Original instructions

666 1 en 2011-08-23

dp1500i Maintenance Manual

Table of Contents

1. INTRODUCTION ............................................................................................................................ 11
1.1. General ................................................................................................................................................................ 12
1.2. Type plate location ........................................................................................................................................... 13
1.3. Intended use ...................................................................................................................................................... 14
1.4. Recommended operating conditions .......................................................................................................... 14
1.5. Warning and information symbols used in this manual ........................................................................ 14
1.5.1. Safety Symbols .............................................................................................................................................. 15

2. SAFETY ......................................................................................................................................... 21
2.1. Main safety risks related to the use and maintenance of the rig ......................................................... 22
2.2. General operation and maintenance safety instructions ...................................................................... 23
2.3. Manner and conditions in which the rig should not be used ............................................................... 26
2.4. Dust ...................................................................................................................................................................... 27
2.5. Danger areas during tramming and drilling .............................................................................................. 28
2.6. Inclination angles ............................................................................................................................................. 29
2.6.1. When tramming and parking ........................................................................................................................ 29
2.6.2. When drilling ................................................................................................................................................... 30
2.7. Centre of gravity ............................................................................................................................................... 30
2.8. Fire safety ........................................................................................................................................................... 31
2.8.1. Location of the fire extinguishers ................................................................................................................ 31
2.8.2. Using the fire extinguisher ............................................................................................................................ 32
2.8.3. ANSUL extinguishing system (optional) ..................................................................................................... 33
2.8.4. AFFF extinguishing system (optional) ........................................................................................................ 35
2.9. Emergency stops and stopping devices .................................................................................................... 37
2.9.1. Emergency stops ........................................................................................................................................... 37
2.9.2. Safety wire ...................................................................................................................................................... 38
2.10. Operation prevention functions ................................................................................................................... 39
2.10.1. Automatic stop functions .............................................................................................................................. 39
2.10.2. Stopper devices ............................................................................................................................................. 39
2.10.3. Dual tramming stopper device ..................................................................................................................... 39
2.11. Location of main switch ................................................................................................................................. 39
2.12. Emergency exit ................................................................................................................................................. 39
2.13. Filling the fuel tank ........................................................................................................................................... 40
2.14. Maintenance of the hydraulics ...................................................................................................................... 41
2.15. Pneumatic system maintenance .................................................................................................................. 42
2.16. Maintenance of the rock drill pressure accumulators ............................................................................ 43
2.17. Maintenance of the electrical system ......................................................................................................... 44
2.18. Maintenance of the batteries ......................................................................................................................... 46
2.19. Safety During Welding .................................................................................................................................... 48
2.20. Safety equipment .............................................................................................................................................. 48
2.20.1. FOPS/ROPS ................................................................................................................................................... 49
2.21. Noise level and noise emissions .................................................................................................................. 49
2.22. Vibration .............................................................................................................................................................. 49

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 2.23. Warning sign locations ................................................................................................................................... 50
2.24. Symbol plates .................................................................................................................................................... 54
2.25. Radio control ..................................................................................................................................................... 56
2.26. Making modifications and corrections to the product ........................................................................... 57

3. MACHINE DESCRIPTION ............................................................................................................. 59

3.1. Main component location ............................................................................................................................... 60
3.1.1. Boom ................................................................................................................................................................ 61
3.1.2. Feed ................................................................................................................................................................. 62
3.1.3. Rod handler .................................................................................................................................................... 63
3.1.4. Hydraulic rock drill ......................................................................................................................................... 64
3.1.5. Track carrier .................................................................................................................................................... 65
3.1.6. Diesel engine CAT C13 ................................................................................................................................ 66
3.1.7. Cabin ................................................................................................................................................................ 67
3.1.8. Hydraulic system ............................................................................................................................................ 68
3.1.9. Pneumatic system ......................................................................................................................................... 69
3.1.10. Shank lubrication unit .................................................................................................................................... 70
3.1.11. Fuel system .................................................................................................................................................... 71
3.1.12. Dust collector system .................................................................................................................................... 72
3.1.13. Main electrical system ................................................................................................................................... 73
3.1.14. Control system ............................................................................................................................................... 74
3.2. Overview of the rig's structure ..................................................................................................................... 75
3.3. Description on Controls and Functions ..................................................................................................... 76
3.3.1. Auxiliary panels .............................................................................................................................................. 76
3.3.2. Left armrest panel .......................................................................................................................................... 79
3.3.3. Right armrest panel ....................................................................................................................................... 80
3.3.4. Pedals .............................................................................................................................................................. 81
3.3.5. Front and rear jack panel ............................................................................................................................. 81
3.3.6. Radio controller .............................................................................................................................................. 82
3.4. Graphical user interface ................................................................................................................................. 84
3.4.1. User interface control .................................................................................................................................... 84
3.4.2. Common elements of the user interface .................................................................................................... 85
3.4.3. Main screens .................................................................................................................................................. 89
3.4.4. Operator management (option) ................................................................................................................... 111
3.5. Fuses ................................................................................................................................................................... 117

4. PERIODIC MAINTENANCE ........................................................................................................... 121

4.1. Importance of scheduled maintenance ...................................................................................................... 122
4.2. General maintenance instructions ............................................................................................................... 122
4.3. Filter kits ............................................................................................................................................................. 123
4.4. Daily checks ....................................................................................................................................................... 124
4.4.3. Checks during drilling .................................................................................................................................... 125
4.5. First maintenance ............................................................................................................................................. 126
4.5.1. Maintenance performed according to diesel engine hours ..................................................................... 126

5. MAINTENANCE INSTRUCTIONS ................................................................................................. 127

5.1. Boom .................................................................................................................................................................... 128
5.1.1. Tightness of bolts and nuts .......................................................................................................................... 128

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5.1.2. Checking and replacing the zoom tube wiper ........................................................................................... 129
5.1.3. The clearances of the zoom tube slide pieces .......................................................................................... 130
5.1.4. Cylinder pins ................................................................................................................................................... 135
5.1.5. Mounting of the hydraulic cylinders ............................................................................................................ 136
5.1.6. Boom's fastening to the carrier .................................................................................................................... 136
5.1.7. The boom and cradle welds ......................................................................................................................... 136
5.1.8. Pressures of the pressure accumulators ................................................................................................... 137
5.1.9. Cradle clearances .......................................................................................................................................... 138
5.1.10. Weekly lubrication of the boom ................................................................................................................... 139
5.2. Feed ...................................................................................................................................................................... 141
5.2.1. Tightness of bolts and nuts .......................................................................................................................... 141
5.2.2. Cleaning the cables ....................................................................................................................................... 141
5.2.3. Condition and wear of cables ...................................................................................................................... 142
5.2.4. Fastening and tightness of cables .............................................................................................................. 143
5.2.5. Feed cylinder guide clearances ................................................................................................................... 149
5.2.6. Clearance of the rock drill carriage and hose reel carriage and condition of the slide pieces .......... 151
5.2.7. Checking the Pito centraliser cylinder jaw pieces .................................................................................... 153
5.2.8. Replacing idler wheel bearings ................................................................................................................... 155
5.2.9. Replacing the feed cylinder seals ............................................................................................................... 155
5.2.10. Lubricating the PITO centraliser cylinder ................................................................................................... 155
5.2.11. Greasing points .............................................................................................................................................. 156
5.3. Rod handler ........................................................................................................................................................ 157
5.3.1. Tightness of bolts and nuts .......................................................................................................................... 157
5.3.2. Conditions of the roller Pito .......................................................................................................................... 158
5.3.3. Rod changer jaws .......................................................................................................................................... 158
5.3.4. Rod handler greasing points ........................................................................................................................ 159
5.4. Hydraulic rock drill ........................................................................................................................................... 160
5.4.1. General ............................................................................................................................................................ 160
5.4.2. Safety precautions ......................................................................................................................................... 160
5.4.3. Main components .......................................................................................................................................... 161
5.4.4. Flushing ........................................................................................................................................................... 162
5.4.5. Lubrication circulation ................................................................................................................................... 163
5.4.6. Tools and parts used in maintenance ........................................................................................................ 165
5.4.7. Checking the tightness of the bolts visually ............................................................................................... 165
5.4.8. Condition of the flushing housing seals (during drilling) .......................................................................... 166
5.4.9. Checking the front end components ........................................................................................................... 166
5.4.10. Removing the flushing housing ................................................................................................................... 167
5.4.11. Checking the flushing housing bearing ...................................................................................................... 167
5.4.12. Checking the shank bushing ........................................................................................................................ 168
5.4.13. Removing and installing the shank bushing .............................................................................................. 169
5.4.14. Checking the coupling ................................................................................................................................... 171
5.4.15. Checking the rotation bushing ..................................................................................................................... 171
5.4.16. Checking and replacing the rotation bushing bearing ............................................................................. 172
5.4.17. Checking the chuck ....................................................................................................................................... 173
5.4.18. Shank wear limits ........................................................................................................................................... 173
5.4.19. Removing the flushing housing cover and fitting flange .......................................................................... 174
5.4.20. Installing the flushing housing cover and fitting flange ............................................................................ 175
5.4.21. Replacing the flushing housing cover bearing .......................................................................................... 176

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 5.4.22. Flushing housing wear limits ........................................................................................................................ 176
5.4.23. Removing and installing the seal housing ................................................................................................. 177
5.4.24. Checking the tightness of the side bolts .................................................................................................... 178
5.4.25. Pressure accumulator bolts ......................................................................................................................... 179
5.4.26. Checking the pressure accumulator ........................................................................................................... 179
5.4.27. Condition of the pressure accumulator’s filling valves and cover plugs ............................................... 179
5.4.28. Checking the charge gas pressure of the pressure accumulators ........................................................ 180
5.4.29. Tightness of the rotation motor bolts .......................................................................................................... 181
5.4.30. Flushing housing bolts .................................................................................................................................. 182
5.4.31. Front cover bolts ............................................................................................................................................ 183
5.4.32. Major overhaul ................................................................................................................................................ 183
5.5. Carrier .................................................................................................................................................................. 183
5.5.1. Washing the rig .............................................................................................................................................. 183
5.5.2. Checking the condition of the fire extinguisher ......................................................................................... 184
5.5.3. Checking the mounting of the track batches ............................................................................................. 184
5.5.4. Tightening the caterpillar track .................................................................................................................... 184
5.5.5. Changing the tramming gear oil .................................................................................................................. 185
5.5.6. Checking the tramming gear oil ................................................................................................................... 187
5.5.7. Checking the idler wheel oil ......................................................................................................................... 188
5.5.8. Checking the (oscillation) bolts of the cylinders ........................................................................................ 189
5.5.9. Greasing the oscillation axle ........................................................................................................................ 189
5.5.10. Lubrication of the oscillation cylinder pins ................................................................................................. 190
5.5.11. Changing the transfer gearbox oil ............................................................................................................... 191
5.5.12. Checking the electrolyte level and battery cable connections ................................................................ 192
5.5.13. Mounting and condition of the winch cable ............................................................................................... 192
5.5.14. Cleaning the battery and the battery terminals ......................................................................................... 193
5.5.15. Checking the welds ....................................................................................................................................... 193
5.5.16. Changing the winch oil .................................................................................................................................. 193
5.5.17. Checking the fastening of cables ................................................................................................................ 193
5.6. Diesel engine ..................................................................................................................................................... 193
5.6.1. Cleaning the diesel engine ........................................................................................................................... 194
5.6.2. Replacing the air filter ................................................................................................................................... 195
5.6.3. Replacing the air filter safety cartridge ....................................................................................................... 196
5.6.4. Replacing the oil and the oil filter ................................................................................................................ 196
5.6.5. Cleaning the crankcase breather ................................................................................................................ 197
5.6.6. Checking the earth terminal of the engine ................................................................................................. 197
5.6.7. Cleaning the radiator core ............................................................................................................................ 197
5.6.8. Cleaning the intercooler ................................................................................................................................ 198
5.6.9. Hoses and connections ................................................................................................................................ 198
5.6.10. Checking the tightness and condition of the V-belt .................................................................................. 198
5.6.11. Checking the starter motor ........................................................................................................................... 199
5.6.12. Checking the turbocharger ........................................................................................................................... 199
5.6.13. Checking the condition of the water pump ................................................................................................ 200
5.6.14. Changing the coolant .................................................................................................................................... 201
5.6.15. Replacing the cooling system thermostat .................................................................................................. 201
5.6.16. Checking the engine monitoring .................................................................................................................. 201
5.6.17. Checking the alternator ................................................................................................................................. 202
5.6.18. Checking the engine brackets ..................................................................................................................... 202

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5.6.19. Checking the crankshaft's vibration damper ............................................................................................. 202
5.6.20. Checking the electronic injector nozzles .................................................................................................... 203
5.6.21. Checking the engine speed / timing sensors ............................................................................................ 203
5.6.22. Checking the valve clearances .................................................................................................................... 203
5.6.23. Checking the valve rotators ......................................................................................................................... 204
5.7. Cabin .................................................................................................................................................................... 204
5.7.1. Operation of the cabin door switch ............................................................................................................. 204
5.7.2. Cabin air filters ............................................................................................................................................... 204
5.8. Hydraulic system .............................................................................................................................................. 205
5.8.1. Cleaning the radiator core ............................................................................................................................ 205
5.8.2. Hydraulic oil tank ............................................................................................................................................ 206
5.8.3. Checking the return pressure sensor ......................................................................................................... 206
5.8.4. Checking the temperature sensor ............................................................................................................... 206
5.8.5. Changing the hydraulic oil tank breather ................................................................................................... 207
5.8.6. Oil pressure filter ............................................................................................................................................ 207
5.8.7. Changing the oil return filters ....................................................................................................................... 208
5.8.8. Operation of the oil level switch ................................................................................................................... 208
5.8.9. Cleaning the hydraulic oil tank ..................................................................................................................... 208
5.8.10. Changing the hydraulic oil ............................................................................................................................ 209
5.8.11. Checking the hydraulic oil thermostat ........................................................................................................ 209
5.9. Pneumatic system ............................................................................................................................................ 210
5.9.1. Checking the intake air line and connections ............................................................................................ 210
5.9.2. Replacing air filter .......................................................................................................................................... 211
5.9.3. Replacing the air filter safety cartridge ....................................................................................................... 212
5.9.4. Operation of the air filter maintenance indicator ....................................................................................... 212
5.9.5. Changing the compressor oil ....................................................................................................................... 212
5.9.6. Oil filter ............................................................................................................................................................ 213
5.9.7. Oil separator ................................................................................................................................................... 213
5.9.8. Cleaning the oil receiver ............................................................................................................................... 214
5.9.9. Checking the thermostat ............................................................................................................................... 214
5.9.10. Cleaning the radiator ..................................................................................................................................... 215
5.10. SLU Shank lubrication unit ............................................................................................................................ 215
5.10.1. Condensed water in the oil tank .................................................................................................................. 215
5.10.2. Changing the oil receiver breather .............................................................................................................. 215
5.10.3. Cleaning the oil receiver ............................................................................................................................... 216
5.10.4. Emptying the shank lubrication return tank ............................................................................................... 216
5.10.5. Checking the operation of the monitoring unit .......................................................................................... 217
5.11. Fuel system ........................................................................................................................................................ 217
5.11.1. Draining water and deposition from the fuel tank ..................................................................................... 218
5.11.2. Replacing the fuel filter / water separator element ................................................................................... 219
5.11.3. Replacing the fuel filter cartridge ................................................................................................................. 220
5.11.4. Bleeding the fuel system .............................................................................................................................. 221
5.11.5. Fuel tank .......................................................................................................................................................... 221
5.11.6. Replacing the fuel tank breather ................................................................................................................. 222
5.11.7. Cleaning the fuel tank ................................................................................................................................... 222
5.12. Dust collector system ..................................................................................................................................... 222
5.12.1. Condition of suction hoses and connections ............................................................................................. 222
5.12.2. Condition of the filter cartridges ................................................................................................................... 223

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 5.12.3. Operation of pulse jet cleaning .................................................................................................................... 223
5.12.4. Integrity of the dust collector ........................................................................................................................ 223
5.12.5. The condition of the fine separator’s impact plate. ................................................................................... 224
5.12.6. Condition of the coarse separator’s skirt rubber ....................................................................................... 224
5.12.7. Condition of the coarse separator’s rubber lining ..................................................................................... 224
5.12.8. Condition of the suction head rubbers ....................................................................................................... 225
5.12.9. Moving suction head cylinder lubrication ................................................................................................... 225
5.12.10. Operation of the cut-off cylinder / butterfly valve ...................................................................................... 225
5.12.11. Operation of the cut-off cylinder / butterfly valve ...................................................................................... 226
5.13. Main electrical system ..................................................................................................................................... 226
5.13.1. Checking the condition of electrical cables and connections ................................................................. 226
5.13.2. Checking electrical cabinets and boxes ..................................................................................................... 226
5.13.3. Checking the fastening of electrical cables ............................................................................................... 226

6. LUBRICANTS AND CAPACITIES ................................................................................................. 227

6.1. General ................................................................................................................................................................ 228
6.1.1. Choosing the oil ............................................................................................................................................. 228
6.1.2. Oil viscosity ..................................................................................................................................................... 229
6.2. Hydraulic system .............................................................................................................................................. 230
6.2.1. Engine oils in the hydraulic system ............................................................................................................. 231
6.2.2. Hydraulic oils .................................................................................................................................................. 232
6.2.3. Biodegradable hydraulic oils ........................................................................................................................ 233
6.2.4. Fire retardant hydraulic fluids ...................................................................................................................... 234
6.3. Rock drill shank lubrication ........................................................................................................................... 235
6.3.1. Shank lubrication with oil .............................................................................................................................. 235
6.3.2. Shank lubrication with grease ...................................................................................................................... 236
6.4. Diesel engine ..................................................................................................................................................... 236
6.4.1. API engine oil classification ......................................................................................................................... 236
6.4.2. Fuel sulphur content ...................................................................................................................................... 236
6.5. Compressor ....................................................................................................................................................... 237
6.5.1. Gardner Denver compressor ....................................................................................................................... 237
6.6. Classifications for transmission and driveline oils ................................................................................. 239
6.6.1. Quality classifications .................................................................................................................................... 239
6.6.2. Viscosity classifications ................................................................................................................................ 240
6.7. Transmission oils (surface rigs) ................................................................................................................... 240
6.7.1. Tracks .............................................................................................................................................................. 240
6.7.2. Transfer gearbox Stiebel .............................................................................................................................. 240
6.7.3. Winch ............................................................................................................................................................... 241
6.8. Drill steel thread grease .................................................................................................................................. 241
6.9. Lubrication grease ........................................................................................................................................... 241
6.9.1. General lubrication greases ......................................................................................................................... 241
6.9.2. Sandvik (SKF) central lubrication system greases ................................................................................... 242
6.9.3. Greases for Lincoln central lubrication system ......................................................................................... 242
6.10. Engine coolant .................................................................................................................................................. 242
6.10.1. Caterpillar engines ......................................................................................................................................... 243
6.11. Compressor oil and refrigerant for the air conditioning unit ............................................................... 243
6.12. Filling capacities ............................................................................................................................................... 244

