03 Lubrications 141248 141249

Bucyrus International, Inc.
39HR Blast Hole Drill
Section 3
Lubrication
Always refer to the safety information in Section 1 of this manual before
starting any maintenance procedure on this machine.
Table of Contents
LUBRICATION PRINCIPLES ......................................................................................................... 3

LUBRICANT SELECTION ............................................................................................................. 4
PROPEL GEARBOX LUBRICANT REPLACEMENT/SAMPLING ...................................... 5
LUBRICANT CLEANLINESS ................................................................................................... 6
LUBRICATION BENCHMARKS ..................................................................................................... 7
ACSL - AIR COMPRESSOR (SCREW-TYPE) LUBRICANT .................................................. 7
HYDO – HYDRAULIC OIL ....................................................................................................... 8
PAO SYNTHETIC HYDRAULIC FLUID .............................................................................. 9
Chart - Recommended Viscosity Ambient Temperature .............................................................. 9
PARAFFINIC BASE PETROLEUM HYDRAULIC FLUID .................................................... 9
Chart - Recommended Viscosity Maximum Temperature ............................................................ 10
MPG LUBRICATION POINTS ...................................................................................................... 11
Mast Machinery Gearcase .......................................................................................................... 11
Hose Drum Carrier Assembly .....................................................................................................12
Pipe Handling Arm ..................................................................................................................... 13
Pipe Carousel ............................................................................................................................ 14
Pipe Retension Device ............................................................................................................... 15
Lower Tensioning Arm ................................................................................................................ 15
Tool Wrench ............................................................................................................................... 16
Breakout Wrench ....................................................................................................................... 17
Power Module Drive Shaft .......................................................................................................... 17
Upper Winch Beam .................................................................................................................... 18
HYDRAULIC FLUID MAINTENANCE ........................................................................................... 19
HYDRAULIC SYSTEM CLEANLINESS ................................................................................. 19
AIR COMPRESSOR OIL ...................................................................................................... 21
AUXILIARY WINCH GEARCASE OIL .................................................................................... 23
PUMP DRIVE TRANSMISSION FLUID .................................................................................. 24
PROPEL GEARCASE OIL .................................................................................................... 27
ROTARY GEARCASE OIL .................................................................................................... 28
FILTER MAINTENANCE ........................................................................................................ 29
HYDRAULIC OIL FILTER RESTRICTION INDICATORS ................................................. 29
Nov 2008 3-1 Manual No. 10660

HYDRAULIC OIL FILTER (CHARGE FILTER) ................................................................. 29

HYDRAULIC RESERVOIR FILTER ................................................................................. 29
HYDRAULIC RESERVOIR BREATHER/DRYER ............................................................ 30
AIR COMPRESSOR SYSTEM OIL FILTERS .................................................................. 30
AIR/OIL SEPARATOR FILTER RESTRICTION INDICATOR ........................................... 31
FLOWMASTER PUMP SERVICING ........................................................................................... 31
PRESSURE RELIEF PROCEDURE .................................................................................... 32
PRESSURE CONTROL VALVE ADJUSTMENT.................................................................... 32
FLOW CONTROL VALVE ADJUSTMENT ............................................................................. 33
FlowMaster Rotary Driven Hydraulic Pump Schematic ................................................................ 33
CRANK CASE OIL ................................................................................................................ 33
PUMP DISASSEMBLY PROCEDURE .................................................................................. 34
FlowMaster Rotory Driven Hydraulic Pump Assembly ................................................................. 35
PUMP ASSEMBLY PROCEDURE ........................................................................................ 36
FlowMaster Rotary Driven Hydraulic Pump Components ............................................................. 37
PUMP TROUBLESHOOTING ............................................................................................... 38
HYDRAULIC SAMPLE POINT LOCATIONS ................................................................................ 39
Hydraulic Pump Assembly ......................................................................................................... 39
Air Compressor .......................................................................................................................... 40
Transmission ............................................................................................................................. 41
Hydraulic Cooler ......................................................................................................................... 42
ADDITIONAL LUBRICATION BENCHMARKS:

MPG - MULTIPURPOSE GREASE .................................................................................... (insert)
EGL - ENCLOSED GEARCASE LUBRICANTS ................................................................. (insert)
CERITIFIED LISTING FOR OGL AND MPG LUBRICANTS ............................................... (insert)
PDT - PUMP DRIVE TRANSMISSION LUBRICANTS ....................................................... (insert)
Manual No. 10660 3-2 Nov 2008

Section 3
Lubrication
LUBRICATION PRINCIPLES
The proper lubrication of this machine is vital to its successful, continued operation. Application of
the CORRECT lubricant in the CORRECT amount at the CORRECT place as part of a PROVEN
maintenance program is required to keep the machine operating at a level of productivity. Proper
lubrication will provide better component service life with a reduction of repairs and downtime.
When not properly lubricated, moving parts wear quicker and fail sooner.
The primary wear items of this machine are lubricated by a series of manual grease points located
in selected areas of the machine. It is critical for machine operation for the points to be lubricated
at the preset interval outlined in this section. It is necessary to inspect the lubrication points to
ensure that the components accept lubrication freely.
You should become familiar with these points so you can service them properly at the intervals
listed. The standard lubrication fittings used for manual service are the standard grease type
having 1/8 inch or 1/4 inch NPT threads.
Bushings and bearings operating in a highly contaminated atmosphere (dust, grit, etc.) should be
lubricated until clean grease seeps out around the journal or seal, or comes out the purge fitting, if
one is provided. Purge fittings need to be checked when the lubrication point is being serviced to
ensure that lubrication or air can escape freely. Clogged purge fittings can cause excessive heat to
bearings, damage to seals, and prevent lubricant from entering components.
Overfilling an anti-friction bearing can cause it to run excessively warm. Grease in a bearing generally
deteriorates gradually, not suddenly. Only a small amount needs to be added to it at regular
intervals to maintain the proper lubricant level. Adding a small quantity of grease to the bearing
every 600 operating hours, unless otherwise specified, is adequate.
CAUTION: Contact with or ingestion of petroleum products can be harmful.
Automatic lubrication systems operate under pressure. Before opening
any lube supply line, relieve the system and that line in particular, of
any residual pressure.
Nov 2008 3-3 Manual No. 10660

