteria for Sufficient Fit of a Boss Clamp:
a. Sufficient fit criteria provides inspection guidelines when the clamp has been
assembled in accordance with the torque procedure and all the bolts are
tightened to the correct torque.
b. Failure to adhere to these guidelines could produce poor clamp performance.
Minimum Range:
- 1/16" clearance between clamp halves (both sides for 4 bolt clamps).
Maximum Range:
- 1/16" interlock between gripping fingers and stem collar (all gripping fingers).
- 1/16" interlock between dovetail extensions. (all gripping fingers).

7-9 HNBR Hose/Victaulic Coupling Installation

The following text contains Installation Instructions for HNBR hose using 2-bolt Victaulic rigid
couplings.

Coupling Installation
1. Read and understand all instructions before attempting to install any

Victaulic piping products.
2. Depressurize and drain the piping system before attempting to install,
remove or adjust any Victaulic piping products.
3. Wear safety glasses, an approved hardhat and foot protection.
Failure to follow these instructions could result in serious personal injury, improper
product installation and/or property damage.
Preparatory Steps for Coupling Installation
1. Check Hose/Pipe Ends: The outside surface of the pipe from the end to the
groove must be smooth and free from indentations, projections (including weld
seams) and roll marks to ensure a leak tight seal for the gasket. All oil, grease,
loose paint and dirt bust be removed.
2. Check Gasket and Lubricate: Check the gasket to make sure it is suitable for
the intended service. Apply a thin coat of silicone lubricant to the gasket lips
and exterior.
! CAUTION
Always use a compatible lubricant to prevent the gasket from pinching or

tearing during installation. Failure to follow this instruction could result
in joint leakage.

3. Position Gasket: Position the gasket over the hose end. Make sure the gasket
does not overhang the hose end.
4. Join Hose/Pipe Ends: Align and bring the hose end and pipe end together.
Slide the gasket into position and make sure it is centered between the grooves
in each hose/pipe end. Make sure no portion of the gasket extends into the
groove in either pipe/hose end.
Coupling Installation
1. Assemble Housings: Insert one bolt into the housings and thread the nut
loosely onto the bolt (nut should be flush with the end of bolt) to allow for the
“swing-over” feature, as shown below.

2. Install Housings: Using the swing-over feature, install the housings over the
gasket. Make sure the housing’s keys engage the grooves properly on both the
hose end and the pipe end.
! CAUTION
Make sure the gasket does not become rolled or pinched while installing
the housings. Failure to follow this instruction could cause damage to the
gasket, resulting in joint leakage.
3. Install Remaining Bolt/Nut: Install the remaining bolt and thread the nut
finger-tight onto the bolt. NOTE: Make sure the oval necks of the bolts seat
properly in the bolt holes.
4. Tighten Nuts: Tighten all nuts evenly by alternating sides until metal-to-metal
contact occurs at the angle bolt pads. Make sure the housing keys completely
engage the grooves. Make sure the offsets are equal at the bolt pads.This is
necessary to ensure a rigid joint (refer to the example below). NOTE: It is
important to tighten all nuts evenly to prevent gasket pinching.

! WARNING
Victaulic rigid, angle-pad couplings must have the nuts tightened evenly
by alternating sides until metal-to-metal contact occurs at the bolt pads.
Victaulic rigid, angle-pad couplings must have equal offsets at both bolt
pads.
Failure to follow these instructions could cause joint failures resulting in

serious personal injury and/or property damage.
Impact Wrench Usage Guidelines
! WARNING
DO NOT use an impact wrench after the visual installation guidelines for
the coupling are achieved.
Nuts must be tightened evenly by alternating sides until metal-to-metal

contact occurs at the bolt pads. For angle-bolt-pad couplings, even

offsets must be present at the bolt pads to obtain pipe-joint rigidity.
Failure to follow these instructions could cause gasket pinching and

coupling damage resulting in joint failure, serious personal injury and
property damage.
Installation Inspection
Proper Installation
Proper pipe preparation and coupling installation is essential for maximum joint performance.
The following conditions must be present to ensure proper joint assembly.
1. The pipe O.D. and groove dimensions must be within the tolerance of current
Victaulic grooving specifications.
2. Unless stated otherwise in specific product instructions, Victaulic grooved pipe
couplings must be properly assembled with the bolt pads in firm, metal-to-
metal contact.