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7. ADDITIONAL INSTRUCTIONS ..................................................................................................... 247
7.1. Towing ................................................................................................................................................................. 248
7.1.1. Releasing the brakes .................................................................................................................................... 249
7.2. Transport ............................................................................................................................................................ 251
7.3. Lifting ................................................................................................................................................................... 252
7.4. Storage ................................................................................................................................................................ 254
7.5. Filling the lubricant reservoir of the pumping unit ................................................................................. 255
7.6. Seat adjustment ................................................................................................................................................ 257
7.6.1. Adjusting the armrest panels ....................................................................................................................... 258
7.7. Cabin's vacuum cleaner ................................................................................................................................. 259
7.8. Filling the fuel tank with the electric pump ............................................................................................... 260
7.9. Filling the hydraulic oil tank with the electric pump ............................................................................... 261
7.10. Filling the water tank with the electric pump ............................................................................................ 262
7.11. Water heater ....................................................................................................................................................... 263
7.11.1. General ............................................................................................................................................................ 263
7.11.2. Orientation of the heater ............................................................................................................................... 263
7.11.3. Control and safety equipment ...................................................................................................................... 265
7.11.4. Operation of the timer ................................................................................................................................... 265

8. MAINTENANCE CARDS ............................................................................................................... 269

8.1. Maintenance label ............................................................................................................................................. 270
8.2. Maintenance program ..................................................................................................................................... 271
8.3. Instructions for reading maintenance cards ............................................................................................. 272
8.4. Maintenance performed according to diesel engine hours .................................................................. 273
8.4.1. Every 50 hours ............................................................................................................................................... 273
8.4.2. Every 250 hours ............................................................................................................................................. 277
8.4.3. Every 500 hours ............................................................................................................................................. 281
8.4.4. Every 1000 hours ........................................................................................................................................... 287
8.4.5. Every 1500 hours ........................................................................................................................................... 293
8.4.6. Every 3000 hours ........................................................................................................................................... 299

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1. INTRODUCTION

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1. INTRODUCTION

1.1. General

Preface

Thank you for choosing a product manufactured by Sandvik Mining and Construction Oy.
This manual describes the use of the product. Only people with the proper training are allowed to
operate this product. In addition, the operator must read and understand the contents of the operation
and maintenance manuals and the safety instructions.
The manual gives you information on the structure and operation of the product that is necessary for
correct use and maintenance. It also instructs you in shift-specific service work. Regular maintenance
procedures are explained in the maintenance instructions.
For more complicated maintenance and repair work, we recommend that you contact the nearest
authorized service center. Our maintenance personnel have the skill and special tools needed for
more demanding work.
Through correct use and by following the maintenance instructions, you can expect a high degree of
utilization and a long service life for your product.

Storage

The manual is part of the product, and it must be kept throughout the life of the product. Attach any
further changes to the manual. Keep the manual clean and readily accessible whenever needed. If
the product is sold, the new owner must be provided with the manual.

Product information

The information in this manual corresponds to the model and appearance of the product at the time
of delivery. Sandvik Mining and Construction Oy reserves the right to change the technical data and
equipment without prior notice. All information included in the manual is valid at the time of publication.

Copyright

This document must not be copied, presented, or delivered to a third party without our permission,
nor used for purposes other than those allowed by us. We reserve the right to change the product’s
settings and equipment, as well as the maintenance and repair instructions, without separate notice.
Sandvik Mining and Construction Oy

Manual contents

The operator's manual contains the following information:

- General information about the purpose and content of the operator's manual, instructions for reading
the manual, and a request for feedback and correction of any inaccuracies.
- Information related to safety
- Daily checks
- Product’s operating instructions.

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1.2. Type plate location

-B
02
5

-B
2
0
5

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1.3. Intended use

The rig is a hydraulic surface drilling rig designed for mines and quarries. It drills vertical, inclined,
and horizontal holes. The maximum hole depth with the cassette is 35 m when drilling with 4.2 m MF
rods and using a 6.1 m starter rod.

1.4. Recommended operating conditions

• Ambient temperature: –30 °C to +50 °C

• Maximum allowed height from sea level: max. 3000 m
• In special cases, please contact the local Sandvik Mining and Construction representative.

1.5. Warning and information symbols used in this manual

The warnings in this manual have been divided into the following three categories.

The term "DANGER" Indicates a hazardous situation which, if not avoided,

will result in death or serious injury.
The term “WARNING” Indicates a hazardous situation which, if not avoided,
could result in death or injury.
The term "NOTICE" Indicates a situation which, if not avoided, could result
in damage to property.

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1.5.1. Safety Symbols

The safety symbols found in this manual may also be posted on

the machine. All personnel who operate, repair, or service the
machine MUST be familiar with and observe all safety symbols,
labels, and instructions!

• Keep safety instructions and safety labels clean and visible at all times.
• Replace any illegible or missing safety instructions and safety labels before operating the machine.

Hazard
The black symbol inside a yellow triangle with a black border describes the
hazard.

Prohibition
The black symbol inside a red ring with a diagonal red bar describes the
action that should not be taken.

Mandatory action
The white symbol inside a blue circle describes the action that must be taken
to avoid a hazardous situation.

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Hazard symbols

These symbols are used in warnings to indicate a hazardous situation or action.

Hazard symbols are divided into six categories according to their nature:
• Mechanical hazards
• Electrical hazards
• Noise hazards
• Radiation hazards
• Material/substance hazards
• Ergonomic hazards
• General hazard

The hazard symbols related to each hazardous situation are presented below.

Mechanical Hazard Symbols

Falling load hazard Squashing hazard Flying material hazard

Crushing hazard - feet Crushing hazard - hands Cutting hazard

Entanglement hazard Entanglement hazard Entanglement hazard

Entanglement hazard - rotating Falling hazard Trip hazard

drill

Skin injection hazard High pressure injection hazard Hanging load hazard

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Run over hazard Slipping hazard Sideways tipping hazard

Forward/backward tipping haz- Sideways tipping hazard Forward/backward tipping haz-

ard ard

Electrical Hazard Symbols

Electrical hazard Dangerous electrical voltage Electrical shock/

Electrocution hazard

Noise Hazard Symbols

Noise hazard

Radiation Hazard Symbols

Radioactive hazard Laser hazard

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Material / Substance Hazard Symbols

Hot surface hazard Explosion hazard Flammable hazard

Hazardous/poisonous material Chemical burn hazard Silica/dust hazard

hazard

Hot coolant splashing hazard Environment pollution hazard

Ergonomic Hazard Symbols

Lifting hazard

General Hazard Symbol

General hazard

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Prohibited action symbols

These symbols are used in warnings and notifications to indicate a the action that should not be taken.
The prohibition symbols are presented in the following table.

No climbing No smoking No open flames

Do not touch Limit or restrict access Do not weld

Do not remove safety guard Do not modify General symbol for prohibited
action

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Mandatory action symbols

These symbols are used in warnings and notifications to indicate the action that must be taken to
avoid a hazardous situation.
The mandatory action symbols are presented in the following table.

Wear safety gloves Wear eye protection Wear safety helmet

Wear safety harness Wear ear protection Wear steel toed safety boots

Wear close fitting overalls Wear high visibility vest Wear respirator

Disconnect from power source Switch off and lockout equip- Read the manual or instructions
ment

Use cardboard for locating leaks Use lap belt General symbol for mandatory
in hoses action

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2. SAFETY

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2. SAFETY

2.1. Main safety risks related to the use and maintenance of the rig

Make sure that there are no unauthorised persons in the

working area when drilling or tramming.

WARNING! PERSONAL INJURY HAZARD! Hazardous moving

parts and dangerous rig movements (boom, feed, rock drill,
hatches, and gratings) could result in death or severe injury.
Make sure there are no unauthorized persons in the danger
areas during drilling, tramming, setting up or servicing the rig.

Dangerous rig movements. Keep an eye on the movements of

the drilling rig when working close to the rig. Watch out in
particular for the rotating drill rod.

WARNING! PERSONAL INJURY HAZARD! Hazardous boom

movement could result in death or severe injury. Do not go
beneath the boom(s) unless absolutely necessary. Stay out of
the danger areas during drilling, tramming or setting up the rig.
Support the boom before servicing the hydraulic system.

WARNING! MACHINE TIPPING HAZARD! Insufficient machine

stability can cause unexpected machine movement which could
result in death or severe injury. Never exceed the specified
maximum inclination angles when parking or operating the
machine.

Slipping, tripping and falling hazard. To avoid death or serious

injury, keep the stairs, steps, handrails, handles, and working
platforms clean of oil, dirt, and ice.

Danger of venting compressed air. Compressed air jets can

cause serious injury. Allow the pressure to be released before
opening the filling cap or the compressed air connector.

HIGH PRESSURE INJECTION HAZARD! Compressed air jets

can cause serious injury. Allow the pressure to be released from
the hydraulic circuit before opening the plugs or connectors.

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2.2. General operation and maintenance safety instructions

DANGER
EXPLOSION HAZARD!
Can cause death or serious injury.
Charging the drill plan, even partially, is strictly forbidden
during drilling!

WARNING
PERSONAL INJURY HAZARD!
Operating or servicing the machine in a dangerous or incorrect
manner or without adequate safety procedures can result in
serious injury or death.
Operating, service and adjustment procedures must be carried
out only by personnel with specialized operation and service
training. Read and ensure that you understand the operating,
maintenance, and safety instructions before using or servicing
the rig. Carefully plan your work beforehand to minimize risk of
damage or injury.

WARNING! PERSONAL INJURY HAZARD!

Gases generated during blasting include large amounts of
noxious gases, which are hazardous to health, such as nitrogen
dioxide and carbon monoxide. In areas where the ore contains
sulphur, sulphur dioxide and other sulphur compounds are also
formed.
Always make sure that the area is thoroughly ventilated after
blasting.

WARNING! PERSONAL INJURY HAZARD!

Danger of death or severe injury.
Always follow all traffic regulations for the work site where
tramming of this rig is concerned. Immediately notify the person
responsible of all faults and defects.

WARNING! PERSONAL INJURY HAZARD!

Neglect of use the personal safety equipment can cause death
or serious injury.
The operator must always wear the required safety equipment,
such as a safety helmet, protective overalls, protective
footwear, hearing protectors, eye protectors, etc.

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FIRE HAZARD!
Danger of death or severe injury.
All heat insulation material must always be reinstalled after
maintenance. The temperature in the engine compartment may
not exceed 300 °C. The temperature may be higher than 300 °C,
if there is no heat insulation in the rig.

PROPERTY DAMAGE RISK!

Do not use the zoom cylinder when the feed is in contact with
the ground or rock.

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It is recommended to keep a record of the use of maintenance and wear parts. This way, the need
for preventive maintenance can be predicted more easily, resulting in the rig’s improved usability,
service life, efficiency and safety.
Failure to take necessary precautions increases the safety risk for the service personnel. All
maintenance personnel working with the rig must be fully aware of possible hazards and must apply
safe working methods. Before any maintenance or repair work, the manufacturer’s instructions must
be read carefully, and they must be followed exactly.
The person responsible for maintenance and repair work must be clearly specified.
Pay attention to the following:
• Never attempt to carry out tasks for which you have not received the relevant training or
authorisation.
• Inform the rig operator about the start of maintenance and repair work.
• Before starting the work, ensure that all unnecessary items are cleared from the vicinity of the site
and that the area is safe to work in.
• If maintenance or repair work is to be carried out on the rig, always ensure that the rig cannot be
accidentally started:
- Turn the main switch off.
- Remove the ignition key.
• Place a DANGER - DO NOT START warning sign on the main switch. The sign may only be
removed by a person who is fully aware of the current status of the work.
• Clean and wash the rig regularly, and always before starting maintenance or repair work.
• Before washing the rig with water, a high-pressure cleaner, a steam cleaner, or any other method,
protect any components that are susceptible to damage from the cleaning method or due to
exposure to water. Pay special attention to the protection of electric motors, boxes, and cabinets.
• If necessary, equip the work site with appropriate steps or working platforms.
• Never use the components of the rig as steps. If the work is carried out at height, or in an otherwise
dangerous position, use proper working platforms to prevent falling. Never climb on the rig's covers.
• Keep all stairs, rails, anti-slip devices, steps, etc. clean of oil, grease, snow, ice, unnecessary items,
and dirt to prevent accidents caused by slipping.
• Use only undamaged, high-quality tools that are appropriate for the work in question.
• Before starting the work, ensure that the rig is on a level surface and the park brake is engaged
and that all tracks/wheels are wedged or that the jacks are lowered to prevent movement.
• Observe the operation and condition of the exhaust pipe and exhaust cleaner in particular, and
ensure sufficient ventilation.
• Diesel engine overheating indicates a fault. Stop the engine and address the cause of the
overheating in order to prevent damage to the engine. Ensure that air can flow freely through the
engine's radiator. If necessary, clean the radiator and remove any obstructions.
• Stop the engine and allow it and the coolant to cool down before checking the coolant level. If this
is not possible, use protective gloves and other protective clothing when opening the radiator cap,
in order to prevent burns and related injuries. Stand as far to the side as possible, turn your face
away, and carefully open the cap slightly. Before opening the cap fully and removing it, wait until
the pressure or coolant stops discharging from the cooling system.
• Use appropriate hoists and lifting methods when moving heavy parts and equipment. Follow the
hoist manufacturer's instructions.

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2.3. Manner and conditions in which the rig should not be used

Risks of personal injury

• The operator has inadequate training

• Unauthorized persons are in the work area
• Safety systems are inadequate or out of order
• The area to be drilled is charged
• The rig is used for personnel transportation
• The rig is being used for lifting

Environmental risks to the rig

• Risk of the embankment collapsing under the rig

• Possibility of a loose boulder falling on the rig
• An icy or otherwise slippery drilling site
• Drilling under power lines with the danger of contact with a live power
line
• Inadequate lighting

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2.4. Dust

Drilling creates dust, which stays at the drilling site and the surrounding area even when drilling is
not in progress.
The dust may be so fine that it cannot be seen. Inhalation of fine, invisible dust can be extremely
dangerous.

DANGER
Breathing dust can cause death or severe injury. Always wear
an approved respirator.

Protection from dust

- When outside the cabin, always wear an appropriate respirator that has been approved by the
manufacturer. Make sure that the respirator is in good condition.
- Always keep the cabin door closed.
- Keep the cabin clean, and clean daily with a vacuum cleaner.
- Replace the cabin air filters regularly. Use only original spare parts.

Dust collector system

Make sure that the dust collector system functions well and effectively at all times. Make sure that
- The suction head is firmly against the ground during drilling.
- The suction head and the suction head rubbers are in good condition.
- The suction hoses are in good condition and tight.
- The dust collector filters are in good condition. Use only original spare parts.

Use the optional DustMizer system to reduce the amount of dust created.
Using the correct drilling parameters and keeping the drilling equipment in good condition reduces
the amount of dust created.
Safe use of the rig requires skilled maintenance personnel
trained by Sandvik, and the use of only original spare parts. The
daily and other periodic checks and maintenance must be
carried out according to the instructions.

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2.5. Danger areas during tramming and drilling

During tramming

3m
3m 3m

3m

When drilling
6m

6m 3m
5m

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2.6. Inclination angles

See the rig's inclination angles in the inclination

angle indicators located in the cabin.

If the terrain inclination is more than 20°, a winch must be used.

When tramming or drilling on a slippery surface, such as ice or

smooth rock, the safe inclination angle is noticeably smaller
than on non-slippery surfaces.

2.6.1. When tramming and parking

During tramming, keep the zoom in and the feed against the
transport support. Keep the oscillation locking open.

The maximum inclination angle during tramming is 20° in all directions.

Max. 20° Max. 20°

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2.6.2. When drilling

The figure indicates the rig's maximum angles of inclination in all directions (oscillation locked) when
drilling is performed with various boom and feed positions. The inclination angles have been
measured with the boom in the extreme positions to the left and right and with the zoom fully extended
and fully retracted.

10°
10°

21° 18°

Tipping hazard. Risk of serious injury or death. Do not exceed

the maximum inclination angles. Keep oscillation locked.
Observe extreme caution when drilling with the boom turned to
the side and the zoom at its extreme position.

2.7. Centre of gravity

Centre of gravity with the boom zoom in and the feed in the rear position, against the transport support.
1550

1350
1300

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2.8. Fire safety

WARNING
FIRE HAZARD!
Danger of death or severe injury.
In the event of a fire, evacuate the area to reduce the risk of
injury from flames, heat, hazardous vapours, explosion, or
other hazards that may arise. Always follow the local
regulations in the event of a fire.

2.8.1. Location of the fire extinguishers

The fire extinguishers are located on the side

wall inside the cabin and on the outside next to
the boom.

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2.8.2. Using the fire extinguisher

Read the operation instructions on the side of the fire

extinguisher. Make sure that the extinguisher's indicator gauge
is not in the red zone. If the indicator is in the red zone, the fire
extinguisher must be serviced immediately at an authorised
service shop.

1. Remove the extinguisher from its holder.

2. Shake the extinguisher once or twice to mix its contents.
3. Pull the ring pin out and take the hose from its holder.
4. Assume a secure position and a good hold on the hose, and aim the nozzle toward the flames.
5. Spray the extinguishing chemical by pressing the nozzle trigger. Stop spraying when the flames
are extinguished, in order to save as much of the contents as possible in case the fire ignites
again.

The extinguisher must be refilled at a service shop after each

use.

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2.8.3. ANSUL extinguishing system (optional)

The ANSUL extinguishing system is available for the rig as an option. The extinguishing system starts
when the operator presses the trigger, after which nozzles at various locations on the rig act as fire
extinguishers.
Manual triggering:
1. Remove the ring pin.
2. Press down the button.

ANSUL extinguishing system

1. Press the drilling rig emergency stop button.

2. Turn the main switch to the OFF position.
3. Use a handheld fire extinguisher if this is possible.
4. Trigger the system. There are two triggers: one at the rear of the rig and the other on the right
side of the cabin, next to the boom.
5. Prepare to extinguish new fire pockets with the handheld fire extinguisher.