LUBRICANT SELECTION
The selection of the proper lubricants for use on this machine is critical to its reliability. Improperly
lubricated bearings, gears, couplings and other precision parts quickly fail. For this reason, lubricants
selected in accordance with the “American Standards Testing Material” (ASTM) standards are
recommended. These standards were compiled in cooperation with major petroleum suppliers to
ensure the consumer of an exact supply to specific requirements, regardless of source.
We recommend you advise the petroleum supplier of the following information to assist in selecting
the proper product for each application of this machine.
Final acceptance of all lubricants supplied to this standard will be based upon their satisfactory
performance in the intended application and does not relieve the supplier of performance
responsibility for brand name products.
Operation of this machine in extreme temperatures (below -20°F/-29°C or above 110°F/44°C)

requires special lubrication. Note the temperature ranges on the following lubricant specification
sheets. Contact your local supplier, your Bucyrus representative, or the Service Department of
you local Bucyrus International office for recommendations if you require additional information or
advice.
• STORE LUBRICATION DRUMS ON THEIR SIDE, WITH THE OPENING TOWARD THE TOP.
• STORE ALL LUBRICANTS IN TIGHTLY COVERED CONTAINERS!
• WIPE OFF COVERS AND SURROUNDING AREA BEFORE OPENING!
• FILTER ALL OIL BEFORE ADDING IT TO THE SYSTEM!
• USE ONLY CLEAN and PROPER LUBRICANTS!
• DO NOT MIX TYPES or BRANDS of LUBRICANTS!
• ENSURE LUBRICANT IS FREE FROM WATER CONDENSATION AND CONTAMINATION!
• ENSURE THAT THE LUBRICANT IS CLEARLY MARKED!
Even the best lubricants are less useful in preventing wear if they become contaminated by dirt or
water due to careless handling or storage.
Manual No. 10660 3-4 Nov 2008

PROPEL GEARBOX LUBRICANT REPLACEMENT/SAMPLING
The recommended mineral oils should have additives that improve corrosion protection and aging
resistance, as well as reduce wear in the mixed friction field. Polyalphaolefin oils (oils on the basis
of synthetic hydrocarbons) as well as bio-oils (oils on the basis of synthetic ester) which satisfy the
demands specified for industrial type gear oils according to DIN 51517, part 3, are also permitted.
Designation to DIN 5157 part 3 : ..................CLP 220
ISO viscosity to DIN 51519 : ........................ISO - VG 220
Kinematic viscosity at 40° C : .......................min. 199 mm2/s (cSt)
max. 242 mm2/s (cSt)
FZG test A /8,3/90 to DIN 51354, pg. 2 : ......min. breakdown load stage 12
The lubricant is to be selected from a proven,

stable, and reliable lubricant vendor that meets
the above listed specification and must be
compatible with multidisc brakes. Listed at the
right are approved fluids for propel gearcases:
CAUTION: The initial oil change is

to be after approximately
150 hours. The gearcase
lubricant should be
changed at 2000 hour
intervals thereafter.
Flush the gearcase prior
to refilling with new oil.
It is strongly suggested that the gearcase lubricant be part of a routine spectrometric oil analysis
program to forecast impending problems and thereby reduce the possibility of catastrophic failure.
This analysis should take place every 500 machine hours and monitor the elements listed in the
following table, at a minimum:
Element Normal Excessive Critical
Iron <400 400-700 >700
Copper <25 25-60 >60
Chromium <5 5-15 >15
Silicon <40 40-60 >60
Nov 2008 3-5 Manual No. 10660

NOTES:
1. All values are Parts per Million.
2. Particle count may be higher during the initial run-in period.
3. The oil should be changed when any element value exceeds normal levels.
4. Maintain an analysis record using the gearcase serial number and machine operating hours.
LUBRICANT CLEANLINESS
Even the best lubricant is a useless wear preventative if it has become contaminated by careless
handling and storage. The lubricant manufacturer packs the lubricant in a tight container to keep
it clean. It is the responsibility of the person performing the machine lubrication to be sure that no
dirt gets into the lubricant.
Follow these points of good lubrication practice:
• Keep all oil and other lubricants in tightly covered containers.
• Wipe off covers before opening containers.
• Keep funnels, oil cans, grease guns, etc., in a clean place and wipe them off before
using them.
• Wipe off each fitting before attaching the lubricant gun.
• Wipe off oil filler caps or covers and the surrounding area before removing them.
Manual No. 10660 3-6 Nov 2008

LUBRICATION BENCHMARKS
ACSL - AIR COMPRESSOR (SCREW-TYPE) LUBRICANT
SCOPE: Lubrication performance requirements and recommendations for Air Compressor

(Screw-type) Lubricants.
IMPORTANT NOTE
These lubricant performance requirements for screw-type air compressors are only
good for A-C Compressor Corporation screw compressors. If the machine is
equipped with air compressors manufactured by other than A-C you must refer to
the vendor’s maintenance information provided with the machine and Section 7 of
this manual.
LUBRICANT RECOMMENDATIONS:
The following lubricants are recommended:
1. If the ambient temperature is expected to always be above -26°C (-15°F), use either:
Automatic Transmission Fluid (ATF) - General Motors Dexron III or Ford Type F.
or
Synthesized Hydrocarbon Fluid - Mobil Rarus SHC 924.
2. If the ambient temperature is expected to drop to -40°C (-40°F), use Mobil Rarus SHC 1024
or Phillips Philesco ISO32 or equivalent.
NOTE: If the ambient temperature drops below -26°C (-15°F), it may cause the lubricant to
thicken in the oil cooler and could result in unit shutdown after a short run. If this
happens often and the compressor is being lubricated with ATF, it is recommended
that a synthesized hydrocarbon lubricant be used instead.
NOTE: These performance requirements are benchmarks and not a specification. Therefore,
meeting these limits as described above does not relieve the supplier of the
responsibility associated with brand name products.
Nov 2008 3-7 Manual No. 10660