3. The housing’s keys must be fully engaged in both grooves.

4. The gasket must be slightly compressed, which adds to the strength of the seal.
Always re-inspect joints before and after the field test to identify points of possible failure. Look
for gaps at the bolt pads and/or keys that ride up on the shoulders. If any of these conditions
exist, depressurize the system and replace any questionable joints.

7-10 ENGINE HEATER

NOTE: Refer to the manufacturer manual for information on the engine
heater.

7-11 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 install such 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, ISO-68 multi-viscosity petroleum based lubricating oil with anti-wear and rust
inhibitor additives. Approximate amounts are shown below.
Table 7:
12 gpm size (45.42 L) 40 oz (1.18 L)

25 gpm size (94.63 L) 84 oz (2.48 L)
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 Checklist 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 IN THE LOW PRESSURE SETTING.
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 adequate fluid
to accommodate the maximum output of the pump, generally a 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 collapsing.
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 and Maintenance
Table 8:
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 worn 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. Install proper filter. Suction
Abrasives in pumped fluid at inlet manifold must be
or severe cavitation. limited to lifting less than
Inadequate water supply. 20 feet of water or -8.5 psi
vacuum.
Fouled or dirty inlet or clean inlet and discharge
discharge valves. valve assemblies
Worn inlet or discharge 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 O- 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
powdery substance in the manifold. the ears of the manifold will
area of the O-ring be bowed when the
manifold is retightened,
causing looseness in the
center cylinder.
Water leakage from under Worn inlet manifold seals. Install new O-rings and
the inlet manifold Leaking sleeve O-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 ISO68 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 O-rings.
sleeve O-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 O-ring, or drain plug O-ring
crankcase rear cover O- as needed.
ring, or drain plug O-ring
Oil leakage from drain plug Loose drain plug or worn Tighten drain plug or
drain plug O-ring replace O-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
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 O-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 O-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 O-rings and backup rings on the valve seat. Replace them if they
are used or worn. Always lubricate O-rings for ease of installation and to avoid
damage.
NOTE: First install O-ring in groove on seat towards seating surface, then
backup ring.
NOTE: Models without outer groove on seat require the O-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 seats with dish side down.
6. Lubricate O-rings on exposed cylinder. Exercise caution when slipping
manifold over cylinders to avoid damaging cylinder O-rings. Completely press
manifold over cylinder.
7. Replace fasteners and torque per torque 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 O-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 piston. Note-cup installation: Wipe
cup inserter with oil. slip backup ring (when used) onto piston. Push cup over
inserter and square with all surfaces. Faulty cup installation causes premature
cup failure. Some models use a one piece piston assembly. The cup does not
separate from the piston. Replace entire assembly. Lubricate piston assembly
and slip piston-cup assembly onto the piston rod with lip facing discharge.
4. Next, replace the piston spacer and retainer on rod.
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 O-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 O-rings and/or backup rings on piston rod for wear and
replace as needed.
Reassembly:
1. Visually inspect that the barrier-slinger is in position.

2. Lubricate new O-rings and/or backup rings and slip onto piston rod. Install the
first O-ring (A) in the groove on the piston rod. Next, position the backup ring
(B) against the stepped shoulder. Then install the second O-ring (C). Exercise
caution as you slip the O-ring over thread end of the piston rod.
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 9: Piston Rod Nut
Pump Model Thread Tool Size Torque

12 gpm M7 x 1.0 10 mm Hex 70 to 120 in/lb (8-13 N·m)
25 gpm M8 x 1.25 13 mm Hex 90 to 150 in/lb (10-17 N·m)
Table 10: Manifold Stud/Nut and Cylinder Bolts
Pump Model Thread Tool Size Torque

12 gpm M10 x 1.5 17 mm Hex 250 in/lb (28 N·m)
25 gpm M12 x 1.75 19 mm Hex 370 in/lb (42 N·m)

Manifold Torque Sequence
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 purged, torque valve 100 and 120 in/lb (11.3 and 13.56 N·m). Then set
drive pump for proper discharge pressure.
! CAUTION
Pulse Pump will not operate with a pressurized inlet to the drive pump.
! 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.
Troubleshooting
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 require.
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: 35 gpm
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. The 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 11: Lubrication Chart for John Bean Water Injection Pumps
Pump Size Lubrication Approximate Quantity

FMC John Bean 18 gpm SAE Texaco Meropa 100 64 oz (1.89 L)
(68.13 L) or Shell Omala 100 oil.
FMC John Bean 25 gpm 64 0z (1.89 L)
(94.63 L)
(132.48 L)