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After a fire

Once the fire is out and the rig has cooled down, open the ventilation hatches to clear the unit of
smoke and gases. Avoid breathing in the combustion gases. Keep a hand-held fire extinguisher ready
for use during ventilation.
Wash the rig with plenty of water as soon as possible after extinguishing, because the powder used
can cause corrosion, especially to the cables. Replace empty tanks and gas cartridges before using
the rig again.
• In the event of a fire, evacuate the area to reduce the risk of injury
from flames, heat, hazardous vapours, explosion, or other hazards
that may arise.
• Manual triggering results in immediate system discharge, which
may obscure vision. Make certain the rig is stopped safely before
manually triggering the system.
• Do not start the rig again until the cause of the fire has been
established and the fault repaired.
• Only personnel who are very familiar with the installation may
remove and fit powder tanks and pressure cartridges. Please see
the maintenance instructions for how to refill the automatic
triggering system.

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2.8.4. AFFF extinguishing system (optional)

The AFFF extinguishing system is available for the rig as an option.

1
2

3 4

1. Triggering module handle

- The system is triggered by turning the triggering module handle in the direction indicated by
the arrows.
2. Safety tie
- The safety tie breaks by itself and must always be replaced after triggering.
3. Pressure switch
4. Electronic alarm/timer housing
5. Radio panel

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Operation

The set includes a pressure switch (3) and electronic alarm/timer housing (4). The switch detects that
the AFFF system has been activated, starts an audiovisual alarm (the indicator light for low pressure
alarm or system discharge goes on and a signal sounds), and starts the engine shutdown delay.
Once the AFFF system has started, the engine is shut down automatically in six seconds. The engine
shutdown remains active until the extinguishing system has been recharged. The alarm/timer has a
manual override function (override button) so that the rig can be moved if necessary.
If the button is pressed within the 6-second period, the timer adds a further 20-second delay during
which the operator can tram the rig before the engine is shut down automatically.
The override button must be kept depressed in order for the override function to remain active. When
the button is released, the unit returns to shutdown mode.

Override adapter

The pressure switch is overridden before the system is delivered to the customer. When implementing
(charging) the AFFF system for the first time, remove the override adapter and connect pressure
switch cable WS223 and pressure switch S223.

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2.9. Emergency stops and stopping devices

2.9.1. Emergency stops

Make sure that the emergency stops can be accessed at all

times.

Check the operation of the emergency stops daily.

When one of the emergency stops is pressed, the engine stops and, along with this, all functions
cease. The emergency stop window is displayed when one of the rig's emergency stop buttons has
been pressed. The engine can be restarted only after the emergency stop has been released.

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2.9.2. Safety wire

Check the operation of the safety wire daily.

When the safety wire is pulled with sufficient force or the wire loosens, the drilling and rod handling
functions and the dust collector stop. The engine still runs.

B A

Adjusting the safety wire

- During adjustment, the diesel engine must remain stopped. The control system must be running.
- Adjust the wire length from point A so that the edge of the attachment link is at mark B on the switch
lever.
- Pull the wire. The control system display shows a message indicating that the safety wire has been
triggered.
- Reset the safety wire switch by pressing button C on the switch, upon which the message is cleared
from the control system display.

An incorrectly adjusted wire may cause the safety wire to be

activated during tramming or drilling.

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2.10. Operation prevention functions

2.10.1. Automatic stop functions

The engine stops if:

1. The hydraulic oil level drops too low.

2. The compressor temperature is too high.
• 105°C Compressor overheating warning
• 110°C Compressor overheating alarm (control system derates the diesel engine to idle and
decreases the compressor pressure)
• 115°C Compressor overheating stop level (control system shuts down the diesel engine)
3. The ECM alarm is activated (CAT diesel engine control).

A message about the cause of the stop appears on the control system display.

2.10.2. Stopper devices

The rig features a stopper device that prevents tramming when the cabin door is open. Also, the rig
will stop if the door is opened during tramming.
The control system monitors the drill bit location and prevents tramming, if the bit and/or drill rod is
in the hole or elsewhere below the starting level of drilling. If necessary, lift the feed or boom.
In addition, tramming is prevented if the armrest panels are not down or the rear jack is not up.

2.10.3. Dual tramming stopper device

Simultaneous tramming from the cabin and with the radio control is prevented. Radio control is
switched on and off with the auxiliary panel selection button.

2.11. Location of main switch

Main switch is located at the back of the rig.

2.12. Emergency exit

The rear window of the cabin can be used as an emergency exit. Next to the window is a hammer
for breaking the window if necessary.

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2.13. Filling the fuel tank

Handle fuel with care: it is highly flammable.

WARNING
FIRE HAZARD!
Smoking, open flames, and sparks cause a highly dangerous
situation when the fuel tank is filled or otherwise handled.
Do not refuel the machine while smoking or when near open
flame or sparks.

When filling the fuel tank, follow these instructions:

Always stop the engine before refueling machine.

- In addition, switch the cabin heater / air conditioning off.

- Fill fuel tank outdoors.
- Keep the fuel gun in contact with the filling tube. This eliminates possible sparks caused by static
electricity. If this is not possible, arrange for the gun to be earthed in some other way.
- Ensure that no fuel is spilled onto hot surfaces.
- Never lock the nozzle lever in motion without looking after.
- Wipe spilled fuel off before starting the engine.
- Prevent fires by keeping machine clean of accumulated trash, grease, and debris.

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2.14. Maintenance of the hydraulics

DANGER
SQUASHING HAZARD!
Danger of death or severe injury.
Before removing the cylinders or their overcentre or non-return
valves, support the boom, feed and rock drill carefully so that
they do not move during the maintenance. Do not work under
components that are supported only by hydraulics.

WARNING
HIGH-PRESSURE FLUID HAZARD!
High-pressure fluid remaining in hydraulic lines can cause
serious injury.
Never carry out maintenance or repair work on a pressurized
system. Relieve pressure before opening fittings, plugs or
hydraulic valve cartridges. Always make sure the parts are not
pressurized. Use a bleeder screw to relieve the pressure behind
the valves or cartridges, or wait until the unit is depressurized,
before removing the components.

WARNING
FIRE HAZARD!
Flammable spray can be caused by heat near pressurized fluid
lines, resulting in severe burns.
Do not weld, solder, or use a torch near pressurized fluid lines
or other flammable materials. Pressurized lines can burst when
heated.

WARNING
BURN HAZARD!
The oil circulating in the hydraulic systems is hot. It can cause
severe burns to the skin.
Let the oil cool down before starting any maintenance work.

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WARNING
HYDRAULIC FLUID INJECTION HAZARD!
High-pressure hydraulic fluid spray can penetrate under the
skin, causing serious injury.
Search for leaks with a piece of cardboard or wood. Never try
to locate a leak by feeling with your hand. Immediate medical
attention is required after injection.

Maintenance and repair work on the hydraulics and installation

of components may only be carried out by persons who have
received the training required for the work. Do not start work
that is not fully familiar to you.

Protect your eyes by wearing goggles.

- Do not use the drilling rig if there is a leak in the hydraulic system.
- Stop the power pack and diesel engine before repairing a leaky hose or tightening a connector.
- Oil spray can also easily cause a fire.
- Prevent oil splashes by wrapping a cloth around the component.
- Avoid skin contact with oil.
- Ensure that the new hose connectors and hose types correspond to the types originally used by
the manufacturer and are the same length. When replacing hoses and connectors, use original
Sandvik parts or equivalent parts recommended by the manufacturer. Also ensure that the hoses
and connectors are rated for the pressure level they will be subjected to.
- Ensure that all the connections will be made according to the hydraulic diagram.
- Check the movements of the rig before use.

2.15. Pneumatic system maintenance

WARNING
HIGH PRESSURE INJECTION HAZARD!
Compressed air jets can cause serious injury.
Ensure that the pneumatic system is not pressurised before
starting maintenance of the compressor or other pneumatic
system component.
The system may not be pressurised to a higher pressure level
than that specified by the manufacturer. Increasing the
pressure level does not increase the rig’s performance level.

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2.16. Maintenance of the rock drill pressure accumulators

WARNING
DANGER OF PRESSURE PNEUMATIC SYSTEM!
Danger of death or severe injury.
Do not pressurize the accumulators to a pressure greater than
that specified.

The disassembly, inspection, assembly, and pressurisation of

the pressure accumulators are discussed in pressure
accumulator instructions.

Rock drill pressure accumulators are filled with

nitrogen N2. Before removing the pressure accu-
mulators from the rock drill, release the accumu-
lators’ pressure by opening the filling valve.

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2.17. Maintenance of the electrical system

DANGER
ELECTRICAL HAZARD. Cut the supply voltage to the light using
the main switches before replacing the bulbs of the working and
driving lights. Exercise extreme caution when performing
maintenance or repair work on HID gas discharge lamps. The
light components include high voltage parts. Failure to follow
these procedures will result in death or serious injury!

Note that parts of the light may be hot after use, so allow it to cool before commencing repair work.
The bulbs of gas-discharge lamps are gas-filled, so handle with care.
Do not touch the lamp holder or the glass part of the bulb when carrying out the replacement.
Electrical modifications to the rig require written permission
from Sandvik Mining and Construction Oy's electrical design
department to ensure the correct operation of the modified
device.

Stop the rig immediately if electrical failure occurs.

Work on electrical equipment or devices is to be performed only

by persons with the required expertise and qualifications
required by the authorities, or under the supervision of a person
meeting these requirements. In addition, the work must be
carried out according to current electrotechnical regulations.

Always follow local safety instructions and electrotechnical

regulations.

Use only original electrical components.

- If required by regulations, switch off the voltage supply to the device or the device components
before inspection, repair, or maintenance. Ensure that the components in question are not live, and
then lock the main switch or arrange appropriate grounding.
- Check the condition of the rig's electrical devices regularly. Immediately repair any faults and defects
observed, such as loose connections or damaged insulation.

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Giving a jump start using a booster-type jump starter is
prohibited. A booster type jump starter raises the voltage of the
electrical system. The use of higher voltage will damage the
electrical system. If a jump start is needed, use additional
batteries of the same battery voltage.

Working with live components

WARNING
If a component must be live, one employee must be ready on-
hand at all times to switch the power off via the emergency stop
or main switch. Follow the electrical safety regulations.

Observe extreme caution.

Use a red and white safety chain and warning signs to mark the
work area.

Use only insulated tools.

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2.18. Maintenance of the batteries

Sulfuric acid in battery electrolyte is poisonous and strong enough to burn skin, eat holes in
clothing, and cause blindness if splashed into eyes. Personal protective equipment and eye
flushing facilities must be available near the charging location. Always wear protective equip-
ment such as goggles, protective overalls, protective footwear, and protective gloves when
working with batteries. Open flames, smoking, and work that causes a spark are strictly pro-
hibited during servicing of batteries! Static sparking must be prevented with insulating shoes
or by safely discharging the static charge.

DANGER
EXPLOSION, ELECTRIC SHOCK AND CHEMICAL BURN
HAZARD!
Incorrect handling of the battery will cause death or severe
injury.
The following special instructions must always be followed in
handling of the batteries.

• Electrical work concerning batteries that have a short-circuit current over 1000 A must be performed
by qualified electricians only.
• Always consider the danger of explosion when handling the batteries. When the battery is charged
or discharged, lead and acid generate oxygen and hydrogen, which, in turn, form a highly explosive
gas. A battery in use must always be handled on the assumption that there is explosive gas in its
cells and ventilation ducts. Gas is present even after charging of the battery for an extended time.
A spark near the battery can ignite the explosive gas. If the battery explodes, the acid flows around
it when it breaks open. The energy of the short circuit is sufficient for melting the metallic parts of
the short-circuited parts. Thus, drops of melted metal can also fly around in the explosion. A spark
can be caused by, for example,
- disconnecting or connecting of the battery clamp
- a short circuit between the battery terminals or between the positive terminal and the frame
- grinding or welding
- use of a match or a lighter
- smoking
- static electricity
In order to eliminate the risk of explosion, the battery electrolyte level must be kept stable and
checked regularly. Add distilled water, if required, before starting, never after that. The space
remaining for gas in the cells can be eliminated by keeping the electrolyte level of the battery as
high as possible.
• Open flames are strictly prohibited in the charging room and the immediate vicinity of the charging
area.
• Battery acid must not be stored in the charging area.
• If you get acid on your skin, rinse it immediately with plenty of water. If battery acid gets in your
eyes, neutralize it first with sodium carbonate. Then rinse with plenty of water and seek medical
advice.

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• Always loosen the battery cell caps before charging, to allow the gases generated during charging
to escape. Ensure appropriate ventilation, to ensure the escape of the gases generated during
charging to external air.
• Charging is done by the machine's own charger or a separate battery charger. If a separate battery
charger is used, see charger manufacturer's instructions.
• Do not charge a frozen battery. Warm battery to 16°C (60°F).
• Be especially careful when you are charging a empty battery.
• Batteries cannot be tilted during charging, measurement, or start-up assistance.
• Do not test electrical equipment by using the battery terminals.
• Never check battery charge by placing a metal object across the posts. Use a voltmeter or
hydrometer.
• Use a flashlight to check battery electrolyte level.

Disconnecting and connecting of the cable shoes:

• Connection and disconnection of the cables must always be done when the system is not energized.
Turn the battery main switch to the open position.
• Use insulated tools only.
• Disconnect the grounded (-) battery clamp first, then the power (+) battery clamp.
• In order to prevent sparking, disconnect the charger cable or switch it off before connecting the
cables to the battery.
• Before connecting the cable shoes, ensure that the power is switched off to all electrical equipment
of the drilling rig.
• The cable shoes must be connected carefully, and the polarity must be taken into consideration.
• Connect first the power (+) battery clamp and then the grounded (-) battery clamp. Thus you can
avoid sparks caused by the tool.
• Do not wear rings or a metallic wristwatch, since these may cause a short circuit, which could, in
turn, can result in sparking and burns.
• Check that the battery terminal covers are intact, and put them in their correct place.

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2.19. Safety During Welding

Before welding, determine the material to be welded and the appropriate welding method and
consumables. If necessary, contact Sandvik Mining and Construction Oy’s service division.

Never repair the boom or its components by welding (special

materials that cannot be welded with normal methods are used
in booms).

Use appropriate protective equipment.

Comply with the welding instructions and use appropriate

welding methods.

The rig is equipped with electrical and electronic components

that can be damaged if the rig is welded. When welding the rig,
comply with the following instructions fully.

- Stop the engine and turn the ignition key to position 0.

- Open the main switch and disconnect the battery cables.
- Provide adequate ventilation and fire-extinguishing equipment.
- Protect the electric cables and other sensitive components from the weld splatters.
- Attach the welding equipment’s ground cable directly to the part to be welded. Connect the cable
as close to the welding point as possible and such that the welding current does not pass through
bearings, hydraulic components, electrical/electronic components, or the rig's ground cable.

2.20. Safety equipment

Check the emergency stops, trip devices, and safety equipment

for proper functioning and condition before the start of each
shift and after tramming.

• Fire extinguisher
• Emergency stops
• Safety wire
• Stopper device (cabin door open, rear jack down, armrests up)
• Dual tramming stopper device
• Reverse alarm
• Rearview mirrors
• Anti-slip tapes
• ROPS/FOPS cabin
• Warning labels
• Rig inclination angle indicators
• Rear jack warning (display panel)

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2.20.1. FOPS/ROPS

Components tested to FOPS (Falling Object Protective Structure) / ROPS (Roll-Over Protective
Structure) include the safety canopy / cabin.
No changes must be made to the cabin / safety canopy, since these will void the rig's FOPS/ROPS
approval.

2.21. Noise level and noise emissions

The sound pressure level and volume measurements in the operator position have been performed
according to the European Standard Drill Rigs - Safety EN 791.
• Noise level at the operator position during drilling................LpA 78 dB (A), ISO 11201-1995
• Noise level caused by the rig during drilling...........................LwA 124 dB (A), ISO 4872-1978

2.22. Vibration

The whole-body vibration during drilling does not exceed 0.5 m/s² *, when tested according to the
European Standard Drill Rigs - Safety EN 791.

* the highest root mean square value of weighted acceleration

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2.23. Warning sign locations

70

8
8

9
9

44

36

43

42
42

4 82

42

82

69

20

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4. WARNING

High pressure air injection hazard. Can cause severe injury. Relieve pressure
before removing filler plug or fittings.

6. WARNING

High pressure fluid injection hazard. Can cause severe injury. Relieve pressure
before removing accumulators. See maintenance instructions.

8. WARNING

Hazardous moving and rotating parts. Can cause severe injury. Do not enter
working range with machine in operation.

9. WARNING

Hazardous boom motion. Can cause bodily injury. Secure boom before
servicing hydraulic system.

20. WARNING

WARNING: REMAINING IN THE WORKING AREA WITHOUT AUTHORIZATION IS

STRICTLY PROHIBITED!

36. SAFETY INSTRUCTIONS

Fasten the seat belt. Do not operate with the doors open and unlatched. Stop
the engine before servicing, adjustment, and refueling. Do not leave running
when unattended.

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42. WARNING
DO NOT USE THE RIG BEFORE YOU HAVE:1. Read the instructions regarding
use/servicing.2. Understood and noted all cautions and warnings.3. Received
training in the use of the rig.Do not work under the boom during drilling. Move
the boom to the transport position before tramming. Turn the feed to horizontal
orientation before tramming. Before removing the oscillation cylinders or
performing any servicing under the rig, ensure that the feed stinger is supported
vertically, pointing at the ground, and secure the boom and the rear section of
the carrier in place by supporting them. The oscillation cylinders of the tracks
must be locked before the carrier is lifted or transported. When using the winch,
always make sure that the winch drum has a minimum of three turns of cable.

43. DANGER

Hazardous voltage. Risk of serious injury or death. Be extremely careful when

approaching power lines or cables.

44. WARNING

Tipping hazard. Risk of serious injury or death. When one is tramming:Keep the
boom in the tramming position.Do not exceed the specified tilting angles.

69. WARNING

Danger of burn injuries. Can cause severe injury. Do not touch the hot surfaces
of the rig.

70. WARNING

Danger of getting tangled in the drilling rod. Can cause severe injury or death.
Do not install the drilling rod into a rotating shank or rod.

82. DANGER

Breathing dust can cause serious injury or even death.

Always wear an approved respirator.

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98. WARNING

Roll over hazard. Can cause severe injury or death. When Drilling:do not exceed
given gradient angleskeep oscillation cylinders locked

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2.24. Symbol plates

Main switch, carrier

If you need to tow the rig, the tramming motors

must be released.

Only lift the machine from these points.

Fuel tank / filling the tank

Compressor pressure controller

Fuses

Selector valve for filling the hydraulic oil tank or

compressor air/oil tank.

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Engine air filter

Compressor air filter

Avoid noise exposure. Use hearing protectors

whenever the engine is running.

To avoid temperature stress, let the engine idle 3 min

for three (3) minutes before stopping it. STOP

rpm

Open the main switch and disconnect the battery

cables before starting any welding work. Refer to
the section “Welding”.

The winch drum should always have a minimum

of three loops of cable.