HYDO – HYDRAULIC OIL
It is recommended to use hydraulic oil suitable for year-round use, rather than summer or winter
only, which can create a mixing of viscosities if a complete draining of oil is not accomplished. This
can compromise the intended oil viscosity. The oil viscosity benchmark for this machine is 3,000
centistokes (CST) maximum on the coldest day for start-up, and 10 centistokes absolute minimum
on the hottest day during machine operation. Optimum oil viscosity at normal operating temperatures
is 30 to 60 centistokes.
For climates that rarely see ambient temperatures drop much below freezing (25°F to 32°F), a
paraffinic-based petroleum hydraulic oil with little or no viscosity improver (VI) can be acceptable.
For climates where ambient temperatures drop as low as -40°F on their coldest day and are as
high as 104°F on their hottest day, a higher VI fluid is required. Paraffinic-based fluids should NOT
be used where ambient temperatures reach freezing or slightly below freezing. At freezing or
slightly below freezing temperatures, the paraffin wax starts to solidify causing the fluid to have a
thicker viscosity than the temperature-viscosity curve actually implies. In addition, the VI additive
in petroleum-based oils has the ability to be mechanically sheared, causing the viscosity to drop.
This can result in a fluid that can be totally incorrect for use after it has been in service for some
time.
For all the above reasons, plus concerns of the oxidation-rate and water-ingestion that leads to
sludging, draining intervals of 2,000 hours are recommended when using petroleum-based paraffinic
or naphthenic-type hydraulic oils.
The preferred hydraulic oil for this machine is a PAO (poly-alpha-olefin) synthetic fluid with a
naturally high VI. Examples being: 198 for Shell® Oil Tellus T 722, a range of 135 to 145 for Mobil®
Oil SHC 500 series, 134 for Esso/Exxon® Terrestic SHP 22 Hydraulic Fluid, or 135 for Conoco®
SYNCON AW Oil.
The 3 to 4 times multiplier in the cost of synthetic fluids, as compared with paraffinic-based petroleum
oils, is offset by the fact that the synthetic oil can be left in the system 4 times longer (i.e. 8,000
hours) before a drain interval requirement. The savings with synthetic fluid use results because
the frequency of draining intervals is decreased by a factor of 4. This reduces the maintenance
time dedicated to changing the system oil and the cost of system oil disposal to 1/4 of what they
would otherwise be.
With all of the above in mind, using a SHC-type oil from Shell®, Mobil®, Esso/Exxon® or Conoco®
can result in considerable cost savings, whether the mine is located in a cold or warm climate.
Manual No. 10660 3-8 Nov 2008

PAO SYNTHETIC HYDRAULIC FLUID
The following bar graph shows

recommended viscosity grades for SHC
hydraulic oil for various ambient
temperatures. For temperatures outside of
these ranges, contact the Bucyrus
International, Inc. Service Department for
the recommended oil.
Chart - Recommended Viscosity Ambient Temperature
PARAFFINIC BASE PETROLEUM HYDRAULIC FLUID
Approved oils will typically have Denison HF-O specification certification. In general, the oils will
meet the following minimum requirements:
1. Maximum Viscosity = 14,000 SUS (3,000 CST) at the minimum expected ambient temperature
(for start-up).
CAUTION: Starting the engine with viscosities greater than 3,000 CST could void
warranty.
2. Minimum Viscosity = 65 SUS at the maximum operating temperature of the hydraulic system.
3. Ideal Viscosity = 100 SUS at normal operating temperature of the hydraulic system.
4. Minimum Viscosity Index = 90
5. Neutralization Number = 10 or less for new oil.
6. Oxidation Hours to 2.0 Neutralization Number per D-943 = 1,500 hours minimum.
7. Demulsibility (easy separation from water) per D-1401 = 30 ±15 minutes to 3 ml. max. of
emulsion.
CAUTION: In general, water will not separate from motor oils or automatic
transmission fluids, therefore THESE FLUIDS ARE NEVER
RECOMMENDED AS HYDRAULIC SYSTEM FLUIDS.
8. Hydrolytic Stability per D-2619 = Copper wt. loss not to be more than .50 mg/cm2
The oil should contain rust and oxidation (R+O) inhibitors and foam depressants.
CAUTION: The use of water or glycol base or any other fire resistant fluid is
prohibited since serious damage to the hydraulic system will occur
which will void the warranty on the machine hydraulic system.
Nov 2008 3-9 Manual No. 10660

Obtain oil from a reputable supplier. Contact the Bucyrus International, Inc. Service Department for
specific oil recommendations or approval. The lower figure in the following chart illustrates the
acceptable temperature range for various viscosity grades (VG) of oil assuming a viscosity index
of 125.
1. The left side of the bars show the absolute minimum ambient temperature for cold start-up.
2. The right side of bars show the absolute maximum oil temperature.
3. Ideal maximum operating oil temperature is a viscosity of 100 SUS.
Chart - Recommended Viscosity Maximum Temperature
NOTES:
• When determining an oil for the hydraulic system, the system is designed for an all-year oil
and for use without heaters. The hydraulic system is tailored to the ambient temperature at
the mine and the correct type of hydraulic fluid is selected. For extremely cold temperatures,
a very light fluid is used with oversize oil coolers to accommodate higher summer temperatures.
With this procedure, viscosity limits as little as 30° above ambient can be met.
• These performance requirements are bench marks and not a specification. Therefore, meeting
these limits as described above does not relieve the supplier of the responsibility associated
with brand name products.
• These performance requirements are bench marks and not a specification. Therefore, meeting
these limits as described above does not relieve the supplier of the responsibility associated
with brand name products.
Manual No. 10660 3 - 10 Nov 2008

MPG LUBRICATION POINTS

Auto-Lube: 61 Points
Manual Lube: 27 Points
Item Description Qty. Type Hours
a Timing Shaft Idler Pinion ............................. 2 Manual 250

b Drive Shaft Lower Bearing .......................... 2 Automatic --
c Guide Roller Frames (4 Places) ................ 12 Automatic --
d Guide Rollers ............................................. 16 Automatic --
Mast Machinery Gearcase
(32 points)
Nov 2008 3 - 11 Manual No. 10660

a Sheave Support Pin .................................... 1 Manual 250

b Side Frame Assembly, Inboard ................... 2 Manual 250
c Side Frame Assembly, Outboard ................ 2 Manual 250
d Timing Shaft Idler Pinion ............................. 2 Manual 250
e Sheave Support Frame .............................. 2 Manual 250
f Hose Drum Assembly Bushings ................. 4 Manual 250
g Guide Rollers .............................................. 4 Manual 250
Hose Drum Carrier Assembly
(17 points)
Manual No. 10660 3 - 12 Nov 2008

a Lower Arm Pivot - Left ................................ 1 Automatic --

b Lower Arm Pivot - Right .............................. 1 Automatic --
c Upper Arm Pivot Shaft Ends ....................... 2 Automatic --
d Upper Arm Pivot Shaft ................................ 1 Automatic --
e Lift Cylinder Pivots ...................................... 2 Automatic --
f Tensioning Cylinder Pivots .......................... 2 Automatic --
g Support Slide ............................................... - Manual 40
(No fitting - apply grease to slide area)
Pipe Handling Arm