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.
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 (18). If either of these parts are
worn or damaged, they should be replaced. A pocket 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 to 10 ft·lb (11 to 13.5
N·m). 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 pilot washers (19) over ends of rods with
groove up.
h. Place O-rings (17) and packing holders (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.
l. 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 to 20 ft·lb (20 to 27 N·m).
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 (12) are properly positioned in the top and
bottom recesses.
p. Tighten capscrews (10) alternately and evenly until the parts are snugly
seated. Torque capscrews 20 to 25 ft·lb (27 to 34 N·m).
q. Important: Clean buildup from cylinders. Submerge the cylinder in uncut
muriat acid (28% hydrochloric acid) for three minutes, rinse in clear water,
wash with strong soap, submerge in acid for two 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 seat 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.
d. Remove the valve seats from the recesses with the opposite end (curved
end) of the puller tool (39).
e. Repeat the four preceding steps (step a, b, c, and d) to remove the suction
valve parts which are identical to the discharge valve parts and are located
immediately “under” them in the valve chamber.
f. Clean all parts and inspect them. Replace 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.

j. 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·lb (40.6 N·m).
5. Servicing the Crankshaft
a. Remove pipe plug (37) and drain oil from pump case.
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).
f. Push the connecting rods and crosshead assemblies into the pump case to
clear the crankshafts (26) and (27).
g. Remove the driven sheave from the crankshaft extension.
h. Remove the snap rings (28) from groove in pump case at outside of
bearings (30 and 31).
i. Use a suitable wood block and hammer to tap against gear ends (outside)
of each crankshaft to remove oil seals and bearings at opposite side of
pump case. Crankshafts, with bearings at gear ends, may then be removed
from bottom of case.
! CAUTION
Never pound directly on bearings (31) when removing or replacing them

on the crankshaft.
j. A block of wood with a suitable sized opening or block supports to assure

reasonable equal support around the bearing in a press is best for this
important work.
k. After inspecting and replacing all the worn parts, press new bearings (if
needed) against the shoulders on the crankshaft, then place the assembly
through openings into the pump case.
l. Important: Timing the Pump - Arrows on gears must be located exactly

as shown above to properly time the pump.
m. With the crankshaft and bearings assembly in place in the pump case,
place the oil seals (29) carefully over the ends of the crankshaft with the lip
of the seals facing the inside of the pump case. Care should be taken when

passing seals over the crankcase to avoid folding the lip of the seal 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 crankshaft.
o. Assemble the connecting rods and crossheads, being sure to rematch the
rod and cap properly as marked when disassembled. Use 6 to 8 ft·lb (8 to
11 N·m) 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 in their exact former positions.
7. Operation
a. Check the drain plug located on the bottom of the base to ensure that it is
properly tightened.
b. Add clean SAE30 API service classification MM or better oil to the pump
crankcase. Maintain oil at the filler plug level.
c. Inspect the pump to see that all nuts and screws are tight.
d. Turn the pump sheave by hand a few 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.

If the speed is increased excessively, there is danger of either overheating the bearings or
causing cavitation in the fluid end of the pump.
If pressure is increased excessively, bearing life will be drastically reduced in addition to
breakage of other parts.
Exceeding pump specification limits for either pressure or speed results in overloading the
power source.

7-12 DHD LUBRICATOR
DHD Lubricator
The Down-Hole-Drill (DHD) lubricator (60 Gallon System CPN 5734755, 7 Gallon System
CPN 57353369) is a sub system of a rotary drill. The sub system consists of five parts; a
reservoir, a timer, an oil pump, flow switch/indicator light and discharge piping. The system
lubricates the DHD by pumping a prescribed amount of oil based on DHD hammer/air
compressor size. An operator is given three settings: 2 pints/hr (.94 liter/hr) for air compressor
capacity less than 600 cfm, 3 pints/hr (1.4 liter/hr) for air compressor capacity over 600 cfm
and up to 900 cfm, and 4 pints/hr (1.89 liter/hr) for air compressor capacity greater than 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 12 VDC or 24 VDC 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 1/3 pt/hr/100 cfm. The terminal strip
allows for both inputs and outputs. The timer accepts both 12 VDC and 24 VDC. To use the
12 VDC, one must remove the protected terminal and switch with the 24 VDC terminal screw.
The protected terminal prevents accidently hooking up 24 VDC 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 (0.375 in3/stroke) at
pressures up to 2000 psi. The pump has two distinct sections: pneumatic and hydraulic.
1. The pneumatic section uses the 12 VDC 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 12 VDC. 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 (0.44 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 location.
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 12: 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 to 90 °F (-6.6 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. If 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?