CHECK THE COMPRESSOR OIL LEVEL BE-

Checking the compressor oil level.
FORE STARTING THE ENGINE

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2.25. Radio control

The rig operator must have sufficient knowledge of this function before attempting to control the rig
via the radio controller.

DANGER
Crushing hazard. Risk of serious injury or death. Ensure that
there are no persons in the rig's danger area. If necessary,
provide monitoring of the blind area behind the rig.

• Read the operating instructions carefully and ensure that you

understand everything fully.
• Keep the operating instructions safe and readily accessible.

• Make sure that there are no radio controllers operating at the same
frequency in the same area.
• Only personnel with adequate training are permitted to use the radio
controller.
• Do not leave the radio controller anywhere where it might fall into
the wrong hands.

• Switch off the radio controller during breaks.

• In the event of a hazardous situation, switch off the rig and
determine the cause of the malfunction before operating the rig
again.
• In the event of a hazardous situation, press the emergency stop
button on the transmitter.

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2.26. Making modifications and corrections to the product

Changes and modifications like mentioned here without risk

assesment, elimination or reduction of risk if necessary and
without appropriate safety measures may lead even to death,
serious personal injuries or damage to property.

All modifications and corrections not mentioned in the

maintenance manual which may affect the operation, safety,
and availability of the machine need to be approved by Sandvik
before implementation. Approval requires careful risk
assessment in the planning phase, taking into consideration the
residual risks and any new risks that the modifications may
bring.

• If modifications and corrections that affect the operation, safety, and usability of the machine are
made without the permission of the manufacturer, the manufacturer is not responsible for any
incidents resulting in death, injury, or property damage brought about by such modifications and
corrections.
• Should you consider a modification or correction necessary, please contact the Sandvik service
organisation and deliver adequate documentation: a description of the modification or correction,
related blueprints, photos, and other material if necessary. Sandvik’s service organisation will
contact the factory that manufactured the machine in order to plan and implement the modification.
• If a modification or correction as described above has been implemented without the manufacturing
factory’s permission, its effect on warranty liability will be considered case-by-case. Thus, the
warranty application may be rejected altogether.

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3. MACHINE DESCRIPTION

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3. MACHINE DESCRIPTION

3.1. Main component location

4
2
3
7 14 11 6 13

1 5 12 8 9 10

1 Boom 2 Feed
3 Rod handler 4 Hydraulic rock drill
5 Track carrier 6 Diesel engine
7 Cabin 8 Hydraulic system
9 Pneumatic system 10 Shank lubrication unit
11 Fuel system 12 Dust collector system
13 Main electrical system 14 Control system

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3.1.1. Boom

1 2 3

4 5 6

7 8 9 10 11

1 Feed extension cylinder 2 Feed swing cylinder

3 Cradle 4 Fastening to the carrier
5 Outer tube 6 Boom swing cylinder
7 Boom lift cylinder 8 Zoom cylinder (inside the outer and inner
tube)
9 Inner tube 10 Feed tilt cylinder
11 Swing piece

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3.1.2. Feed

1 Hose reel 2 Carriage

3 Feed cylinder 4 Feed beam
5 Pito 6 Moving suction head
7 Stinger

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3.1.3. Rod handler

1 7

8
2

9
3

10
4

11
5

12
6

1 Rotation motor 2 Upper casing

3 Upper casing position, 12' steels 4 Upper jaw
5 Lower jaw 6 Lower casing
7 Dividing plate 8 Square pipe
9 Dividing plate position, 12' steels 10 Roller PITO
11 Safety latches 12 Roller PITO extension cylinder

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3.1.4. Hydraulic rock drill

1 2 3 4

5 6 7

1 Rear cover 2 Rotation motor

3 Gear housing 4 Front cover
5 Pressure accumulators 6 Flushing housing
7 Shank

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3.1.5. Track carrier

1 2 3 4

1 Front idler wheel

2 Tracks
3 Oscillation cylinders
4 Final drive

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3.1.6. Diesel engine CAT C13

3
2

8 9 10 11

1 Coolant expansion tank 2 Air filter unit

3 Engine aftertreatment system 4 Intercooler
5 Cooler 6 Fuel filter with water separator
7 Oil filter 8 Fuel filters
9 Engine control module (ECM) 10 Starter motor
11 Transfer gearbox

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3.1.7. Cabin

1 2 3 4 5 6 7

8 4 9 10 11

1 Control system display 2 Auxiliary panel 3

3 Right armrest panel 4 Emergency stop
5 Auxiliary panel 1 6 Auxiliary panel 2
7 Electrical connections 8 Pedals
9 Door 10 Left armrest panel
11 Front and rear jack panel

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3.1.8. Hydraulic system

1 3 4 5 6 2

12

13

7 8 9 10 11

1 Tank 2 Breather
3 Return filters 4 Thermostat
5 Cooler 6 Rotary actuator (cooling fan)
7 Pumps 8 Pressure filter
9 Boom valves 10 Driving valves
11 Oscillation valves 12 Drilling valves
13 Cassette valves

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3.1.9. Pneumatic system

1 2

8 9 10

1 Thermostat 2 Cooler
3 Air filter 4 Pressure regulator
5 Control block 6 Intake valve
7 Compressor 8 Oil filter
9 Flushing valve 10 Air receiver

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3.1.10. Shank lubrication unit

3 2

1 Sight glass 2 Level sensor

3 Breather 4 Filler opening
5 Tank 6 Pump
7 Connecting element

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3.1.11. Fuel system

1 2 3

4 5

1 Breather 2 Filler opening

3 Tank 4 Cooler
5 Fuel filter with water separator 6 Fuel filters

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3.1.12. Dust collector system

1 2 3

4 5 6 7 8 11

10

1 Rotary actuator 2 Cover (propeller wheel)

3 Suction hose 4 Exhaust muffler
5 Blow-out valves 6 Fine separator
7 Pump 8 Service hatch (filters)
9 Coarse separator 10 Moving suction head
11 Dust collector feeder

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3.1.13. Main electrical system

1 2

4 7

5 6

1 ESG (Electric Switchgear) 2 FCC (Front Carrier Controller)

3 MP (Main Power) 4 DM (Drilling Master)
5 RHC (Rod Handling Controller) 6 Alternator
7 ECM (Engine control module) 8 Starter motor
9 Batteries (2 x 12VDC)

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3.1.14. Control system

9
1

2 10

11

15 16

12
17

13
3
14
4

18
22 25
19 21 23

CAN HMI 20
24
26

CAN BB
CAN RRC
CAN FEED
CAN DRILL
CAN ENG
CAN BOOM

Optional

1 RHS (Rod Handling Slave) 2 SDP (Sensor Drifter Position)

3 SFI (Sensor Feed Tilt, vertical holes) 4 SFI2 (Sensor Feed Tilt, horizontal holes)
5 DM (Drilling Master) 6 DC (Drilling Controller)
7 RHC (Rod Handling Controller) 8 SDC (Sampling Device Controller)
9 Radio Receiver 10 HM (HMI Master)
11 RRC (Radio Receiver Controller) 12 SAU (Sensor Aiming Unit)
13 RAR (Right Arm Rest) 14 LAR (Left Arm Rest)
15 SPC (Switch Panel Controller) 16 SM (System Master)
17 Data Collector 18 PPC (Power Pack Controller)
19 RCC (Rear Carrier Controller) 20 PPS (Power Pack Slave)
21 ECM (Engine Control Module) 22 WIC (Water Injection Controller)
23 FCC (Front Carrier Controller) 24 Internal terminator
25 SCI (Sensor Carrier Inclination) 26 SBA (Sensor Boom Swing)

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3.2. Overview of the rig's structure

Right

Front section Rear section

Left

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3.3. Description on Controls and Functions

3.3.1. Auxiliary panels

Auxiliary panel 1

1 2 3 4 5

A A A A

B B B B

C C C C

6 7 8 9 10

1. Emergency stop
2. Windscreen wiper One sweep when turned to the left
Four different speeds when turned to the right
3. Stopping the engine
4. Starting the engine
5. Ignition key 0 = Control current off
I = Control current on
6. Track oscillation locking indicator
lights
7. Track oscillation locking A) Right track locked
B) Tracks released (indicator lights on)
C) Left track locked
8. Windscreen washer fluid and horn A) Windscreen washer fluid,
B) -
C) Horn
9. Cabin lights A) All cabin lights on
B) General cabin lights on
C) Cabin lights off
10. Working and driving lights A) Working and driving lights on
B) Driving lights on
C) Working and driving lights off

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Auxiliary panel 2

3
2

4 5 6

1. Air conditioning A) On
B) Off
2. Temperature adjustment
3. Fan speed
4. USB port
5. 24 V connector Max. 10 A
6. 12 V connector Max. 10 A

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Auxiliary panel 3

A A A A A A

B B

B B B B C C

1 2 3 4 5 6 7 8

1. Buzzer
2. Remote control safety switch
3. Remote control (optional) A) On
B) Off
4. Engine aftertreatment system A) Prevent automatic start of the process
B) Start the manual process
5. Ether/cold starting A) Automatics on
B) Automatics off
6. Beacon A) On
B) Off
7. Sampling device (optional) A) Sample into sack
B) Sample collection
C) No sample collection
8. Dust suppression (optional) A) On: suppression agent spraying into flushing air and
dust collector feeder
B) Off
C) On: suppression agent spraying into flushing air

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3.3.2. Left armrest panel

4 5 6

3 7

2 8

1 9

12 11 10

1 Boom control lever Control of the boom movements

2 Suction cut-off On/off selection
3 Dust collector On/off selection (also controls the optional dust collector
feeder, on/off)
4 Flushing On/off selection by pressing, air amount adjustment by
turning
5 Water binding On/off selection by pressing, water amount adjustment by
turning
6 Rod handling, PITO, and Control of rod handling and PITO; Control of the left track
tramming control lever if two-hand tramming is used
7 Guiding PITO open
8 Guiding PITO closed
9 Power extractor (optional) On/off selection
10 Reset depth measurement
11 Suction head down
12 Suction head up

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3.3.3. Right armrest panel

2 3 4 5

1 9

1 Navigation buttons For navigating the control system user interface

2 Drilling, flushing, and tramming Control of drilling, flushing, and tramming movements
control lever
3 Flushing control (anti-jamming) On/off selection
4 Anti-jamming control On/off selection
5 Rotation speed adjustment Rotation speed adjustment by turning
6 Drilling power control Drilling power adjustment by turning; adjusts both the
percussion and feed pressure
7 Feed pressure adjustment Feed pressure adjustment by turning
8 Feed control lever Control of feed movements
9 Automatic aligning selection Automatic aligning selection
button(optional)

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3.3.4. Pedals

2 3
1

1 Forced flushing
2 Thread greasing
3 Tramming pedal

3.3.5. Front and rear jack panel

1 2 3 4

1 Front jack in
2 Front jack out
3 Rear jack up
4 Rear jack down

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3.3.6. Radio controller

1 2 3

B
A C 4

5
15
A

14 B

7
A

13 8
B

12 11 10 9

1 Boom and feed rail control Boom control when the button is pressed, feed rail control
when the button is not pressed
2 Oscillation locking A) Left side locked
B) Both open
C) Right side locked
3 Tramming control
4 Winch control Reeling in the cable
5 Emergency stop
6 Winch control Reeling out the cable
7 Switching off the remote control
8 Remote control indicator light Lit = remote control in use
9 Controlling the rear jack A) Jack down
B) Jack up
10 Adjusting the automatic winch +) Tighten the cable
tensioning -) Loosen the cable
11 Winch operation method A) Manual control of the winch (push-buttons 4 and 6)
B) Automatic winch tensioning (10)
12 Not in use
13 Switching on the remote control /
Sound alarm
14 Oscillation Upper carrier tilt forward
15 Oscillation Upper carrier tilt backward

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Boom and feed rail control

Lower end of feed beam forward /

Boom down

Lower end of feed beam Lower end of feed beam

to the left / Boom to the right / Boom to the
to the left right

Lower end of feed backward /

Boom up

Tramming control

Right track forward Both tracks forward Left track forward

Right track forward, Left track forward,

left track backward right track backward

No movements No movements

Right track backward, Left track backward,

left track forward right track forward

Right track backward Both tracks forward Left track backward

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3.4. Graphical user interface

The graphical user interface is a clear and logical tool for controlling the drilling rig. It is integrated
with the other control devices and is an essential part of the daily use of the drilling rig.
Navigation within the user interface has been made simple and quick. The most important work stages
have their own screens. The buttons on the right armrest panel are used to navigate and operate the
screens.

3.4.1. User interface control

Navigation in the user interface

The user interface can be controlled via the buttons on the right armrest panel.

1 Navigation buttons 1
2 Menu button
3 Selection button
4 Cancel button 2

3 4

The navigation buttons are used to control the

cursor, shown on the display as a blue frame.

When the cursor is at the desired item, it can be activated by pressing the selection button. A grayed-
out item cannot be selected.
The menu button opens the main menu.
The cancel button returns the view one level up in the display hierarchy.

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Operating the numerical value fields

The numerical value fields in the settings screens can be operated as follows:
1. Move the cursor to a numerical value field with the navigation buttons.
2. Press the selection button to change the background colour of the field to yellow.
3. Change the numerical value with the navigation buttons. The arrow up button increases and the
arrow down button decreases the value, one step at each press. Keeping the button depressed
changes the value constantly.
4. Press the selection button. The background colour of the numerical value field changes to white
and the value is adopted.
5. Close the screen to save the new value in the system.

3.4.2. Common elements of the user interface

Gauges

The graphical user interface includes gauges related to drilling and a panel for monitoring general
operations of the rig.

1
Drilling gauges
6
1 Percussion pressure
7
2 Rotation pressure
3 Effective feed pressure 8

Flushing flow rate and flushing monitoring 2 9

4
limit value
10
5 Water injection setting
Monitoring panel 11

6 Engine speed 12

7 Engine coolant temperature 3

8 Fuel level
9 Compressor pressure
10 Compressor temperature
11 Hydraulic oil temperature
12 Hydraulics heating status (on/off)
4 5

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Bottom bar

The bottom bar is always displayed at the bottom of the screen when the system has started up,
regardless of what else is displayed.
The bottom bar contains the following components:
Rig equipped with GPS:

1 2 3 4 5 6

Rig equipped with 3D:

1 2 3 7 4 6

1 Time
2 Number of active warnings Tier 4 in the rig shows the number of warnings and the
status of the after-treatment equipment operation.
3 Number of active alarms Tier 4 in the rig shows the number of warnings and the
status of the after-treatment equipment operation.
4 Service mode indicator Visible when service access has been used for logging in
to the control system
5 GPS status indicator Green = Signal OK / Red = No signal
6 Button for opening the main menu
7 3D status indicator (Tier 4) Green = signal OK / Yellow = weak signal (the rig can be
used, but accuracy is low) / Red = No signal
Details of the system warnings and alarms are indicated in the event log, which can be accessed
from the main menu.
The icons presented in the following table are used only in a tier4 rig (the icons appear on the bar at
the bottom between items 1 and 2):

Clog warning concerning the after-treat-

ment equipment for exhaust fumes

Automatic operation of the after-treatment

equipment for exhaust fumes prevented.

After-treatment equipment for exhaust

fumes in operation

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Equipment diagnostics messages

In case of a situation that endangers or prevents safe operation of the rig, the equipment diagnostics
system warns the operator with a pop-up window. The pop-up windows can be operated in the normal
manner using the navigation buttons and selection button. There are four different types of diagnostics
pop-up windows.

Notifications

Notifications indicate an exceptional state of the

rig or system. For example, a notification can in-
dicate that the cabin door is open.
The checkbox in the notification window can be
used to prevent the same notification from being
displayed again if the same situation recurs.
The notification window closes automatically
when the cause of the notification has been re-
moved, or it can be closed with the Close button.

Warnings

Warnings indicate a hazardous state of the rig or

system that could cause rig failure. The number
of active warnings is shown on the bottom bar of
the display. Details of the warnings can be viewed
in the event log.
The checkbox in the warning window can be used
to prevent the same warning from being dis-
played again if the same situation recurs.
The warning window closes automatically when
the cause of the warning has been removed, or it
can be closed with the Close button.

If a notification or warning has been prevented from being

NOTE! displayed, that pop-up window cannot reappear until the system
has been restarted.

Alarms

Alarms indicate a rig or system state that could

cause immediate rig failure. The number of active
alarms is shown on the bottom bar of the display.
Details of the alarms can be viewed in the event
log.
The alarm window closes automatically when the
cause of the alarm has been removed, or it can
be closed with the Close button.

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Emergency stop

The emergency stop window is displayed when

one of the rig's emergency stop buttons has been
pressed. The message in the pop-up window in-
dicates the location of the emergency stop button
pressed.
The emergency stop window closes when the
emergency stop button is released, or it can be
closed with the Close button.

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3.4.3. Main screens

Screen map

The DPi rock drill screen hierarchy is displayed to the operator in two levels. Access to the settings
and calibration screens as well as the diagnostics screens is limited or completely blocked.

Drilling screen Hole aiming screen Tramming screen Main menu

Work settings Hole settings Counters Drilling settings

Horizontal hole settings Rig settings Alarm log Diagnostics

Control panel General settings Logging in and out Drill plan

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Drilling screen

The drilling screen is displayed when the system has started up. This is the rig's default screen from
which you can move to the tramming or hole aiming screen to perform these functions. The drilling
screen consists of the following elements:

3 4

1 2

14 15

7 8 9 10 11 12 13

1 Gauges
2 Drilling progress and number of rods
3 Penetration rate
4 Drilling depth
5 Target drilling depth
6 Hole aiming follow-up
7 Flushing status:

Flushing on Flushing off

8 Flushing monitoring status:

Flushing monitoring on Flushing monitoring off

9 Water injection status:

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Water injection on Water injection off

10 Dust collector status:

Dust collector on Dust collector off

11 Suction cut-off status:

Suction off Suction on

12 Dust suppression status:

Dust suppression on Dust suppression off

13 Drilling method:

Automatic single-rod drilling on Automatic single-rod drilling off

Automatic one-hole drilling on Automatic one-hole drilling off

Manual drilling on

14 Percussion status:

Percussion off Percussion on

15 Rod handler status:

Manual rod handling

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Hole alignment screen

The hole aiming screen opens when you move the boom control levers. It consists of the following
elements:

1 3

4 5

1 Gauges
2 10° hole aiming circle
3 Feed position
4 Reference direction status:

Hole aiming performed Hole aiming not performed

5 Hole aiming method:

Automatic alignment Manual hole aiming

The hole aiming screen closes and the drilling screen opens when you release the boom control
levers.

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Tramming screen

The tramming screen displays when the tramming pedal is pressed. It consists of the following
elements:

3 4

1 Gauges
2 Speed range:

Slow tramming Fast tramming

3 Oscillation locking status:

Left track locked Right track locked

Both tracks released

4 Rear jack position:

Rear jack up Rear jack down

The tramming screen closes and the drilling screen opens when you release the tramming pedal.