(9 points)
Nov 2008 3 - 13 Manual No. 10660

a Rear Support Bushing ................................ 1 Automatic --

b Front Support Bushing ................................ 1 Automatic --
Pipe Carousel
(2 points)
Manual No. 10660 3 - 14 Nov 2008

a Gate Pivot Pin Retainers, Upper ................. 2 Automatic --

b Gate Pivot Pin Retainers, Lower ................. 2 Automatic --
Pipe Retension Device

(4 points)
a Outboard Sheave Pin ................................. 1 Automatic --

Lower Tensioning Arm
(1 point)
Nov 2008 3 - 15 Manual No. 10660

a Pawls ............................................................ 2 Automatic --

b Actuating Cylinder Pivots .............................. 3 Automatic --
c Arm Pivot Pins .............................................. 2 Automatic --
d Support Pillow Blocks ................................... 2 Automatic --
e Clamp Assembly ........................................... 6 Manual AR
Tool Wrench
(15 points)
Manual No. 10660 3 - 16 Nov 2008

a Jaw Pivot Pins ............................................ 2 Automatic --

b Actuating Cylinder ‘A’ .................................. 3 Automatic --
c Actuating Cylinder ‘B’ .................................. 2 Automatic --
d Actuating Cylinder ‘C’.................................. 2 Automatic --
Breakout Wrench
(9 points)
a U-Joints ...................................................... 2 Manual --

Power Module Drive Shaft
(2 points)
Nov 2008 3 - 17 Manual No. 10660

a Carrier Rope Sheave Pins .......................... 2 Automatic --

Upper Winch Beam
(2 points)
Manual No. 10660 3 - 18 Nov 2008

HYDRAULIC FLUID MAINTENANCE
HYDRAULIC SYSTEM CLEANLINESS
It is extremely important to use the correct oil in the system. It is equally important to keep the oil
clean. Contamination is the most common source of problems in a hydraulic system. It will cause
excessive wear of parts, interference with the close clearances, and hinders normal operation.
CAUTION: Never add oil to the system by removing the reservoir breather and
pouring it in through a funnel. Even new drum oil can be dirty which
could cause sticking valves.
When hydraulic oil is added to the system, it should always be pumped into the system. The
delivery pump discharge line should be attached to the system in order to insure that the new oil
will pass through the tank return filters before entering the system.
If the pump used to add the oil is equipped with a filter and the pump has been used for other
fluids, the pump system and filter must be purged of the other fluid prior to connecting the pump
unit to this system. This purging can be accomplished by flushing the pump unit and filter with at
least one gallon of the specified hydraulic oil.
1. Park the machine on level ground.

2. Raise the mast to 90o and retract all cylinders.
3. Shut off the diesel engine so the hydraulic pumps are
not running.
CHECK OIL LEVEL:
The oil level should be at the “FULL” decal on the side of the
hydraulic tank. If not, add fluid.
NOTE: If the fluid must be added frequently, determine

the source of a possible leak or indications of
excessive wear. Make repairs as soon as
practical.
Nov 2008 3 - 19 Manual No. 10660

ADD OIL:
1. Clean the quick-disconnect coupling mounted on the power module support below the hydraulic
tank, then connect the discharge hose from the oil drum pump to the coupling.
2. Pump hydraulic oil into the tank until the oil level is at the “FULL” mark and then disconnect
the discharge hose.
CHANGE OIL:
CAUTION: Allow time for the hydraulic tank to cool down before draining the oil.
Failure to comply with this caution may result in serious burns. To
prevent an explosion or fire, Do NOT smoke or create sparks while
changing hydraulic fluid.
DANGER: STORED ENERGY! Oil in the hydraulic lines and cylinders may be
under trapped pressure. Relieve the pressure carefully before doing
any maintenance.
NOTES:
• Approximate capacity of the hydraulic tank is 713 liters (190 U.S. gallons).
• This drain valve is located underneath the rear of the hydraulic reservoir, below power
module base.
1. Open the drain valve to drain the oil from the hydraulic tank. Close the valve after draining
has been completed.
2. Add new hydraulic oil as described in the steps above.
Manual No. 10660 3 - 20 Nov 2008

AIR COMPRESSOR OIL
Park the machine on level ground and/or use the

leveling jacks to level the machine. Shut down
the engine and wait 10 minutes to allow the oil to
settle.
CHECK OIL LEVEL:
The oil level should be 1 to 2 inches from the bottom

of the sight glass.
NOTE: If the fluid must be added frequently,

determine the source of a possible leak or
indications of excessive wear. Make
repairs as soon as practical.
ADD OIL:
DANGER: This is a pressurized vessel. Make sure the air compressor is NOT
running and the air/oil receiver pressure is at ZERO before removing
the oil fill plug.
1. Clean around the oil fill plug and then remove the plug.
2. Add air compressor oil through the coupling, mounted on the power module support and
below the air compressor tank, until the oil level is 1 to 2 inches from the bottom of the sight
glass. Then install the fill plug.
CHANGE OIL:
CAUTION: Shut down the air compressor and allow time for the compressor to
cool down before draining the oil. Failure to comply with this caution
may result in serious burns. To prevent an explosion or fire, Do NOT
smoke or create sparks while changing hydraulic fluid.
DANGER: STORED ENERGY! Oil in the hydraulic lines and cylinders may be
under trapped pressure. Relieve the pressure carefully before doing
any maintenance.
Nov 2008 3 - 21 Manual No. 10660