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 24 VDC,
while some truck mounted rigs use 12 V DC. Verify proper voltage to timer. (Re-
wire as needed).
NOTE: 12VDC means 12 volts nominal and actual voltage is between 9
and 15 VDC. Also 24 VDC means 24 volts nominally and actual voltage
may be between 20 and 30 VDC.
4. When the timer cycles 1 second ON, is 12 VDC 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 13: 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 clearance between 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 lamps. 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, the unit must be 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).

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.
2. Open inlet valve. Light should flash with pump cycle. Turn setscrew CW until
light starts flashing.

Glossary
DRILLING SOLUTIONS February 2014 GL-1

T3W Instruction Manual
Glossary Of Terms
The following table provides a brief definition of some of the common terms that are used throughout
this manual.
Term Definition
A/C Air Conditioner
AC Atlas Copco
Actuator A motor or cylinder that is being put into motion by the flow
of a hydraulic pump.
Adapter (or Adaptor) 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 A pump that provides grease to various components of the
drill through hoses. It can be manual or computer controlled.
Aux Auxiliary
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 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.
GL-2 February 2014 DRILLING SOLUTIONS

Term Definition
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.
BOM Bill of Materials
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.
BTM Best Tuning Memory
Burden Distance from the blasthole to the nearest face. Distance
measured from face to a row of holes.

Term Definition
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.
Cable A strong, heavy steel, wire rope. Also known as Wire 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.
CAC Charge Air Cooler
CAN Controller Area Network
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 Special 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.
CAT Caterpillar
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.
CC Central Computer or Customer Center
CCW Counterclockwise
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.
cfm Cubic feet per minute

Term Definition
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.
cm3 Cubic centimeters
COC Compressor Oil Cooler
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.

Term Definition
CS Cab side
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.
CW Clockwise
dB Decibel
dBa A-weighted decibels
DC Direct current or Distribution Center
DCS Dust collector side (non-cab side)
DEAC Diesel engine anti-freeze/coolant
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 (also called
DTH).
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.

Term Definition
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 the bit 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.
DTH Down The Hole. Process of drilling with a pneumatic
hammer at the bit end of the drill string. Also called hammer
drilling, percussion drilling, and down hole drill.
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.
EARS Electronic Air Regulation System
ECM Electronic Control Module
ECU Electronic Control Unit
ELC Extended life coolant
EPA Environmental Protection Agency
Face Vertical surface on an elevation. Also called bank.

Term Definition
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-metallic 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.
ft foot or feet (12 inches)
ft·lb foot-pound(s)
ft/min Feet per minute
FTP File Transfer Protocol
gal Gallon(s)
gpm Gallons per minute
GP General Purpose
GPS Global Positioning System
Grouting To fill the hole or annulus with grout, i.e., cement and water.
GUI Graphic User Interface

Term Definition
Hammer A different name for a Down Hole Drill (also called DTH
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.
HID High Intensity Discharge
HOC Hot Oil Cooler
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.
HPD Hydraulic Pump Drive
HPTO Hydraulic Power Take-off
Hydraulic Cylinders Double acting cylinders that are extended and retracted to
perform various functions 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.
I/O Input/output

Term Definition
in Inch(es)
Inclinometer An instrument for measuring the angle to the horizontal or
vertical of a drill hole or vein.
IREDES International Rock Excavation Data Exchange Standard
ISO International Standardization Organization
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.
J Wrench 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.
Kelly Bar A fluted or square drill pipe that is turned by a rotary table
using a set of pins.
kg Kilogram(s)
km/hr Kilometers per hour
kN Kilonewton
kW Kilowatt
L Liters
lb Pounds
LCD Liquid-crystal Display
LED Light-emitting diode
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.
m Meter(s)
m/min Meters per minute
m3 Cubic meter(s)

Term Definition
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.
min Minute
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.
mm Millimeter(s)
Module Component of the RCS control system that either reads
electrical signals from senors and or sends commands to
actuators. Also called I/O module.
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.
MWD Measure While Drilling
N/O Normally open (electrical)

Term Definition
N·m Newton meters
NCS Non-cab side
NDE Non-drill end
O.D. Outside diameter
OEM Original equipment manufacturer
OP Operator
Open Hole Any uncased portion of a hole.
Operator The person who performs the drilling operation with the drill.
See Driller.
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.
Overburden Any unconsolidated material lying on top of the bedrock or
the coal seam.
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.
PCM Proheat Control Module
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 rock.
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.