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Main menu

During normal operation of the rig, the display toggles between the hole aiming and drilling screens
depending on the position of the status switch. Other screens can be accessed from the main menu.
To open the main menu, press the menu button on the right armrest panel or move the cursor onto
the Menu button with the navigation buttons and press the selection button.
The main menu opens in the right section of the display, so the gauges remain visible. The Menu
button is grayed out when the main menu is open.

1 2 3

4 5 6

7 8 9

10 11 12

The following screens can be accessed from the main menu:

1 Work settings 2 Hole settings

3 Counters 4 Drilling settings
5 Horizontal hole settings 6 Rig settings
7 Alarm log 8 Diagnostics
9 Control panel 10 General settings
11 Logging in / Logging out 12 Drill plan

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Work settings

The work settings screen is used to select the drilling method and the desired drilling and equipment
parameters.
The screen can be opened by clicking the corresponding icon in the main menu.

5 6

1 Drilling method selection Inclined/horizontal drilling

2 Drilling parameters selection
3 Equipment parameters selection
4 Button for drill bit setting Opens a "Change drill bit" pop-up window
5 Cancel the selections
6 Confirm the selections

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2 3

1 Drill bit ID field

2 Resetting field information
3 Set ID for a drill bit Saves information given in the "drill bit" -field

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Hole settings

The Hole settings screen can be opened by clicking the corresponding icon in the main menu. The
screen is used to determine the hole aiming method, aiming method (if used), and hole settings. The
appearance of the screen varies according to the method used and the parameters to be determined.
The figure below shows hole aiming by aiming in the blast direction.

1
4

5 6

1 Hole aiming method Aiming / Feed rail / GPS

2 Aiming method Blast direction / Reference direction
3 Hole settings Bench inclination, bench height, side inclination, hole
length, laser receiver in use / not in use
4 Image of the operation
5 Cancel the selections
6 Confirm the selections

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Counters

The counters screen shows statistical data related to the operation of the rig and drilling in particular.
The counters screen can be opened by clicking the corresponding icon in the main menu.

Times and drilled meters

2 3 4
5
6
7 10
8
9

11

12
13

1 Times and drilled meters tab The selected tab is highlighted in yellow
2 User's counter column
3 Service counter column
4 History column
5 Percussion time
6 Drilling time
7 Number of holes
8 Drilled meters
9 Total drilled meters
10 Reset buttons for service counters Available only to users logged in with the service password
11 Reset button for user counters Resets the user counter hours
12 Diesel engine hours
13 Close button

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Productivity

2 3 4

9 9

10
11

1 Productivity tab The selected tab is highlighted in yellow

2 User's counter column
3 Service counter column
4 History column
5 Average penetration rate
6 Average fuel consumption / depth
7 Average fuel consumption / time
8 Total fuel consumption
9 Reset buttons for counters Resets the counter hours
10 Diesel engine hours
11 Close button

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Drilling settings

Pressures

2 7

3 8

4 9
5 10
6
16
11
12

13 14 15

1 Pressures tab The selected tab is highlighted in yellow

2 Percussion pressure
3 Feed Pressure
4 Feed-percussion sensitivity
5 Maximum feed speed
6 Rotation speed
7 Anti-jamming
8 Torque control
9 Feed ease level
10 Feed pull-back level
11 Target rotation pressure
12 Sensitivity
13 Save as...
14 Cancel
15 Ready
16 Optional screens The screen depends on whether Anti-jamming or torque
control has been selected

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Automatics

2 9

3 10

4 11

5
12
6
13
7
14
8

15 16 17

1 Automatics tab The selected tab is highlighted in yellow

2 Collaring speed
3 Collaring depth The depth until which the automatics is in the 'Starting a
hole' mode
4 one-hole drilling In use / Not in use
5 Rattling time
6 Rattling pressure
7 End flushing time
8 Thread greasing amount
9 Percussion activates flushing Optional with item 10
10 Rotation activates flushing Optional with item 9
11 Flushing control limit
12 Unthreading position control in Enables automatic unthreading
use
13 Pulse control in use Pulse control of the rod handler jaws
14 Four-button basic control / two- Selection of rod handler jaw control method
button parallel control
15 Save as...
16 Cancel
17 Ready

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Horizontal hole settings

The horizontal hole settings screen can be opened by clicking the corresponding icon in the main
menu. The screen is used to determine the drilling angle, horizontal hole depth, and absolute hole
depth. The image of the operation varies according to the parameter to be changed.
The figure below shows a situation in which the hole angle is being determined.

4
1

5 6

1 Drilling angle
2 Horizontal hole depth
3 Absolute hole depth
4 Image of the operation
5 Cancel the selections
6 Confirm the selections

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Rig settings

The rig settings screen can be opened by clicking the corresponding icon in the main menu. From
this display, you can specify the general settings for the rig and access rig-maintenance-related
functions.

Settings

2
3
4
5
6
7
8
9

1 Settings tab The selected tab is highlighted in yellow

2 Boom and feed maximum speed Setting the speed of the boom and feed movements as a
percentage of the maximum speed
3 Feed alignment accuracy Allowable feed angle offset during aiming
4 Bit positioning tolerance Allowed bit positioning error
5 Hole shift threshold When you are starting a hole that is further from the
planned hole than the limit value allows, the “Move hole”
pop-up window is opened.
6 Show hole ID's in the navigation
view
7 Two-hand tramming in use Tramming method selection
8 Shank lubrication oil amount Shank lubrication oil flow rate in g/h
9 Thread greasing antifreeze in use

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Service

1 Maintenance tab The selected tab is highlighted in yellow

2 Vacuum cleaner start/stop
3 Water tank pressure release
4 Water line cleaning sequence
start/stop
5 Water line drying sequence start/
stop
6 Water tank draining
7 Hydraulic oil heating start/stop

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Alarm log

The alarm log includes details of warnings and alarms that occur in the system. The contents of the
log can be filtered according to the event type or time of occurrence. The contents displayed can be
sorted in alphabetical or chronological order. The alarm log can be opened by clicking the
corresponding icon in the main menu.
The alarm log consists of the following elements:

1 2 6 3 7 4 5 8

9 10

1 Event type
2 Time of occurrence
3 Event name
4 Event fault code
5 Number of events
6 Select event type
7 Select time of occurrence
8 Select sorting method
9 Clear log button
10 Close the window

Active warning Expired warning that was not reset

Active alarm Expired alarm that was not reset

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Diagnostics screens

The main diagnostics screen can be opened by clicking the corresponding icon in the main menu.
The icons in the screen provide access to diagnostics screens related to various system areas and
functions.

1 2 3 4 5

6 7 8 9 10 11

12 13

14 15 16 17 18

1 Boom
2 Rod handling
3 Tramming
4 Oscillation
5 Winch
6 Drilling
7 Shank lubrication
8 Circulating shank lubrication
9 Dust collector
10 Flushing
11 Water injection
12 Diesel engine
13 Powerpack
14 Control devices
15 Cabin
16 Safety switches
17 GNSS
18 Alignment

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Control panel

The control panel main screen can be opened by clicking the corresponding icon in the main menu.
The icons in the screen provide access to settings screens related to various system areas and
functions.

1 2 3 4

5 6 7 8 9

10 11 12

13 14 15

1 Service access
2 File management
3 Backup
4 USB settings
5 Joysticks
6 Boom
7 Tramming
8 Rod recipes
9 Sensor calibration
10 Sensor by-passing
11 Service tool
12 Rig information
13 CAN-bus structure
14 System IO
15 Parameters

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General settings

The general settings main diagnostics screen can be opened by clicking the corresponding icon in
the main menu. In this display you can define the control system's time, date, language, and
measuring unit settings.

1 2

3 4

5
6
7
8
9
10
11 12

1 Language selection
2 Date setting
3 Measuring unit selection The Custom option allows you to select units for items 6–
10 separately
4 Time format selection
5 Time setting
6 Length
7 Mass
8 Volume
9 Pressure
10 Temperature
11 Cancel
12 Ready

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Logging in / Logging out

1
5
6
2
7
8

3 4 3 9

1 Language selection
2 Operator selection
3 Cancel
4 Log in
5 Operator The operator currently logged in
6 Working time Time elapsed since last login
7 Drilled meters Meters drilled since last login
8 Drilled hole count Holes drilled since last login
9 Log out

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Drill plan

2 3 4

1 Drill plan file Contains the drill plan information

2 Load plan Loads the selected drill plan for use
3 Unload plan Unloads the drill plan (only one drill plan can be loaded at
a time)
4 Close the window

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3.4.4. Operator management (option)

Logging in

1. In the control system's user interface, go to the login window (Menu → Login).

2. Select your own operator name from the operator list (2).
A default language was selected for each operator when the operator was created, and the
operating system offers this language when one is logging in. You can also log in with a different
language from the language menu (1).

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3. Press Login(3).

You are now logged in and your operator name can be seen in the bottom bar of the display (4).

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Logging out

1. In the control system's user interface, go to the logout window (Menu → Logout(1)).

2. The following information from your shift can be seen in the logout pop-up window: Operator(2),
Working time(3), Drilled depth(4), and Drilled holes (Drilled holes)(5).

2
3
4
5

3. Log out by pressing Logout(6).

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Adding a new operator

1. In the control system's user interface, go to the Manage Operators window (Menu → Control
Panel → Operators(1)).

2. Enter the new operator's name in the Add new operator field (2).
The operator name can be 1 to 8 characters in length.

3
4

3. Select a language for the operator in the language menu (3).

The selected language will be the control system's user interface default language when the
operator in question logs in.

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4. Press the Add button (4).
The new operator has now been created and can be seen in the operator list. There can be up to
20 operators.
5. Exit the window by pressing Close(5).

Deleting an operator

1. In the control system's user interface, go to the Manage Operators window (Menu → Control
Panel → Operators).
2. Select the operator to be deleted from the operator list (1).

3 4

3. Press Remove(3).
4. The control system confirms the deletion of an operator with a pop-up window. Respond Yes(2).
5. Exit the window by pressing Close(4).

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Transferring operator files

Name the external USB memory as “REMOVABLE”.

1. Go to the control system's File management window (Menu → Control panel → File
management).

2 3

5 6

2. Select the direction of the file transfer (1).

3. Select Operator files(2) as the file type.
4. Select the desired USB memory (3).
5. Select the file to be transferred (4).
6. Press Copy.
The control system indicates that copying was successful.
7. Exit the window by pressing Close.

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3.5. Fuses

Main switchgear

The main switchgear, with main fuses F1–F8 (1) and other fuses F9–F26 (2), is at the rear of the rig.
16A

F26

- + 101 110
- + 101 110
1A

F25

408 . 101 111

101 111

8
408 .
102 112

XM 4

XM1
407 .

7
2A

F24

407 . 103 114

5 6
104 115

1
322 105 116
321
2A

106 117
F2 3

16A
320 308 107 118

F32
319 307 108 119
318 306 109 120
6A

F2 2

-A01

Spare
10 A
317 305 109 121

F3 1
316 304
109 122
314 304 109 123
313 303
6A

F2 1

10 A
312 303 201 214

XM3
F30
311 302 202 214
311 302 203 214

XM2
6A

F2 0

309 301 204 214

10A

F2 9
309 301 205 215
206 215
10 A

. 213 207 215

F1 9

10 A
. 213 208

F2 8
215
223 213 209 216
222 212 210
10 A

217
F1 8

221 211
10 A
211 218

F2 7
220 210 212 219
219 209 213 220
10 A

218 208 213

F1 7

221
217 207 213 222
216 206 213 223
215 206
6A

F1 6

215 205 301 309

XM2
215 204 301 309
214 203 301 311
10 A

XM3
302 311
F1 5

214 202
214 201 302 311

2
303 312
123 110
303 316
10 A

-A02
F1 4

122 110 304 317

20A 20A 40A 20A 121 109 304 318
120 109 305 319
119 108
6A

F1 3

K3.1 K6 K10 K16 118 107

306
307
320
321
117 106 308 322
116 105
323
6A

F1 2

115 104

XM 4
XM1
114 103 . 407
20A 40A 40A 112 102 . 407
10 A

111 101 . 408

F1 1

111 101 . 408

K3.2 K7 K11 K30 111 101 +

+
-
-
16 A

111 101
F1 0

-X1
-X2
16 A

F9
6A

F8

12
13
14
15
16

5
10 A

F7

6
7
8
9

8
8
9
8
9

9
4
5
6
7
10
11

17
18
19

12
13
14
15
16
17
18

10
11
12
13
14
15
16
Spare

3
4
5
6
7

1
6A

A1
F6

K8 K9 K12 K13 K14 K15 K17

1
2

8
8
9

2
3
4
4

1
2
2
3
3
4
5
5
5
6
7
7

1
2
3
4
5
6
7
8
1
2
3
3
16 A

-X3

-X7
-X4

-X5

-X6

1
F5
25 A

F4

14
25 A

F3
50 A

F2

K5
50 A

F1

F1 Cabin supply 24 VDC

F2 Other function supply
F3 Fuel pump
F4 Wate pump
F5 Eberspächer
F6 Not in use
F7 Powerpack controller
F8 Eperspächer timer
F9 Ether valve
F10 Rear working lights
F11 Central lubrication
F12 Eperspächer timer
Emergency stop circuit supply
Fire system status
F13 Ignition signal
F14 Rear carrier controller
F15 Front carrier controller
F16 Drilling master

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F17 Drilling master

F18 Rod handling controller
F19 Hydraulic oil filling pump
F20 Signal
F21 Grinder
F22 Water injection
F23 GUI master SPS
F24 Data collection unit SPS
F25 CAN sensor
F26 Hydraulic oil pump
F27
F28
F29
F30
F31 Not in usw
F32 CRS

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Cabin switchgear

The switchgear in the cabin includes cabin fuses F01–F15 (3).

F01 Door switch

F02 Air conditioner
F03 Interior and spot lights
Alarm beacon

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F04 24/12 VDC converter

F05 Front wiper motor
Washer pump motor
F06 Working lights
F07 Working lights
F08 Working lights
F09 Working lights
F10 24 VDC outlet
F11 Seat heating
F12 HMI master
Data collection
Radio receiver controller
Radio receiver
F13 HMI bus power supply
F14 Programming bus
F15 Pilot power supply
Display (PC)

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4. PERIODIC MAINTENANCE

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4. PERIODIC MAINTENANCE

4.1. Importance of scheduled maintenance

The continued operation of the rig is ensured by regular maintenance carried out correctly at the
proper intervals. The purpose of regular maintenance is to check the rig at regular intervals, ensuring
a high uptime for the rig. This prevents high repair costs and lost productivity. Neglecting maintenance
leads to high extra costs.
It is important to carry out daily maintenance routines carefully. All possible faults must be repaired
immediately or reported to the person in charge. Daily maintenance includes general lubrication,
inspections, and adjustments. Each new operator must be familiarised with the daily maintenance
routines.
Intervals listed for scheduled maintenance are usually based on
NOTE!
diesel engine hours or rock drill percussion hours.

4.2. General maintenance instructions

RISK OF POLLUTION!
Dispose of used parts and fluids in accordance with the local
environmental regulations.
See the general safety instructions for maintenance-related
environmental protection measures.

1. Park the rig on a steady and level surface.

2. Ensure that the rig cannot move by itself. Lift the rig onto the jacks, or use a safety brake and tire
wedges.
3. Always stop the rig before commencing maintenance procedures. Prevent accidental starting of
the rig by turning the main switch off or removing the ignition key.
4. Wash the rig before maintenance.
• Do not use solvents that contain aromatic or chlorinated hydrocarbons. Using mineral-oil-
based fuels, such as gasoline, diesel oil, or petroleum, as detergent is also forbidden! These
substances can cause deterioration, cracking, or softening of rubber and plastic parts.
5. Ensure that all necessary tools, spare parts, and accessories (oils, lubricants, etc.) are to hand.
6. Clean the area around the filling cap thoroughly before adding fuel or oil.
7. When replacing the filters or changing oils, ensure that the oil added is pure. A high particle content
in the oil (e.g., the filter becomes clogged rapidly) can indicate some kind of fault. Find out the
reason for this situation before more serious damage is done.
8. Beware of hot surfaces and oils. Dispose of waste oil and used filters according to local
regulations.
9. Reinstall protective rails and covers after maintenance.
10. Ensure that the hoses and cables cannot get entangled or tightened during use of the rig.

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4.3. Filter kits

250h Filter kit (ID 552 094 27) including following filters

Item ID Quantity
Engine secondary fuel filter 886 618 49 2
Primary fuel filter / water separator 551 987 18 1
Engine oil filter 550 558 74 1

500h / 1000h Filter kit (ID 552 094 28) including following filters

Item ID Quantity
Engine secondary fuel filter 886 618 49 2
Primary fuel filter / water separator 551 987 18 1
Engine oil filter 550 558 74 1
Compressor oil filter 818 937 49 1
Hydraulic return oil filter 867 272 89 2
Hydraulic oil pressure filter 872 701 09 1
Hydraulic oil tank breather 850 794 09 1
Engine air filter 551 875 29 1
Compressor air filter 551 933 92 1

1500h / 3000h Filter kit (ID 552 094 29) including following filters

Item ID Quantity
Engine secondary fuel filter 886 618 49 2
Primary fuel filter / water separator 551 987 18 1
Engine oil filter 550 558 74 1
Compressor oil filter 818 937 49 1
Hydraulic return oil filter 867 272 89 2
Hydraulic oil pressure filter 872 701 09 1
Hydraulic oil tank breather 850 794 09 1
Engine air filter 551 875 29 1
Compressor air filter 551 933 92 1
Engine air filter safety cartridge 560 408 22 1
Compressor air filter safety cartridge 551 933 96 1
Cabin air filter EU6-DOP 550 999 05 3
Cabin air filter 30ppi 550 999 10 1
Cabin air recirculation filter 551 711 50 1
Compressor oil separator filter 551 844 29 2

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4.4. Daily checks

Routine checks before starting the engine

• Check the engine's coolant level

• Check the engine oil level
• Visually check the engine
• Check the fuel water separator and drain the water
• Check the transfer gearbox oil level
• Check the oil level in the shank lubrication unit
• Check the hydraulic oil level.
• Check the compressor oil level
• Check the pneumatic system water separator and drain the water
• Check the fastening of the rock drill to the carriage
• Check the tightness and condition of the flushing housing bolts
• Check the tightness and condition of the feed cables
• Grease the greasing points of the rod handler's lower end
• Check the tightness of the tracks
• Check the condition of hoses and connections

Routine checks before operating

• Check for oil leaks

• Check the flushing housing seals.
• Check for any rock drill oil leaks.
• Check the coolant, compressor, and hydraulic oil temperatures
• Check the operation of the working and driving lights
• Check the operation of the emergency stops
• Check the operation of the safety wire
• Lubricate the boom greasing points

Checks during drilling

• Check the flushing housing seals.