1. Remove the pipe plug from the drain valve and attach a short 1 inch NPT hose, to drain the
fluid into a barrel or into a lubrication truck.
NOTES:
• The air/oil receiver drain valve is located below the main deck at the bottom of the air/
oil receiver.
• The oil cooler drain valve is located below the main deck at the bottom of the oil cooler.
• Approximate capacity of the air compressor/oil receiver is 19 liters (5 U.S. gallons).
• Approximate capacity of the air compressor oil cooler is 102 liters (27.3 U.S. gallons).
2. Open the drain valve to drain the oil from the air/oil receiver. Close the drain valve after
draining has completed.
3. Open the drain valve to drain the oil from the oil cooler. Close the drain valve after draining
has completed.
4. Add new air compressor oil through the fill plug opening until the oil level is at the top of the
sight glass. Install the oil fill plug.
NOTE: It may be necessary to repeat the next step several times to fill the air/oil receiver to
the proper level.
6. Start the compressor and run it for approximately 15 seconds. Shut down the compressor
and check the oil level. If necessary add oil to bring the level to 2 inches from the bottom of
the sight glass.
For locations of compressor components and further information on the air compressor, refer to
Section 7 - COMPRESSED AIR SYSTEM in this manual.
Manual No. 10660 3 - 22 Nov 2008

AUXILIARY WINCH GEARCASE OIL
1. Park the machine on level ground and/or use the leveling jacks to level the machine.
2. Lower the mast to its horizontal position.
CHECK OIL LEVEL:

1. Have an assistant observe the winch from the left side of the machine.
2. Operate the winch control to payout its cable until the oil level/fill/drain plug is viewable
through the access hole in the side of the winch frame. (This hole will be at approximately a
9 o’clock position when the mast is lowered.)
CAUTION: DO NOT overfill the gearcase. Overfilling may cause overheating and
possible component malfunction.
3. Remove the oil level/fill/drain plug to check the gearcase oil level. The oil level should be at
the bottom of the plug opening. If the oil level is low, add RGL through the level/fill/drain plug
opening until the proper level is reached. Install the level/fill/drain plug.
NOTES:
• If the fluid must be added frequently, determine the source of a possible leak or
indications of excessive wear. Make repairs as soon as practical.
• Approximate capacity of the gearcase is 2.25 liters (2.5 quarts).
CHANGE OIL:
1. Operate the winch control to payout its cable

until the oil level/fill/drain plug is viewable
through the access hole in the side of the winch
frame. (This hole will be at approximately a 6
o’clock position when the mast is lowered.)
2. Install a short 1" NPT pipe nipple into the larger

threads of the drain port. Place a catch pan
under the pipe nipple.
3. Insert a 3/8" hexagon wrench through the pipe

nipple to remove the 1/2" NPT level/fill/drain plug
to drain the oil.
4. After draining is completed, remove the pipe

nipple and rotate the drum to the 9 o’clock
position.
5. Add RGL through the level/fill/drain plug opening

until the oil drips from the opening.
Nov 2008 3 - 23 Manual No. 10660

PUMP DRIVE TRANSMISSION FLUID
The pump drive transmission fluid is cooled by circulating the fluid through an additional cooler in
the radiator. The fluid capacity of this system includes the cooler at the radiator plus the hoses to
and from the pump and cooler.
Park the machine on level ground and/or use the leveling jacks to level the machine.
CAUTION: Shut down the machine. Lock out and tag the operator’s controls to
prevent restarting.
Manual No. 10660 3 - 24 Nov 2008

CHECK OIL LEVEL:
Remove the dipstick to check the gearcase oil level.
ADD OIL:
1. Clean dirt and debris from around the oil fill plug at the top of the transmission then remove
the plug.
2. Add new transmission fluid until the dipstick shows “FULL” and then install the fill plug and
dipstick.
NOTE: If the fluid must be added frequently, determine the source of a possible leak or
CAUTION: Allow time for the motor and transmission to cool down before
draining the oil. Failure to comply with this caution may result in
serious burns. To prevent an explosion or fire, Do NOT smoke or
create sparks while changing hydraulic fluid.
Nov 2008 3 - 25 Manual No. 10660

CHANGE OIL:
1. With the motor shut down and cooled off, clean dirt and debris from around the oil fill plug at
the top of the transmission then remove the plug.
2. Place a suitable container below the transmission to catch the drain oil.
3. Remove the plug at the bottom of the transmission. Allow the fluid to drain then install the
plug once draining is completed.
4. Add new transmission fluid until the dipstick shows “FULL”. Install the fill plug.
Manual No. 10660 3 - 26 Nov 2008

PROPEL GEARCASE OIL
NOTE: These procedures apply to either side of the machine. The oil level plug is identified by
the word “OIL” next to it.
CHECK OIL LEVEL:

1. Propel the machine so that the oil level plug and the drain plug are as shown in the figure.
CAUTION: Once the machine is positioned, shut down the engine. Lock out and
tag the operator’s controls to prevent restarting the engine.
CAUTION: Place a rag around the plug in the event the gearcase has become
pressurized. Slowly remove the plug, allowing air to escape.
CAUTION: THE OIL MAY BE HOT!
2. Clean around the oil level plug and

then remove the plug.
3. The oil should be at the bottom of

the oil level plug opening. If
necessary, add Propel Gear Oil
through the oil level plug opening
until the proper level is obtained.
NOTES:
• If the fluid must be added frequently, determine the source of a possible leak or
• Approximate capacity of the propel drive gearcase is 26.5 liters (7 U.S. gallons).
• Measure the amount of oil removed and note the viscosity of the oil to ensure that the
hydraulic oil has not contaminated the case due to a bad motor shaft seal or brake
seal.
CHANGE OIL:
1. Clean around the oil level plug and then remove the plug.
2. Remove the drain plug to drain the oil. Reinstall the drain plug.
3. Add new RGL through the oil level plug opening until the oil level is at the bottom of the
opening.
4. Install the oil level plug.
Nov 2008 3 - 27 Manual No. 10660

ROTARY GEARCASE OIL
1. Park the machine on level ground and/or use the leveling jacks to level the machine and
place the mast at 90o.
2. Remove the drill pipe from the mast. Lower the mast machinery to the bottom stops or drill
a full length hole.
CHECK OIL LEVEL:
Check the gearcase oil level by

viewing the sight glass on the front
cover of the gearcase.
ADD OIL:
1. Clean the area around the

breather / fill cap and remove
the breather.
2. Add Regular Gear Lube (RGL)

until the level is at the center of
the sight glass. Then install the
breather.
NOTE: If the fluid must be added frequently, determine the source of a possible leak or
CHANGE OIL:
1. Clean the area around the breather / fill cap and remove the breather.
2. Open the drain valve and allow the oil to drain. Close the valve after draining is completed.
Add oil using the above steps.
Manual No. 10660 3 - 28 Nov 2008

FILTER MAINTENANCE
Filter maintenance is a very important part of preventative maintenance. When operating in extremely
dusty or humid environments, cleaning and changing intervals should be shorter. Follow these
points for good filter maintenance practice:
• Keep all new filters in their original sealed containers.