Term Definition
Potable Water Water that is safe to drink.
Powder Factor/Specific Relationship between the weight of explosives in a
Charge 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 The complete sub-assembly of base, engine, compressor,
and hydraulic drive.
PPE Personal protective equipment
ppm Parts per million
PPP Point-to-Point Protocol
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.
psi Pounds per square inch
psia Pounds per square inch, absolute
PTO Power Take-off
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.
qt Quart(s)
Quick Fill This is a central location where fluids can be filled on a
drilling rig. Fluids can be both drained and filled while the
machine is running. Also called Fast service, Wiggins Quick
Fill.

Term Definition
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.
RCS Rig Control System. This is an advanced operating system
for drilling rigs. It utilizes computer control, levels of
automation, production reporting, and can network.
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.
Rev Revision
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.
RP Remote Pressure
rpm Revolutions per minute
RRA Rig Remote Access
RS Remote Sensing
SAE Society of Automotive Engineers
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.

Term Definition
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
without 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 rock.
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.

Term Definition
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 pump(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.
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.
TCP/IP Transmission Control Protocol/Internet Protocol
Threaded and Coupled Steel casing using a coupling between each section of pipe.
Casing (T&C) 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
designs and sizes. Deephole drills normally use API style
threads, while Blasthole drills use Beco style threads.

Term Definition
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.
ULSD Ultra-low sulfur diesel
UL88 The unloader valve that controls pressure and volume on a
high-pressure compressor 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.
V Volts
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.

Term Definition
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.

Committed to
sustainable productivity.
© 2013 Atlas Copco Drilling Solutions, Garland Texas, USA

9881 0084 01
Atlas Copco Drilling Solutions, LLC

A Company Within the Atlas Copco Group
P.O. Box 462288, 2100 North First Street
Garland, Texas 75040 USA
www.atlascopco.com/drillingsolutions

T3W Instruction Manual - Feb 2014

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Atlas Copco Drilling Solutions

Instruction Manual Original Instruction

Read the instruction manual before operating this equipment.

MANUAL REVISION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Safety First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

SECTION 3 - SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

OPERATING CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

SECTION 5 - OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

OPERATING SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

6-1 MAINTENANCE SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

7-1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

DRILLING SOLUTIONS February 2014 1-1

1-2 February 2014 DRILLING SOLUTIONS

This page is intentionally blank

DRILLING SOLUTIONS February 2014 1-3

1-4 February 2014 DRILLING SOLUTIONS

Receiving the Drill

DRILLING SOLUTIONS February 2014 1-5

1. Engine Serial Number (ESN)

1-6 February 2014 DRILLING SOLUTIONS

2. Control Parts List

Carrier Vehicle Identification

Instruction Manual Location

DRILLING SOLUTIONS February 2014 1-7

T3W Waterwell Drill Description

1-8 February 2014 DRILLING SOLUTIONS

Your life may be endangered if the following is not complied with: DO

DRILLING SOLUTIONS February 2014 1-9

1. Diesel driven, deck mounted power pack

Identification of Major Components

NOTE: Pictures shown are for reference only.

1-10 February 2014 DRILLING SOLUTIONS

1 Single rod loader 6 Fuel tanks

2 Console 7 Auxiliary hoist

3 Operator platform 8 Main hoist

4 Rear jack 9 Rod box

5 Batteries 10 Hydraulic reservoir

DRILLING SOLUTIONS February 2014 1-11

1 Tower 5 Fuel tank

2 Helper platform 6 Chassis

3 Fuel tank 7 Auxiliary hoist

1-12 February 2014 DRILLING SOLUTIONS

1 Main hoist 5 Tool box

2 Leveling jack 6 Cooler package

3 Mud pump (if equipped) 7 Water injection

4 DHD lubricator 8 Receiver tank

DRILLING SOLUTIONS February 2014 1-13

1 Receiver 6 Rod spinner (if equipped)

2 Control console 7 Single rod loader (if equipped)

3 Table 8 Rotary head

4 Operator platform 9 Swivel and yoke

1-14 February 2014 DRILLING SOLUTIONS

DRILLING SOLUTIONS February 2014 2-1

2.1 Safety First

Warnings and Cautions

2-2 February 2014 DRILLING SOLUTIONS

Notice is used to notify people of installation, operation or maintenance

DRILLING SOLUTIONS February 2014 2-3

2.2 Equipment Safety Decals

1. Laminated Safety Manual: quantity of