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4.4.3. Checks during drilling

Checking the flushing housing seals

The flushing housing seals must be replaced when flushing air or water escapes from the sides of
the seal housing through the drain holes, and they should be checked whenever the shank is
changed. Seals are easier to install if they are lubricated. Install the new flushing housing seals,
making sure they face the right direction (as illustrated). Use of a spare flushing housing is
recommended, since this speeds up on-site maintenance of the rock drill.

19 19

Water flushing Air flushing

In addition, if the seal plate (19) is damaged, it must be replaced,

NOTE!
because of the risk of corrosion.

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4.5. First maintenance

4.5.1. Maintenance performed according to diesel engine hours

DIESEL HOURS - AFTER FIRST (h)

MAINTENANCE PROCE-
1-20 50 100 250
DURE
Boom
Check the tightness of bolts and
• 128
nuts
Feed
Check the tightness of bolts and
• 141
nuts
Rod handler
Check the tightness of bolts and
• 157
nuts
Carrier
Change the transfer gearbox oil • 191

Pneumatic system
Change the compressor oil • 212

Replace the oil filter • 213

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5. MAINTENANCE INSTRUCTIONS

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5. MAINTENANCE INSTRUCTIONS

5.1. Boom

5.1.1. Tightness of bolts and nuts

Check the tightness of all bolts and nuts on the rig using suitable tools.

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5.1.2. Checking and replacing the zoom tube wiper

Checking the inner and outer tube wiper ring

Regularly check the condition of the zoom tube wiper ring. The wiper ring prevents drilling dust from
getting in between the inner and outer tube. Replace the wiper ring if its edge is ragged or otherwise
worn.

Replacing the wiper ring

A B
C

A Wiper ring
B Wiper flange
C Screw
1. Remove the wiper flanges (B) and wiper ring (A) by removing the screws (C).
2. A damaged wiper ring can be replaced without removing the inner tube from the outer tube. In
this case, the bottom part of the new wiper ring must be cut.

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5.1.3. The clearances of the zoom tube slide pieces

Checking and replacing the slide pieces

1. The wear of the slide pieces (4) below can be checked by measuring the distance from the inner
tube to the outer tube surface. If the distance (B) exceeds 58 mm, the slide piece (4) must be
changed.
2. If the locking screw (3) on the top of the boom sinks into its boring by more than 8 mm (A), the
slide piece (1) must be changed.
3. If the locking screw (3) on the side of the boom sinks into its boring by more than 15 mm (C), the
slide piece (2) must be changed.

4 3

max 15 mm = A
B = max 8 mm

C = max 15 mm
4

1 Slide pieces 2 Slide pieces

3 Locking screw 4 Slide piece
A max. 8 mm B max. 58 mm
C max. 15 mm
4. The wear of the slide pieces (2) above can be checked by measuring the distance from the inner
tube to the outer tube surface. If the distance (C) exceeds 63 mm, the slide piece (2) must be
replaced. When replacing the slide piece (2) the inner tube must be removed.

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5. If the locking screw (3) under the boom sinks into its boring by more than 12 mm (B), the slide
piece (1) must be replaced.
6. If the locking screw (3) on the side of the boom sinks into its boring by more than 8 mm (A), the
slide piece (1) must be changed.

2
A = max 8 mm

1 1

C = max 63 mm

B = max 12 mm 3

1 Slide pieces 2 Slide piece

3 Locking screw A max. 8 mm
B max. 12 mm C max. 63 mm
Checking the clearances of the zoom tube slide pieces

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Check the boom clearances by running the boom to different positions and observing the clearances
at the joints and joint surfaces during the movements. Pay special attention to the hydraulic cylinders
and their mountings. Replace worn cylinder eye bushings and pins if necessary. The new bushing is
easier to install if it is cooled before installation.

1
1 2

5
6

1 Locking screw 2 Adjusting screw

3 Slide piece 4 Slide piece
5 Slide piece 6 Slide piece

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Adjusting the clearance of the boom inner tube

1. Prior to adjusting the inner tube (2) clearance, run the inner tube (2) fully out. The feed must be
off the ground.

3
1
4
A = max 8 mm

3 1

B = max 15 m m

1 Locking screw 2 Inner tube

3 Adjusting screws 4 Slide piece
5 Slide piece A max. 8 mm
B max. 15 mm
2. Remove the locking plates (1) on top of the boom, 4 pcs. Tighten the adjusting screws (3)
alternately by half a turn until no clearance exists. Tighten the locking screws (1) with moderate
force.
3. Remove the locking screws (1) on both sides of the boom, 2 pcs. Working on both sides, tighten
the adjustment screws (3) alternately by half a turn until no clearance exists. Tighten the locking
screws (1) with moderate force.
If the locking screw (1) on top of the boom sinks to its boring by
more than 8 mm (A), the slide piece (4) must be replaced.

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If the locking screw (1) on side of the boom sinks to its boring
by more than 15 mm, the slide piece (5) must be replaced.
4. Remove the locking screws (1) on the rear end under the boom, 2 pcs. Tighten the adjusting
screws (3) alternately by half a turn until no clearance exists. Tighten the locking screws (1) with
moderate force.
5. Remove the locking screws (1) on the rear end on both sides of the boom, 2 pcs. Working on both
sides, tighten the adjustment screws (3) alternately by half a turn until no clearance exists. Tighten
the locking screws (1) with moderate force.

2
1

A = max 8 mm

4 3 1

B = max 12 mm

1 Locking screws 2 Inner tube

3 Adjusting screw 4 Slide piece
A max. 8 mm B max. 12 mm

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If the locking screw (1) under the boom sinks into its boring by
more than 12 mm, the slide piece (4) must be replaced.

If the locking screw (1) on side of the boom sinks to its boring
by more than 8 mm, the slide piece (4) must be changed.

5.1.4. Cylinder pins

Check the condition of the cylinder pins. If play

is evident, replace the pin and the bearing bush-
ings.

Check the fastening of the cylinder pin latches.

If any of the latches are loose or broken, check
the condition of the pins and the bearing bush-
ings.

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5.1.5. Mounting of the hydraulic cylinders

Check the mounting points and ends of the hydraulic cylinders. Ensure that there are no cracks,
bends, or other defects.

5.1.6. Boom's fastening to the carrier

Check the fastening of the boom to the carrier.

Check the condition of the mounting pins and the
fastening welds.

5.1.7. The boom and cradle welds

Check the condition of the boom, cradle, and swing piece welds, paying special attention to any
cracks. Do not use the drilling rig if there are faults in the boom or cradle welds.

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5.1.8. Pressures of the pressure accumulators

Checking the pressure and replacing the feed tilt cylinder pressure accumulators

1. Move the feed to the transport position using the tilt cylinder. The cylinder is close to the extreme
position, i.e., the rod is fully extended.
2. Run the rock drill to its front position against the front limiter.
3. Run the feed extension to the front so that the stinger is against the ground. The extension cylinder
is at its minimum position, i.e., the rod is fully retracted.
4. Connect a hose to the tilt cylinder’s measuring point (1). Place the other end of the hose in a
receptacle. Release the pressure from the cylinder rod side.
5. Connect a hose to the tilt cylinder’s measuring point (2). Place the other end of the hose in a
receptacle. Release the pressure from the cylinder piston rod side.

1 2

Checking the pressure

1. Wait until the pressure is completely discharged from both sides of the cylinder before measuring
the pressure of the pressure accumulators. The measurement result will be incorrect if the cylinder
is loaded.
2. Check the pressure of the pressure accumulators with an appropriate gauge, such as the check
gauge for the rock drill high-pressure accumulators. The charge gas is nitrogen (N2). The charge
pressure is 100 bar. You may charge the pressure accumulators using, for example, the rock drill
pressure accumulator filling device.

Replacing the pressure accumulators

1. Wait until the pressure is completely discharged from both sides of the cylinder before removing
the pressure accumulators.
2. Remove the accumulator(s).
3. Install a new pressure accumulator on the cylinder.
4. Pressurise the new pressure accumulator. The charge gas is nitrogen (N2). The charge pressure
is 100 bar.
5. Test run the cylinder.

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5.1.9. Cradle clearances

1 2

Check the cradle clearances.

Measure the clearance (1) with the slide piece of
the other side against the (2) beam.
If the clearance (1) is more than 3 mm, change
the slide pieces.

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5.1.10. Weekly lubrication of the boom

Certain greasing points on the boom must be greased twice, with the boom in different positions. This
is to ensure sufficient lubrication at the necessary locations.
Greasing is particularly important at points with a pivoting joint, such as the vertical pins of the boom
and the cylinder pins.
Failure to follow the greasing instructions will result in damage
to the rig!

1. Tilt the top section of the feed backward. Lower the boom so that the rig's weight rests on the
stinger. When the rig is properly supported, the front part of the tracks is slightly off the ground.
Use oscillation if necessary.

2. Apply grease to all points indicated in the figure "Weekly greasing points".
3. Keep the feed tilted backward. Lift the boom slightly so that the stinger rises off the ground and
the weight moves onto the tracks.

4. Apply grease to the points indicated in red in the figure "Weekly greasing points".

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Weekly greasing points

* Be careful not to add too much grease to the lifting cylinder, as this can cause the cylinder wiper to
become displaced.

Grease daily in two different load positions

Grease daily

Grease weekly

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5.2. Feed

5.2.1. Tightness of bolts and nuts

Check the tightness of all bolts and nuts on the rig using suitable tools.

5.2.2. Cleaning the cables

Wash the cables with solvent and a brush.

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5.2.3. Condition and wear of cables

Check the cables whenever possible damage to them may have

NOTE!
occurred.

• Check the cables (1) with respect to the following:

• are there any cut wires (3)
• are there broken strands (2)

1 1

• is there a decrease in cable diameter (min. 11 mm)

• is there corrosion on the entire length of the cable
• extruding strands or threads

• If one of the above-mentioned faults occurs in the cables, both the draw and return cables must be
replaced.
• For more detailed information on checking and rejecting cables, refer to the ISO 4309 standard.

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5.2.4. Fastening and tightness of cables

NOTE! Check the cables whenever they may have been damaged.

Checking the condition and tightness of cables

• Check the fastening and tightness of cables.

The cables are adequately tight if the cup spring
pair below the tightening nut straighten when
pressed.
• Check the overall condition and wear of the ca-
bles. Pay particular attention to joint areas and
places where the cable passes the idler wheel.
• Check that the cables run straight (especially
under the carriage) and that the bottom is clean.

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Adjustment of cables

In the hose reel version, the position of the rock

drill in relation to the hose reel cannot change. If
the distance between the rock drill and the hose
reel changes, the rock drill hose tightness
changes, which can damage the rock drill hoses
or the hose reel roller.

1. Open the locking nuts (3, 8)

15
8

11
12
3
15

2. Refer to the chart for the positioning distance of the carriage (D = the distance between the front
edge of the carriage and the end tip of the feed).

Rock drill D / mm
HF 800 T 60
HL 1060 135
HF 1560 T 135

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3. Remove the locking plates (5) from the sides of the tightening nuts (4) of the return cables. Position
the rock drill carriage according to the chart to D + 5 mm by adjusting the return cable. Hold the
edge (14 mm) of the cable connection rod (1) to prevent the cable from twisting during tightening.
Adjust both return cables to the correct tightness by tightening the tightening nuts (4) so that the
cut spring pairs (3) beneath them press against each other and straighten. Attach the locking
plates (5).

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A B

1
3

2 4

A. The cables are correctly tightened.

B. The cables are too loose.
4. Remove the locking plates (5) from the sides of the tightening nuts (4) of the draw cables. Adjust
both draw cables to the correct tightness by tightening the tightening nuts (4) so that the cut spring
pairs (3) beneath them press against each other and straighten. Hold the edge (14 mm) of the
cable connection rod (1) when tightening. Attach the locking plates (5).

Replacing cables

When replacing cables, always replace both of the draw or return cables.

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Removing cables

1. Position the boom and feed on the center line of the rig.
2. Fully extract the tilt cylinder.
3. Run the feed as far forward as possible and drive the drill forward, but not on top of the idler wheel.
4. Lower the stinger into the ground.

5. Support the rock drill carriage in its place so that it cannot collapse.
6. Open the lock nut (3, 8), and remove the tightening nut (2, 9).
7. Draw cables: Remove the cable rotation guides from the idler wheel assembly. Return cables:
Remove the rotation guide mounting screws. Push the guides inwards.
8. Move the cable (5, 6) from the idler wheel (4, 7) groove.
9. Pull the cable connection rod away from the carriage embedding. Remove the cable by pulling it
under the carriage.

9
8
7
6
5
4
3
2

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Installing the cable

1. Draw cables: Remove the cable rotation guides from the idler wheel assembly. Return cables:
Remove the rotation guide mounting screws. Push the guides inwards.
2. Drop the cable, screw rod first, under the carriage.
3. Install the cable in the idler wheel groove.
4. Push the connecting rod through the mounting plate and two pairs of cut springs. Screw the
tightening nut in place.
5. Fasten the rotation guides.
6. Fasten the locking plate.
7. Check that the cables run straight under the carriage and over the plastic folding plate.
8. Because cables stretch and straighten slightly at first, their tightness must be checked daily for
an initial period following their replacement.

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5.2.5. Feed cylinder guide clearances

Adjusting the feed cylinder guide piece clearances

Guide pieces (2) are installed in the guide plate (1) of the feed’s draw cable idler wheel assembly.
They support the feed cylinder movements inside the feed beam. Adjust the guide piece (2)
clearances to 0.5–1 mm.

1 2

0,5 - 1 mm

In the version not equipped with hose reels, guide pieces (2) are also installed in the guide plate of
the return cable’s idler wheel assembly. Adjust the guide pieces when the feed cylinder is in its
minimum position (clearance 0.5–1 mm).

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0,5 –1 mm
2

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5.2.6. Clearance of the rock drill carriage and hose reel carriage and condition of the slide
pieces

2
1

1. Stainless steel plinth

2. Steel beam

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Adjusting the rock drill carriage and hose reel carriage slide piece clearances

The wear piece clearance is adjusted using the oval holes on the carriage. If the pieces are so worn
that the clearance (1) exceeds 3 mm, the clearance must be adjusted to the specified value. Loosen
the fastening screws (4) of the slide piece frame sections. Three Allen screws (3) are provided on
both sides of the drill carriage for adjusting the slide piece frame section. The hose reel carriage is
adjusted by knocking the slide piece frame to tighten it. For both carriage types, adjust the carriage
clearance (1) to 1 mm and tighten the frame section screws to 200 Nm.

1 2 3

1. Clearance 1.00 mm
2. Clearance 0.00 mm
3. Adjusting screws 3 pcs/side (only for drill carriage)
4. Fastening screws 14 pcs/side

Condition of the rock drill carriage and hose reel carriage slide pieces

Support the rock drill when replacing the slide pieces.

Replace the slide pieces if their clearances cannot be adjusted to the specified value or if the slide
pieces are damaged.

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5.2.7. Checking the Pito centraliser cylinder jaw pieces

Check the condition and alignment of the Pito

centraliser jaws. If necessary, align the jaws in
accordance with the instructions. If the jaws are
damaged, replace them with new ones.

Tube equipment operation

18mm 22mm

When 3 1/2" tube equipment is used, the distance between the arms can be increased by turning the
plates (7) by 180 degrees (L 164 mm -> L 172 mm).

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Replacing the jaws

NOTE! The engine must be stopped when replacing the jaws.

Check that the hole in the jaws matches your drilling equipment
NOTE!
(1 3/4”, 2”, 2 3/8”, 3”, Tube 3 1/2”).

Open the jaws, remove the mounting screws (4) of the jaws (5), and tap the pieces off. Install new
jaws and tighten the mounting screws (310 Nm).

Centraliser maintenance

5 6

4 7

3 8

2 9

1 10

13 12 11

1. Remove the stinger and suction head assembly from the Pito.
2. Remove the Pito from the feed.
3. First, drive out the spring pins (11). Use a suitable punch that will not damage the eye of the pin.
4. Tap out the shafts (10). The hydraulic cylinder (12) comes off.
5. Remove the connecting bolt (6). The front plate (3) comes off.
6. Remove the supporting arms (1) from their shafts (2, 9).
7. Remove the spring pins (8) and shafts (2, 9).
8. Wash the components thoroughly.
9. Check the shafts as well as the bearing bushings of the eyes of the supporting arms and cylinders.
10. Assemble the centraliser.
11. Lubricate the shafts through the nipples (13).

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Aligning the centraliser

1 2

3 4

The feed beam must be vertical during the alignment.

The jaws (1) must be in line with the rock drill shank (2). Loosen the nuts (4), 4 pcs. Align the Pito
centraliser (3) so that the rock drill shank is centred with respect to the sleeve pressed in the jaws.
Tighten the bolts.

5.2.8. Replacing idler wheel bearings

Contact Sandvik Mining and Construction service division.

5.2.9. Replacing the feed cylinder seals

Contact Sandvik Mining and Construction service division.

5.2.10. Lubricating the PITO centraliser cylinder

Add grease from the grease nipples of the PITO centraliser hydraulic cylinder.

1 Grease nipples of the PITO centraliser cylinder

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5.2.11. Greasing points

Greasing idler wheel bearings

As idler wheel lubrication is not part of the central lubrication (optional), the wheels must be lubricated
by the grease nipples.

1 1

2
2

1. Grease nipples of the idler wheels

2. Grease nipple in the joint between the idler wheel body and cylinder

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Greasing the hose reels

As hose reel bearing lubrication is not part of the central lubrication (optional), the bearings must be
lubricated by the grease nipples.

1. Grease nipple of the big hose reel

2. Grease nipple of the small hose reel

5.3. Rod handler

5.3.1. Tightness of bolts and nuts

Check the tightness of all bolts and nuts on the rig using suitable tools.

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5.3.2. Conditions of the roller Pito

Check the condition of the roller Pito. Pay atten-

tion to the condition of the rollers’ coating rubbers 1 3
(1), chain (2), and wheels (3).

5.3.3. Rod changer jaws

Check the fastening of the rod changer jaws (1).

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5.3.4. Rod handler greasing points

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5.4. Hydraulic rock drill

5.4.1. General

The hydraulic rock drill is intended for surface and underground drilling of vertical and horizontal holes.
Following these instructions will significantly increase the safety, reliability and operating life of the
rig. Sandvik Service is always willing to provide advice and help with any problems related to the rig.
These instructions are intended for properly trained personnel responsible for servicing, adjustment,
and repair procedures. Familiarise yourself with the instructions and always utilise the information in
disassembling, assembling, and servicing the rig.