• Wipe off areas around the old filter before removing it.
• Use a safety solvent to clean washable filters and housings.
• For the proper replacement element part numbers, refer to the parts book
for this machine.
NOTE: Instructions given are provided for general filter maintenance.
When available, follow the manufacturer’s instructions provided
for the manufacturer’s supplied component.
HYDRAULIC OIL FILTER RESTRICTION INDICATORS

Several of the hydraulic filters use on this machine are
equipped with restriction indicating switches. Filter
restriction indications are displayed as fault messages on
the display in the operator’s cab. A filter is in need of
replacement when a fault message appears on the
monitor while the hydraulic system is in use.
HYDRAULIC OIL FILTER (CHARGE FILTER)
1. Remove the cap, backup ring and O-Ring from

the housing. Remove the filter element.
2. Insert a replacement filter element.
3. Replace backup ring and/or O-Ring if damaged.
4. Reinstall the cap.
HYDRAULIC RESERVOIR FILTER
1. Remove four capscrews at the top of the filter.

2. Remove the filter cover assembly and O-Ring.
3. Remove filter element from housing.
5. Replace the O-Ring if damaged.
6. Install the cover assembly and capscrews, then
tighten the capscrews.
Nov 2008 3 - 29 Manual No. 10660

HYDRAULIC RESERVOIR BREATHER/DRYER
The hydraulic reservoir breather/dryer is located on top of the hydraulic reservoir. One of the functions
of the breather/dryer is to remove moisture from the reservoir. An indicator window on the outside
of the replaceable cartridge turns pink as the drying agent (desiccant) takes on moisture. Replace
the cartridge when the window is almost entirely pink
To replace the cartridge, unscrew it from the base. Replace the gasket with a new one furnished
with the replacement cartridge. Install the new cartridge until it bottoms on the gasket and then
tighten it an additional 1/8 to 1/4 turn.
AIR COMPRESSOR SYSTEM OIL FILTERS
The air compressor lubrication oil filter restriction indicator is displayed as a fault message on the
isplay in the operator’s cab. To replace the filter:
1. Remove the cap, backup ring and O-Ring from the housing. Remove the filter element.
3. Replace backup ring and/or o-ring if damaged.
4. Reinstall the cap.
Manual No. 10660 3 - 30 Nov 2008

AIR/OIL SEPARATOR FILTER RESTRICTION INDICATOR
The air compressor air/oil separator filter is equipped with a pressure gauge connected to a manual
valve that allows pressure to be measured above and below the separator plate. The filter elements
are in need of replacement when the air pressure differential across the separators reaches
approximately 0.7 bar (10 psig) or if the machine starts to consume oil.
CAUTION: Make sure the air compressor is not running and that the pressure in
the air/oil receiver is at zero.
For the replacement of the air compressor separator filter elements, refer to Section 7 ~
COMPRESSED AIR SYSTEM in this manual.
FLOWMASTER PUMP SERVICING
CAUTION: To reduce the risk of serious bodily injury, including fluid injection,
injury from moving parts, and splashing in the eyes or on the skin:
always follow the following Pressure Relief Procedure whenever you
shut off the pump; when checking or servicing any part of the spray
system; when installing, cleaning or changing dispense valve
nozzles; or whenever you stop dispensing.
Nov 2008 3 - 31 Manual No. 10660

PRESSURE RELIEF PROCEDURE
1. Close the shut-off valve to the material supply line.
2. Turn power OFF to lube pump at the control panel. Disconnect 24DCV power supply at the
solenoid valve.
3. Relieve pressure at safety unloader.
The lube pump is factory set at 350 (24.1 bar) working inlet hydraulic pressure with a flow rate of
2.5 GPM (9.5 LPM). Maintain hydraulic pressure between 300-450 PSI (20.6 - 31.0 bar). Maximum
flow rate is 7 GPM (26.5 LPM). However, adjusting the lowest pump outlet pressure and hydraulic
fluid flow to obtain the desired to results will minimize pump wear.
Pump pressure and flow rate will vary depending on operating temperatures. DO NOT ADJUST
THE PUMPS PRESSURE BEFORE THE INITIAL START-UP PROCEDURE. For more information
on installation and start-up, refer to the manufacturer’s literature included with this machine.
PRESSURE CONTROL VALVE ADJUSTMENT
1. Loosen the locknut on the pressure reducing valve by turning the nut COUNTER-
CLOCKWISE.
2. Turn the valve stem COUNTER-CLOCKWISE until it reaches the stop. This adjustment
allows the minimum pressure setting which is approximately 170 psi (11.7 bar).
3. With the pump stalled against pressure, turn pressure control valve stem CLOCKWISE
until desired pressure is attained on manifold pressure gauge. DO NOT EXCEED 450 PSI
(31.0 bar).
4. Tighten (CLOCKWISE) the locknut to 20-25 Ft.Lbs. (27.1 - 33.9 N-m).
Manual No. 10660 3 - 32 Nov 2008

FLOW CONTROL VALVE ADJUSTMENT
1. Loosen the locknut on the flow control valve by turning the nut COUNTER-CLOCKWISE.
2. Adjust the flow by turning the valve stem CLOCKWISE to reduce the flow and COUNTER-
CLOCKWISE to increase it. The flow valve can be turned in until the valve is completely
closed, and out a maximum of 2-1/2 turns.
3. After adjusting the flow to the desired setting, tighten (CLOCKWISE) the locknut to 20-25
Ft.Lbs. (27 - 34 N-m).
FlowMaster Rotary Driven Hydraulic Pump Schematic
WARNING: Relieve pressure from the pump and supply lines before servicing or
repairing the pump, to reduce the risk of an injury from injection,
splashing fluid or moving parts.
CRANK CASE OIL
Check the crank case oil every 100 hours of operation. Change
the crank case oil every 500 hours of operation. Use SAE 10W30
motor oil in all units except Model 85610. In Model 85610, the
manufacturer recommends Mobil Arrow HFA Low Temp oil for
use at -70°F (-57°C) ambient temperatures.
The crank case should be filled to the center of the drain plug
located on the back of the crankcase.
Nov 2008 3 - 33 Manual No. 10660

PUMP DISASSEMBLY PROCEDURE
1. Remove and separate manifold (37) from the hydraulic motor (42).
2. Remove the pipe plug (45) and drain the crank case oil from the pump housing (46).
3. Remove the housing cover (30) and cover gasket (31).
4. Remove the retaining ring (57) and pull the shovel plug (56) from the housing tube (55).
5. Remove and separate the hydraulic motor (42) from the pump housing (46).
6. Remove the 2 outlet pin nuts (50) from the pump housing (46).
7. Remove the pump sub-assembly (1-28) from the pump housing (46). Pushing the sub-
assembly up with a wooden or plastic rod .75 inch O.D. (19 mm O.D.) against the check seat
housing (28) is helpful.
8. Remove the housing tube (55) from the pump housing (46) by inserting a .75 inch O.D. (19
mm O.D.) rod through the inlet holes at the bottom of the housing tube (55) and unscrewing
it.
9. Remove the bronze bearing (51), o-ring (52) and back-up washer (53) from the housing tube
(55).
10. Remove the crankrod assembly (1-8) from the pump by unscrewing the screws (12) and
then pulling out the wrist pin bushings (13).
11. Remove the check seat housing (28) from the reciprocating tube (21).
12. Unscrew the wrist pin anchor (14) from the reciprocating tube (21) and pull the plunger
assembly (9-20) from the tube.
13. Using a .50 inch O.D. (12.7 mm O.D.) rod, push the cup seal (22) and pump cylinder (24)
from the reciprocating tube (21).
14 Remove the pump plunger (20) from the plunger link rod (17). A spanner wrench is required.
15. Unscrew the plunger link rod (17) from the plunger tube (11) and slide off the cup seal (16),
back-up washer (15) and the wrist pin anchor (14).
16 Unscrew the plunger tube (11) from the outlet pin (9).
17. To dismantle the crankrod assembly (1-8), remove the screws (1) and counter weights (2).
18. Remove the retaining rings (6) and press the crank eccentric (7) out of the ball bearing (8). Be
sure to support the ball bearing (8) on the inner race.
Manual No. 10660 3 - 34 Nov 2008

FlowMaster Rotory Driven Hydraulic Pump Assembly
Nov 2008 3 - 35 Manual No. 10660

PUMP ASSEMBLY PROCEDURE
1. When the pump is disassembled, it is recommended to replace all seals and gaskets. For
replacement parts and service kits, refer to part sheet, “PUMP, HYDRAULIC, ROTARY
DRIVEN” in the parts manual for this machine.
2. In the process of disassembly, examine the following components and replace if excessive
wear is indicated:
• Ball Bearing (8)
• Crank Eccentric (7)
• Crank Rod (5)
• Wrist Pin (13)
• Plunger Tube (11)
• Pump Plunger, Ball & Spring (18-20)
• Pump Cylinder (24)
• Check Seat Housing & Ball (26 & 28)
• Upper Bronze Bushing (51)
• Housing Tube (55)
• Shovel Plug (56)
• Reciprocating Tube (21)
3. The assembly procedure is reverse of the disassembly procedure except for the following:
4. Install parts (22-28) into reciprocating tube (21) after the plunger assembly (9-20) is installed.
5. Install the pump sub-assembly (1-28) into the pump housing (46) before tightening the housing
tube (55) to the pump housing (46). Be sure the reciprocating tube (21) is inserted through
both bushings before tightening the housing tube (55).
6. Use loctite 242 (or similar product) medium strength thread lock on all torqued threaded
connections. Extreme care must be exercised to prevent excess compound from flowing
into critical areas such as clearance fits and ball check. Allow a minimum of 30 minutes cure
time before operating the pump.
Torque Specifications:
Plunger Tube (11) to Outlet Pin (9) ~ Tighten to 100-110 In.Lbs. (11.3 - 12.4 N-m)
Button Head Screws (12) to Wrist Pin Anchor (14) ~ Tighten to 100-110 In.Lbs. (11.3 - 12.4 N-m)
Plunger Tube (11) to Plunger Link Rod (17) ~ Tighten to 100-110 In.Lbs. (11.3 - 12.4 N-m)
Manual No. 10660 3 - 36 Nov 2008

Plunger Link Rod (17) to Pump Plunger (20) ~ Tighten to 100-110 In.Lbs. (11.3 - 12.4 N-m)
Flat Head Screws (1) to Counter Weight (2) ~ Tighten to 100-110 In.Lbs. (11.3 - 12.4 N-m)
Wrist Pin Anchor (14) to Reciprocating Tube (21) ~ Tighten to 20-25 Ft.Lbs. (27.1 - 33.9 N-m)
Check Seat Housing (28) to Reciprocating Tube (21) ~ Tighten to 20-25 Ft.Lbs. (27.1 - 33.9 N-m)
Outlet Pin Nut (50) to Pump Housing (46) ~ Tighten to 30-35 Ft.Lbs. (40.7 - 47.4 N-m)
Housing Tube (55) to Pump Housing (46) ~ Tighten to 20-25 Ft.Lbs. (27.1 - 33.9 N-m)
Socket Head Screw (44) to Pump Housing (46) ~ Tighten to 50-55 Ft.Lbs. (67.8 - 74.6 N-m)
Pressure Reducing Valve (38) to Manifold (37) ~ Tighten to 20-25 Ft.Lbs. (27.1 - 33.9 N-m)
Flow Control Valve (39) to Manifold (37) ~ Tighten to 20-25 Ft.Lbs. (27.1 - 33.9 N-m)
Solenoid Valve (34) to Manifold (37) ~ Tighten to 15-20 Ft.Lbs. (20.3 - 27.1 N-m)
Socket Head Screws (33) to Manifold (37) ~ Tighten to 20-25 Ft.Lbs. (27.1 - 33.9 N-m)
FlowMaster Rotary Driven Hydraulic Pump Components
Nov 2008 3 - 37 Manual No. 10660