5.4.2. Safety precautions

DANGER
DANGER OF ENTANGLEMENT!
Beware of moving and rotating parts. Entanglement in the
rotating parts can cause serious injury or death.
Carry out maintenance and repair work only when the rig is not
running. Make sure that the rig cannot be started unintentionally
during maintenance work.

Always follow the safety instructions and perform your work

with care.

Operating, service and adjustment procedures must be carried

out only by personnel with specialized operation and service
training. Read and ensure that you understand the operating,
maintenance, and safety instructions before using or servicing
the rig.

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5.4.3. Main components

1 2 3 4

5 6 7

1 Rear cover 2 Rotation motor

3 Gear housing 4 Front cover
5 Pressure accumulators 6 Flushing housing
7 Shank

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5.4.4. Flushing

2 3

Except for the flushing housings, the construction of air and water-flushed rock drills is identical. Water
is the most common reason for percussion piston seal failures. Water can enter the rock drill from
outside the flushing housing if the rock drill is vertical and shank blow is not on. If not drained regularly
from the lubrication device, water can also flow with lubricating system air. Water in the front end of
the rock drill can cause cavitation pitting in the body components near the piston seal and wiper ring
and in the piston.
To prevent water from entering the gear housing, the flushing
housing seals must be replaced immediately if water is leaking
from the drain holes (4). This is why the rock drill’s front end
NOTE!
must not be left pointing upward during pauses in drilling. If this
cannot be avoided, blow the flushing housing dry with air before
the break in drilling.

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5.4.5. Lubrication circulation

The percussion mechanism and the rotary actuator of the rock drill are lubricated using the hydraulic
oil that flows through them. The rotation mechanism and shank are lubricated via oil mist lubrication.
The lubrication line from the central lubrication device is connected to the fitting in the rock drill spacer.
From there, the oil mist passes to the front end of the rock drill, where it lubricates the stabiliser,
rotation mechanism, chuck, coupling, and flushing housing bearing. In the underground model, the
lubricating system’s air flow from the rear section of the piston is led out through the passage. In the
surface model, the drain oil from the rear section of the piston is led to the front through the passage.
Do not let the rear cover make contact with water when the
lubrication blow is not on. Oil mist that has travelled through
NOTE! the rock drill’s lubrication circulation system is removed from
the rock drill through the flushing housing fitting. This used
lubrication oil can be conveyed to a container with a hose.

NOTE! Never convey oil mist into the hydraulic system return line.

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5.4.6. Tools and parts used in maintenance

Ensure that the operator keeps the tools and parts required for
maintenance with the drilling rig.

The rock drill toolkit includes a torque wrench and sockets. A socket and extension are required for
tightening the rock drill/carriage's front and rear end mounting bolts.

For maintenance purposes, the drilling rig should also carry spare flushing housing seals, a spare
shank, and a spare coupling.

5.4.7. Checking the tightness of the bolts visually

Visually check that the bolts between the carriage and rock drill, as well as the flushing housing bolts,
are properly tightened.

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5.4.8. Condition of the flushing housing seals (during drilling)

Checking the flushing housing seals

Check the condition of the seals regularly as specified in the maintenance chart and always when
replacing the shank. The flushing housing seals must be replaced when the flushing air or water
escapes from the sides of the seal housing through the drain holes. It is recommended to use a spare
flushing housing as necessary, as this shortens the breaks in drilling caused by maintenance.

5.4.9. Checking the front end components

Check the shank, chuck, flushing housing, coupling, and rotation bushing. Refer to the instructions
under ‘Shank wear limits’, ‘Checking the chuck’, ‘Flushing housing wear limit measurements’,
‘Checking the coupling’, and ‘Checking the rotation bushing’.

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5.4.10. Removing the flushing housing

Remove the flushing housing by removing the bolts (4) and nuts (6). This also releases the rod shank
(7). When you open the clamp screw (5), the coupling (1) and chuck (2) are released first. When you
open the screw further, the rotation bushing (3) is released.

3
2
1

6
5

5.4.11. Checking the flushing housing bearing

The bearing must be replaced when its surface has worn to the level of the wear indicator groove at
any point. The indicator grooves are marked with arrows in the figure.

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5.4.12. Checking the shank bushing

The shank bushing must be replaced when a 1 mm notch has formed in it.

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5.4.13. Removing and installing the shank bushing

Use a hydraulic press and a punch (42) to remove the shank bushing (20).

42 20

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Installing the shank bushing

Install the shank bushing in the seal housing so that the locking surface (A) faces right, as shown in
the figure.

Press the shank bushing (20) into the flushing housing with a suitable punch. Take advantage of
temperature difference by heating the flushing housing and cooling the shank bushing.

20

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5.4.14. Checking the coupling

Pull the coupling out of the rotation bushing. Check it, and replace it if the edges of the inner teeth
are worn to a pointed shape.
The length of the coupling is 125.5 mm. The old coupling
(length: 130 mm) MUST NOT be used in the rock drill.

5.4.15. Checking the rotation bushing

Check the wear of the rotation bushing teeth, bearing surfaces, and bearing. The bearing must be
replaced when its surface has worn to the level of the wear indicator groove at any point. The indicator
grooves are marked with arrows in the figure. The bearing is replaced with a hydraulic press and the
punches included in the toolkit.

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5.4.16. Checking and replacing the rotation bushing bearing

The bearing (15) must be replaced when the bearing surface is worn to the level of the wear indicator
groove at any point. The indicator grooves are marked with arrows in the figure. Use a hydraulic press
and the punches (6 and 35) in the toolkit.

15

6 35

Figure: Removing the rotation bushing bearing

Take advantage of temperature difference by heating the rotation bushing and cooling the bearing.
Use the punches (14 and 35).

35 14

Figure: Installing the rotation bushing bearing

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5.4.17. Checking the chuck

The chuck must be replaced if its front surface has worn by over 1 mm or if the chuck has cracks in
it.

1 mm

5.4.18. Shank wear limits

The shank must be replaced when 1 mm of the 2 mm bevel at its rear has worn off or any other wear
limit is exceeded.

1 2

1. max. 1 mm
2. max. 1 mm
3. Initial: 2 mm / Rejection threshold: 1 mm

When installing a new shank for the rock drill, ensure that no
impurities are carried into the rock drill with the shank. Push the
shank carefully through the flushing housing to avoid damaging
the flushing housing seals.

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5.4.19. Removing the flushing housing cover and fitting flange

Remove the fitting flange (5) by removing the two bolts (10). Remove the four bolts (10) on the cover
(2). You can replace the two bolts (21) with longer bolts and use these to pull out the cover (2).

10

10 21 2

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5.4.20. Installing the flushing housing cover and fitting flange

Install the O-rings (12, 13, and 8). Install the seals (14 and 18) on the fitting flange and the cover.
Attach the flange and the cover. The pre-tightening torque for the cover screws is 100 Nm, and the
final tightening torque is 200 Nm. Tighten the screws in a crosswise pattern.

12

13
8
14

18

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5.4.21. Replacing the flushing housing cover bearing

Use a hydraulic press and a punch (42) to remove the bearing (3).

42 3

Press the bearing (3) onto the cover (2) with a punch (42). Take advantage of temperature difference
by heating the cover and cooling the bearing.

2 3 42
3 2

5.4.22. Flushing housing wear limits

1. The flushing housing bearing must be replaced when its surface has worn to the level of the wear
indicator groove at any point.
2. The shank bushing must be replaced when a 1 mm notch has formed in it.
3. The coupling must be replaced if the edges of the inner teeth have worn to a point.
4. The rotation bushing bearing must be replaced when the wear indicator groove has worn down
to the level of the surface at any point.
5. The chuck must be replaced if its front surface has worn by over 1 mm or if the chuck has cracks
in it.

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5.4.23. Removing and installing the seal housing

Use a hydraulic press, a punch (3), and a second punch to remove the seal housing (4).

4 3

Install the four seal housing seals (9) (refer to ‘Checking the flushing housing seals’) and the four O-
rings (8), and install the seal housing with a suitable punch. The hole in the seal housing (A) must be
aligned with the sealing flange. If you are replacing the shank bushing, remove it before installing the
seal housing.

8 A 8

9 9

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Removing and installing the seal housing, tube equipment

Removing (1) and installing (2) the seal housing with punches.

2 1

5.4.24. Checking the tightness of the side bolts

Check the tightness of the rock drill side bolts (7, 7a). The correct tightening torque is 600 Nm.

7 7a

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5.4.25. Pressure accumulator bolts

Required tools:
- torque wrench
- socket, 24-mm

1. First lubricate the bolts with grease.

2. Pre-tighten all four bolts to 100 Nm (10 kpm) with a torque wrench. Use the tightening sequence
1-2-3-4.
3. The final tightening torque is 200 Nm (20 kpm). Use the same tightening sequence, 1–2–3-4.
4. Also tighten the three stabiliser accumulator bolts in two stages.

2
4

3
1

5.4.26. Checking the pressure accumulator

1. Visually check the inside and outside of the accumulator for wear, damage, and corrosion.
2. Carefully clean and check the threading.

If the threads are corroded, the pressure accumulator must be

scrapped.

If necessary, use liquid penetrant testing to check the

accumulator for damage. Damaged pressure accumulators
must be scrapped.

5.4.27. Condition of the pressure accumulator’s filling valves and cover plugs

Check the condition of the pressure accumulator’s filling valves and cover plugs.

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5.4.28. Checking the charge gas pressure of the pressure accumulators

The charge gas pressure of a pressure accumulator must be checked once a week. The check is
performed by using a pressure gauge included in the rock drill’s special toolkit. The pressure gauge
range for the high-pressure and low-pressure accumulators is 0 to 100 bar and 0 to 10 bar,
respectively.

3
2

1. Remove the cap (A).

2. Screw the pressure gauge to the filling valve.
3. Open the locking nut (B).
4. Wait until the gauge pointer stops moving. Check the reading.
5. Close the locking nut (B).
6. Disconnect the gauge from the filling valve and replace the cap (A).

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5.4.29. Tightness of the rotation motor bolts

Required tools:
• torque wrench
• socket, 30-mm

1. Lubricate the bolts with petroleum jelly.

2. Pre-tighten all four bolts to 200 Nm (20 kpm) with a torque wrench. Use the tightening sequence
1–2–3–4.
3. The final tightening torque is 400 Nm (40 kpm). Use the same tightening sequence 1-2-3-4.

1 3 2 4

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5.4.30. Flushing housing bolts

Required tools:
- torque wrench
- socket, 36-mm

1. Lubricate the bolts and nuts with grease.

2. Pre-tighten all four bolts to 300 Nm (30 kpm) with a torque wrench. Use the tightening sequence
1–2–3–4.
3. The final tightening torque is 600 Nm (60 kpm). Use the same tightening sequence (1-2-3-4).
Alternative tightening procedure for the flushing housing bolts: Pre-tighten to 300 Nm and then
60° more (see figure).

1
4

3
2 60

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5.4.31. Front cover bolts

Required tools:
- torque wrench
- socket, 24 mm

1. Lubricate the bolts and nuts with grease.

2. Pre-tighten all four bolts to 100 Nm (10 kpm) with a torque wrench. Use the tightening sequence
1–2–3–4. The final tightening torque is 200 Nm (20 kpm). Use the same tightening sequence
(1-2-3-4).

1 4

3
2

5.4.32. Major overhaul

A major overhaul for the rock drill must be performed every 500
percussion hours or every 1,000 engine hours.

Contact your local Sandvik representative.

5.5. Carrier

This section describes the operation and components of the carrier and provides instructions for safe
maintenance, adjustment, and repair of the carrier.

5.5.1. Washing the rig

Wash the equipment regularly.

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5.5.2. Checking the condition of the fire extinguisher

Check the condition of the fire extinguishers (2

pcs).
If necessary, clean the extinguisher and ensure
that it includes the operating instructions.
Make sure that the extinguisher's indicator
gauge is not in the red zone. If the indicator is in
the red zone, the fire extinguisher must be serv-
iced immediately at an authorised service shop.

5.5.3. Checking the mounting of the track batches

Visually check the mounting of the track batches. Tighten all loose mounting screws and replace
missing mounting screws with new ones.

5.5.4. Tightening the caterpillar track

Both tracks are equipped with a grease-filled

tightening cylinder meant for tightening the cat-
erpillar track. When tightening the track, press
grease into the cylinder with the grease gun de-
livered with the rig.
The track is correctly tightened when its top sec-
tion sag is 15–35 mm. When loosening the track,
open the grease nipple carefully for 2–3 rounds.
The grease is then pressed out of the cylinder
along the groove in the nipple thread.

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5.5.5. Changing the tramming gear oil

Changing Rexroth tramming gear oil

1. Filler cap
2. Inspection and drain plug 1 2
3. Correct oil level
3

1. Tram the gear to a position where the drain plug (2) is pointing downward.
2. Open both plugs and drain the oil into a container.
3. Tram the tramming gear to filling position.
4. Add oil to the tramming gear. The tramming gear oil amount is 2.0 litres.
5. Close both plugs.

Check the oil grade from the oil recommendations.

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Changing Trasmital final drive oil

1. Checking and filling plug

2. Drain plug 1 2
3. Oil level

1. Move drive to such a position that the drain plug (2) is downwards.
2. Open both plugs and drain the oil to a receptacle.
3. Close the drain plug (2).
4. Add oil to the final drive. The filling capacity is 4.4 liters.
5. Close the filling plug.

Ref. Oil recommendation for the quality of oil.

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5.5.6. Checking the tramming gear oil

Checking and adding Rexroth tramming gear oil

1 2 3

1. Filler cap
2. Inspection and drain plug
3. Correct oil level.

When checking the gear oil level and adding oil, the gear must be in a position where the filler plug
(1) is pointing upward and the lower edge of the inspection plug (2) is along the gear’s centre axis
(see figure).
When adding oil, open both plugs. Check the oil grade from the oil recommendations.
If the oil level in the tramming gear rises, the shaft seal of the
NOTE!
hydraulic motor is probably damaged.

Checking and adding Trasmital final drive oil

1 2 3

1. Checking and filling plug

2. Drain plug
3. Oil level

When checking the final drive oil and adding oil, the final drive must be in such a position that the
drain plug (2) is downwards (ref. fig.).
When adding oil, open the plug (1). Ref. Oil recommendation for the quality of oil.
If the oil level in the final drive increases, the oil seal of the
NOTE!
hydraulic motor is probably damaged.

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5.5.7. Checking the idler wheel oil

Check the idler wheel oil level on both tracks.

Tram the drilling rig until the Allen screw on the

idler wheel points directly up.
Remove the Allen screw. The oil level must be
at the level of the threaded hole. Add oil if nec-
essary.

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5.5.8. Checking the (oscillation) bolts of the cylinders

Check the tightening torque of the cylinders’ ex-

pansion pin screws (1). The torque should be 290
Nm.

2 3 2 1

Expansion pin parts:

1. Tightening screw
2. Conical sleeves (2 pcs)
3. Pin

5.5.9. Greasing the oscillation axle

Lubricate both ends of the oscillation axle from

the grease nipples.

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5.5.10. Lubrication of the oscillation cylinder pins

Lubricate the cylinder pins via the grease nip-

ples.

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5.5.11. Changing the transfer gearbox oil

Open the filling cap to facilitate draining the

transfer gearbox.
Drain the transfer gearbox oil through the drain-
ing valve on the right-hand side of the rig. Drain
the used oil into a suitable receptacle.
When the transfer gearbox is empty, close the
drain valve.
Refer to “Filling capacities” for the correct oil
volume for the transfer gearbox.

Check the oil level with the dipstick when ap-

proaching the correct level.

Do not screw the dipstick in when checking the

level.
The oil level must be between the Min and Max
level marks.

Clean the breather with compressed air whenever the oil is changed.
Use only oils specified in the oil recommendations.

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5.5.12. Checking the electrolyte level and battery cable connections

Check the battery electrolyte level. The level

must be at the cells above the plates.
Check the connection and clean any oxidised
parts of the battery connectors and cables.

5.5.13. Mounting and condition of the winch cable

Check the mounting of the winch cable to the

winch drum.

Check the condition of the cable with respect to the following:

• any cut wires
• any broken strands
• a decrease in cable diameter
• corrosion on the entire length of the cable
• extruding strands or threads

Replace the cable if it has any of the above defects.

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5.5.14. Cleaning the battery and the battery terminals

Clean the batteries and the battery compart-

ment.
Clean the battery connectors and terminals, re-
moving any oxidised layers and dirt. Grease the
battery connectors and terminals with battery
terminal grease to prevent oxidisation.

5.5.15. Checking the welds

Check all carrier welds regularly. Should you detect any faults in the welds, contact Sandvik Mining
and Construction service division.

5.5.16. Changing the winch oil

1. Open the upper plug.

2. Place a waste oil container under the winch
and open the lower plug.
3. Wait until the winch oil is fully drained. Close
the lower plug and tighten it.
4. Add oil to the winch. Refer to the lubricant
and coolant recommendations for the cor-
rect oil grade and filling level.
5. Install the upper plug and tighten it.
6. Make sure that no oil is leaking from the
winch.

5.5.17. Checking the fastening of cables

Check the fastening of the cables. Firmly attach any loose cables.

5.6. Diesel engine

Perform the checks with the engine stopped.

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5.6.1. Cleaning the diesel engine

Clean the diesel engine. Remove any impurities and splashes from the engine surface if necessary.
Accumulated grease or oil on the engine is a fire hazard. When cleaning the engine, prevent water
from damaging electric parts of the engine such as the alternator, starter motor, and ECM.
Do not use any solvents for cleaning that might damage the
plastic or rubber parts of the engine.

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5.6.2. Replacing the air filter

Replace the diesel engine air filter.

Always check the seals and the sealing surfaces
when replacing the filters. The seals must be in-
stalled carefully in their proper positions.

2
The air filter (1) prevents dust and other impur-
1
ities from entering the engine. Clean intake air
is very important for the correct operation of the
engine. Any impurities in the intake air cause the
engine to wear rapidly. It is therefore important
to check and perform maintenance of the intake
system regularly and correctly.

When replacing the filter, check the engine in-

take lines for proper condition and tightness of
the connections.

The control system display shows a message when the engine

NOTE! air intake is restricted because of a clogged air filter. In this
case, the air filter must be replaced.

NOTE! The air filter element must not be cleaned.

When the air filter element is changed the air safety filter
NOTE!
element must be kept in place.

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5.6.3. Replacing the air filter safety cartridge

Replace the diesel engine air filter safety car- 2

tridge (2).
When replacing the air filter safety cartridge, 1
make sure that no dirt can enter the inlet duct.
Always check the seals and the sealing surfaces
when replacing the filters. The seals must be in-
stalled carefully in their proper positions. When
replacing the filter, check the engine intake lines
for proper condition and tightness of the con-
nections.

The air filter safety cartridge (2) must be replaced if the air filter cartridge (1) has been removed three
times.