PUMP TROUBLESHOOTING
Condition Possible Cause Corrective Action
Pump does not run. No pressure on gauge (32):

- Closed Supply line shut off valve. Open shut-off valve.
- No power to solenoid valve (34). Correct electrical fault.
- Faulty Solenoid (35). Replace solenoid (35).
- Pressure Reducing Valve (38) is Reset Pressure Reducing Valve (38).
Set too low.
- Insufficient Hydraulic Fluid supply. Check hydraulic supply for proper
pressure and flow.
Pressure is shown on gauge (32):

- Closed Fluid outlet line. Check outlet line and clear
obstructions.
- Flow Control valve is fully closed. Readjust valve to 3/4 turn open.
- Pump is stalled due to grease Readjust valve to 3/4 turn open.
backpressure.
Pump is seized or damaged. Dismantle the pump and repair
defective or seized component. See
disassembly and assembly procedure.
Pump speeds up or runs erratically. Low level of grease or reservoir Refill reservoir.
is empty.
Follower plate is stuck and Check follower plate and container
separated from grease. for damage.
Pump piston or checks are worn. Disassemble the pump and repair.
Pump runs, but output is low. Insufficient hydraulic fluid supply. Check hydraulic supply and adjust
flow using valve (39).
Inlet pressure too low. Increase pressure using valve (38).
Faulty inlet (25, 26, 27) or Replace faulty components.
discharge check valve (18, 19, 20).
Weepage from housing cover (30). Cup seal (16) or O-Ring (48) wore out. Check the seals and replace if
necessary.
Pump becomes noisy. No crank case oil. Add crank case oil. Remove Pipe
Plug (45) from Pump Housing (46).
Oil level should be at the bottom of
the Pipe Plug opening. For Models
85480, 85481, 85482, 85483 and
85247Add 10W30 motor oil until
the crankcase is full.
For Model 85610, add light weight
Mobil Arrow HFA Hydraulic Oil until
the crankcase is full.
Worn wrist pin bushing (13). Check the bushings and replace if
necessary.
Pump does not build pressure. Foreign material holding lower Dismantle & clear check. Consider
check open. installing inlet screen (63)
before returning pump to service.
Manual No. 10660 3 - 38 Nov 2008

HYDRAULIC SAMPLE POINT LOCATIONS
Hydraulic Pump Assembly
Nov 2008 3 - 39 Manual No. 10660

Air Compressor
Manual No. 10660 3 - 40 Nov 2008

Transmission
Nov 2008 3 - 41 Manual No. 10660

Hydraulic Cooler
Manual No. 10660 3 - 42 Nov 2008

03 Lubrications 141248 141249

Încărcat de

Informații document

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

03 Lubrications 141248 141249

Încărcat de

Drepturi de autor:

Formate disponibile

Bucyrus International, Inc.

39HR Blast Hole Drill

LUBRICATION PRINCIPLES ......................................................................................................... 3

Nov 2008 3-1 Manual No. 10660

39HR Blast Hole Drill

HYDRAULIC OIL FILTER (CHARGE FILTER) ................................................................. 29

ADDITIONAL LUBRICATION BENCHMARKS:

Manual No. 10660 3-2 Nov 2008

39HR Blast Hole Drill

Nov 2008 3-3 Manual No. 10660

39HR Blast Hole Drill

Operation of this machine in extreme temperatures (below -20°F/-29°C or above 110°F/44°C)

Manual No. 10660 3-4 Nov 2008

39HR Blast Hole Drill

PROPEL GEARBOX LUBRICANT REPLACEMENT/SAMPLING

The lubricant is to be selected from a proven,

CAUTION: The initial oil change is

Nov 2008 3-5 Manual No. 10660

39HR Blast Hole Drill

Follow these points of good lubrication practice:

• Keep all oil and other lubricants in tightly covered containers.

• Wipe off covers before opening containers.

• Wipe off each fitting before attaching the lubricant gun.

Manual No. 10660 3-6 Nov 2008

39HR Blast Hole Drill

ACSL - AIR COMPRESSOR (SCREW-TYPE) LUBRICANT

SCOPE: Lubrication performance requirements and recommendations for Air Compressor

The following lubricants are recommended:

Nov 2008 3-7 Manual No. 10660

39HR Blast Hole Drill

HYDO – HYDRAULIC OIL

Manual No. 10660 3-8 Nov 2008

39HR Blast Hole Drill

PAO SYNTHETIC HYDRAULIC FLUID

The following bar graph shows

Chart - Recommended Viscosity Ambient Temperature

PARAFFINIC BASE PETROLEUM HYDRAULIC FLUID

Nov 2008 3-9 Manual No. 10660

39HR Blast Hole Drill

3. Ideal maximum operating oil temperature is a viscosity of 100 SUS.

Chart - Recommended Viscosity Maximum Temperature

Manual No. 10660 3 - 10 Nov 2008

39HR Blast Hole Drill

MPG LUBRICATION POINTS

Item Description Qty. Type Hours

a Timing Shaft Idler Pinion ............................. 2 Manual 250

Nov 2008 3 - 11 Manual No. 10660

39HR Blast Hole Drill

Item Description Qty. Type Hours

a Sheave Support Pin .................................... 1 Manual 250

Manual No. 10660 3 - 12 Nov 2008

39HR Blast Hole Drill

Item Description Qty. Type Hours

a Lower Arm Pivot - Left ................................ 1 Automatic --

Pipe Handling Arm

Nov 2008 3 - 13 Manual No. 10660

39HR Blast Hole Drill

Item Description Qty. Type Hours

a Rear Support Bushing ................................ 1 Automatic --

Manual No. 10660 3 - 14 Nov 2008

39HR Blast Hole Drill

Item Description Qty. Type Hours

a Gate Pivot Pin Retainers, Upper ................. 2 Automatic --