Do not attempt to extend the operating life of the air filter safety
NOTE!
cartridge through cleaning; it must always be changed.

5.6.4. Replacing the oil and the oil filter

Change the diesel engine oil and replace the filter. When changing oil, the engine must be warm.

Replacing the filter

1. Place a receptacle under the oil filter.
2. Clean the filter (2) and the area around the
filter.
3. Remove the filter cartridge by turning it anti-
clockwise.
4. Empty the filter into the receptacle.
5. Clean the seal surfaces.
6. Dampen the seal surface with clean oil.
7. Screw the new filter cartridge in place man-
ually. Follow the instructions of the filter
manufacturer.
2 1

Changing oil
1. Open the drain valve.
2. Empty the oil into the receptacle.
3. Close the drain valve.
4. Fill the engine from the oil filler opening (1)
with the recommended oil. Refer to ‘Filling
capacities’ for the correct oil volume.
5. Check the oil level with the dipstick.

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5.6.5. Cleaning the crankcase breather

Clean the crankcase breather (1).

For detailed maintenance instructions, refer to
the instruction manual for the engine.

5.6.6. Checking the earth terminal of the engine

Check the earth terminal tightness in connection with every oil change. All earth connections must
be tightened. If there is corrosion on the connections, clean the connections.

5.6.7. Cleaning the radiator core

Always stop the diesel engine before checking

or cleaning the radiator core (1).
Check that the radiator has no damaged fins,
corrosion, or dirt (grease, oil, insects, leaves,
etc.).
If you use a pressure washer for cleaning the
core, be careful not to damage the core fins.
Dust can also be removed with compressed air.
Do not use over 4 bar of pressure.

1 2

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5.6.8. Cleaning the intercooler

Stop the diesel engine before checking or clean-

ing the intercooler (2) .
Check that the intercooler has no damaged fins,
corrosion, or dirt (grease, oil, insects, leaves,
etc.).
If you use a pressure washer for cleaning the
core, be careful not to damage the core fins.
Dust can also be removed with compressed air.
Do not use over 4 bar of pressure.

1 2

5.6.9. Hoses and connections

Check the hoses to the diesel engine and their clamps and connections. Replace cracked and
softened hoses. Tighten all loose connections.

5.6.10. Checking the tightness and condition of the V-belt

Check the tightness and condition of the V-belt

(1). Replace the belt if it is cracked or worn.
Press the V-belt between the belt pulleys with
your fingers. When the tightness is correct, the
belt deflection is about 10 mm.

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5.6.11. Checking the starter motor

Check the condition, tightness and correct op-

eration of the starter motor (1).
Turn the main switch into '0' position. Check and
clean all electrical connections.

5.6.12. Checking the turbocharger

Check the turbocharger (1) regularly.

Check that the exhaust pipe and intake hose are
properly attached and free from leaks.
Check that there are no oil leaks in the charger.

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5.6.13. Checking the condition of the water pump

Check the condition of the water pump (1).

A damaged water pump can cause serious en-
gine overheating problems. Check the water
pump visually for possible leaks.
Refer to the engine manual for more informa-
tion.

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5.6.14. Changing the coolant

Change the diesel engine coolant. For detailed

operation and maintenance directions, refer to 1
the instruction manual for the engine.
Always use antifreeze or an anti-corrosive ad-
ditive in the cooling system. Verify the correct-
ness of the concentration by consulting the en-
gine's instruction manual.
Open the expansion tank cap (1). Open the
drain valve (2) and drain the old coolant into a
suitable receptacle. Close the drain valve (2),
and fill the cooling system.
The coolant level is correct when it is at the mid-
dle of the sight glass in the expansion tank.
Start the engine, and leave the expansion tank
cap (1) open. Allow the coolant level to settle. 2
Add fluid if necessary. Close the expansion tank
cap (1) before the engine has reached the nor-
mal running temperature.
Check that the cooling system is free of leaks.

DANGER
Hot fluid and steam can cause serious injury. Never open the
expansion tank cap while the engine is hot or running.

Never add cold coolant to a hot engine. Doing so could damage

the cylinder head and other engine components.

5.6.15. Replacing the cooling system thermostat

Depending on the engine load, a thermostat jammed partly open can either cause the engine to
overheat or a too low operating temperature. If the thermostat is jammed shut, the engine overheats.
If the thermostat is jammed open, the engine’s running temperature remains too low on a partial load.
The preventive thermostat replacement prevents unexpected shutdowns. In order to replace the
thermostat, contact the local Caterpillar representative.

5.6.16. Checking the engine monitoring

Check visually the condition of all gauges, sensors, and wires. Note any loose, cracked, or damaged
wires and components. Any damaged wires and components must be repaired or replaced
immediately.

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5.6.17. Checking the alternator

Check the condition of the alternator (1) and

verify its correct operation. Check and clean all
electrical connections.
Refer to the engine’s operation instructions for
more information if necessary.

5.6.18. Checking the engine brackets

Check the engine brackets (4 pcs) (1) for weak-

ening. Brackets in poor condition can cause the
engine to shake.
Check that the bracket fastening screws are
tight.

5.6.19. Checking the crankshaft's vibration damper

Check the damper (1) for possible leaks. If you

detect any leaks, identify the type of fluid that is
leaking. The vibration damper fluid is silicone
(transparent, rigid, soft and difficult to remove
from surfaces). If the fluid leaked is oil, check
the crankshaft seals for leaks. Refer to the en-
gine manual for more information.

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5.6.20. Checking the electronic injector nozzles

Using the Caterpillar engines with wrong elec-

tronic pump nozzle adjustments may weaken
the engine power. This can cause the fuel con-
sumption to increase and the engine operating
hours to decrease.
Only qualified maintenance personnel can
check and adjust the electronic pump nozzles.
Contact the local Caterpillar representative.

5.6.21. Checking the engine speed / timing sensors

The engine speed and timing sensors are to be checked and calibrated by qualified maintenance
personnel only. Contact the local Caterpillar representative.

5.6.22. Checking the valve clearances

Adjustment of the valve clearances of new en-

gines is recommended in connection with the
first oil change. The adjustment is needed due
to initial wear and adaptation of the valve gear
parts.
Only qualified personnel with adequate training
are allowed to adjust the valve clearances. You
can also contact a Caterpillar representative to
carry out the procedure.

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5.6.23. Checking the valve rotators

The engine valve rotators rotate the valves as

the engine is running. This keeps the valves and
valve seats free of deposits. If a damaged rota-
tor is not replaced, the valve seat surface may
become chafed and decrease the operating
hours of the valve, or metal fragments from the
chafed valve may fall into the cylinder and cause
further damage.
Check the operation of the valve rotators when
adjusting the valve clearances. Contact the lo-
cal Caterpillar representative.

5.7. Cabin

5.7.1. Operation of the cabin door switch

Check the operation of the cabin door switch. The control system display shows a message indicating
that the door is open.

5.7.2. Cabin air filters

The cabin air filters (interior circulation and suc-

tion filters) must be replaced at the intervals
specified in the maintenance instructions.
Open the filter housing cover on the left side of
the cabin.
Remove the old filters.
Clean the filter housing and press the new filters
into place.
Close the cover.

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5.8. Hydraulic system

5.8.1. Cleaning the radiator core

Always stop the diesel engine before checking

or cleaning the radiator core (1).
Check that there are no damaged fins, corro-
sion, or dirt (grease, oil, insects, leaves, etc) in
the radiator.

If you use a pressure washer for cleaning the

core, be careful not to damage the core fins.
Dust can also be removed with compressed air.
Do not use over 4 bar of pressure.

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5.8.2. Hydraulic oil tank

The oil level in the hydraulic oil tank is checked

2
with the sight glass (1) on the side of the tank. The
oil level should be in the middle of the sight glass.
The hydraulic oil tank and the compressor oil tank
are filled with a manual pump. The tank to be filled
is chosen with a 3-way valve.
The oil tank breather filter (2) is located on the left
side of the rig, above the coolers.
The hydraulic return oil filters (3) are located in-
side the tank. When changing the filter cartridges,
the cover on top of the tank must be opened.
The hydraulic pressure filter (4) is located on the
right side of the rig. The filter is equipped with an
electric service indicator indicating when the filter 4 1 3
cartridge must be replaced.

If hydraulic oil is cold, the service indicator lamp may be lit for
a while after the engine is started, even if the filter was not dirty.

5.8.3. Checking the return pressure sensor

Visually check the condition of the hydraulic oil

tank return pressure sensor (1). Ensure that the
connector and cable are intact and properly
positioned.

5.8.4. Checking the temperature sensor

The hydraulic oil tank temperature sensor (1)

must be checked when the tank has been
drained for an oil change or for cleaning.
Visually check the condition of the sensor, ca-
1
ble, and connector.
Warm the sensor and measure its temperature.
Compare the temperature with the hydraulic oil
temperature displayed by the control system.
Replace the sensor if necessary.

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5.8.5. Changing the hydraulic oil tank breather

The hydraulic oil tank breather (1) must be re-

placed in accordance with the maintenance pro-
gramme. The oil tank breather filter is located
aboveof the radiator core.

5.8.6. Oil pressure filter

Replace the oil pressure filter.

The hydraulic pressure filter is located on the
right-hand side of the rig. The filter is equipped
with an electric service indicator indicating when
the filter cartridge must be replaced.

Ensure that the hydraulic system is not pressur-

ised.
Open the filter housing and remove the old filter
cartridge and seal.
Install the new filter cartridge and seal.
Close the filter housing by twisting. Ensure the
tightness of the filter housing upon the next
start-up.

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5.8.7. Changing the oil return filters

Replace the return oil filters (2 pcs) (1), located

in the hydraulic oil tank.
The filters are located inside the tank. When
changing the filter cartridges, the covers on top
1
of the tank must be opened.
Before opening the covers, clean the top of the
tank carefully so that no dirt gets into the oil tank.
During the replacement, check that the filter car-
tridge’s seals are undamaged and fit their
grooves well.
Replace the covers’ O ring seals if necessary.

5.8.8. Operation of the oil level switch

Check the operation of the oil level switch during the oil change.
The control system display should show a message indicating a low oil level when the oil has been
drained from the tank.

5.8.9. Cleaning the hydraulic oil tank

Clean the outside of the hydraulic oil tank.

Empty the oil tank using the drain valve (1).

2
Remove the return filter holder (3) at the top of
the tank by opening screws (2) to facilitate
3
cleaning.
Clean, rinse, and dry inside of the tank (4) thor-
oughly. 4
After cleaning the tank, install the return filter
holder.
Before filling the tank, ensure that it is free of
impurities.

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5.8.10. Changing the hydraulic oil

Empty the oil tank to the receptacle using the

drain valve. 4
Refer to the oil recommendation table for the
correct oil grade.
3
Fill the hydraulic oil tank so that the oil level is in
the middle of the sight glass.
Check the oil level when the machine has been 1
running for a few minutes after changing the oil.
Add oil if necessary.
The hydraulic oil tank (3) and the compressor oil
2
tank (4) are filled with a manual pump (1). The
tank to be filled is chosen with a 3-way valve(2).

5.8.11. Checking the hydraulic oil thermostat

Check the operation of the thermostats if the

hydraulic oil overheats or if the oil is too cold.

A disassembled thermostat.

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5.9. Pneumatic system

5.9.1. Checking the intake air line and connections

Check the intake air line and connections.

Check the condition of the suction hoses, tight-
ness of the connections, and tightness of the air
filter housing.
Check the fastening of the intake valve and the
tightness of the connections.

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5.9.2. Replacing air filter

Replace the compressor air filter.

Always check the seals and the sealing surfaces
when replacing the filters. The seals must be in-
stalled carefully in their proper positions.

2
The air filter (1) prevents dust and other impur-
1
ities from entering the engine. Clean intake air
is very important for the correct operation of the
engine. Any impurities in the intake air cause the
engine to wear rapidly. It is therefore important
to check and perform maintenance of the intake
system regularly and correctly.

The control system display shows a message when the air

NOTE! intake is restricted because of a clogged air filter. In this case,
the air filter must be replaced.

NOTE! The air filter element must not be cleaned.

When the air filter is changed the air filter safety cartridge must
NOTE!
be kept in place.

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5.9.3. Replacing the air filter safety cartridge

Replace the compressor air filter safety car- 2

tridge (2).
When replacing the air filter safety cartridge, 1
make sure that no dirt can enter the inlet duct.
Always check the seals and the sealing surfaces
when replacing the filters. The seals must be in-
stalled carefully in their proper positions. When
replacing the filter, check the engine intake lines
for proper condition and tightness of the con-
nections.

The air filter safety cartridge (2) must be replaced if the air filter cartridge (1) has been removed three
times.
Do not attempt to extend the operating life of the air filter safety
NOTE!
cartridge through cleaning; it must always be changed.

5.9.4. Operation of the air filter maintenance indicator

Check the operation of the air filter maintenance indicator. The control system display shows a
message if the filter is clogged.

5.9.5. Changing the compressor oil

Change the compressor oil.

Ensure that there is no pressure in the pneu- 4
matic system before changing the oil.
Drain the oil from the tank into a receptacle by
opening the drain valve on the right-hand side. 3
Close the valve. Add the amount of oil specified
under ‘Filling capacities’ with a hand pump.
Check the sight glass on the side of the tank to 1
ensure that the oil level is correct. The oil level
must be between the Min and Max marks.
The hydraulic oil tank (3) and the compressor oil 2
tank (4) are filled with a manual pump (1). The
tank to be filled is chosen with a 3-way valve (2).

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5.9.6. Oil filter

Replace the oil filter.

Ensure that there is no pressure in the pneu-
matic system.
Open the filter housing, and remove the old filter
cartridge and seal.
Install the new filter cartridge and seal.
Close the filter housing by twisting. Ensure the
tightness of the filter housing upon the next
start-up.
The control system display shows a message
when the oil filter is clogged.

5.9.7. Oil separator

Replace the oil separator filter cartridges.

Ensure that there is no pressure in the pneu-
matic system.
Open the tank cover and pull out the old filter
cartridges. Ensure that the cartridge O rings do
not remain in place.
Press the O rings and filter cartridges into place
and reinstall the tank cover.

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5.9.8. Cleaning the oil receiver

Empty the oil tank to the receptacle using the

drain valve (1).

Clean the oil receiver.

Clean, rinse, and dry the tank thoroughly.
Before adding oil, ensure that the tank is free of
impurities.

5.9.9. Checking the thermostat

Check the operation of the thermostat.

If the compressor oil temperature increases too
much or is too low, clean the thermostat and
check the correct operation.
Replace the thermostat if necessary.

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5.9.10. Cleaning the radiator

1
Always stop the diesel engine before checking
or cleaning the radiator core (1).
Check that there are no damaged fins, corro-
sion, or dirt (grease, oil, insects, leaves, etc) in
the radiator.
If you use a pressure washer for cleaning the
core, be careful not to damage the core fins.
Dust can also be removed with compressed air.
Do not use over 4 bar of pressure.

5.10. SLU Shank lubrication unit

5.10.1. Condensed water in the oil tank

Drain the condensation water from the oil tank to

the receptacle using the drain hose (1).

5.10.2. Changing the oil receiver breather

Replace the breather (1) at the intervals speci-

fied in the maintenance instructions or earlier as
required e.g. in the event that the breather has
become wet.

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5.10.3. Cleaning the oil receiver

Empty the oil tank into the receptacle. Remove

the receiver cover (1) and clean the receiver
from the inside. Replace the cover seal if nec-
essary.

5.10.4. Emptying the shank lubrication return tank

Empty the shank lubrication return tank into the

receptacle.

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5.10.5. Checking the operation of the monitoring unit

1. Check the operation of the monitoring unit as follows:

• Disconnect the directional valve (CT5) plug: the alarm must activate after four operational
cycles.
• Disconnect the flow monitoring cable from the monitoring unit (CT1): the alarm must activate
after four operational cycles.
• Short-circuit the flow monitoring cable to the pump body: the alarm must activate after four
operational cycles.

5.11. Fuel system

For detailed operation and maintenance instructions, refer to the instruction manual for the engine.

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5.11.1. Draining water and deposition from the fuel tank

1 3

Regularly drain water from the fuel tank.

Place a fuel receptacle under the drain hose (4).
Drain water and any deposition by opening the
valve (4) until clean fuel runs from the tank.
Close the valve.
1. Filling cap
2. Level sensor
3. Breather
4. Drain valve and hose

2 4

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5.11.2. Replacing the fuel filter / water separator element

Close the valves on the fuel line between the fuel

tank and the engine before changing the element.
This helps prevent the fuel from flowing from the
tank when you are replacing the element.
Replace the filter element according to mainte-
nance schedule or if you notice any power loss in
the engine.

• Remove element (1) from the element mount-

ing base (3) while bowl (2) is attached.
• Remove bowl (2) from element (1). 3
• Remove the O-ring from the bowl (2).
• Clean the bowl, O-ring and mounting base. Re-
place O-ring, if necessary. 1
• Lubricate the O-ring with clean diesel fuel.
• Install bowl (2) on a new element. Tighten the 2
bowl by hand. NOTICE! Do not use any tools
for the tightening.
• Lubricate the top seal of element (1) with clean
diesel fuel.

Do not pre-fill the filter with fuel!

• Install the new element on the element mount-

ing base. NOTICE! Do not use any tools for
the tightening!
• Open the fuel valves.
• Bleed the fuel system. Refer to " "Bleeding the
fuel system" (p. 221) ".
• Start the engine and check for leaks. Run the
engine for one minute
• Stop the engine and check for leaks.

The fuel 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.

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5.11.3. Replacing the fuel filter cartridge

Close the valves on the fuel line between the fuel

tank and the engine before opening the filter. This
helps prevent the fuel from flowing from the tank
when you are replacing the filter cartridge.

The fuel filter cartridges (1) must be replaced at 2

the intervals specified in the maintenance instruc-
tions or if power loss is observed.
1. It may be necessary to relieve residual fuel
pressure from the fuel system before remov-
ing the fuel filter. Loosen one of the fuel supply
connections (2) in order to purge any residual
pressure.NOTICE! Do not loosen fuel lines
or fittings at the fuel manifold or ECM. The
engine components may be damaged.
2. Place a fuel receptacle under the filter.
3. Clean the filter and the area around the filter.
4. Remove the filter cartridge by turning it anti-
clockwise.
5. Clean the seal surfaces.
6. Dampen the seal surface with clean fuel.
7. Install the new filter cartridge. Spin the fuel fil-
ter onto the fuel filter base until the gasket
contacts the base. Use the rotation index
marks on the filter as a guide for proper tight-
ening. Tighten the filter for an additional 3/4
turn by hand. Do not use tools for tightening.
1

Do not pre-fill the filter with fuel!

Open the valve on the fuel line between the fuel tank and the engine after having changed the
cartridge.

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5.11.4. Bleeding the fuel system

When the ignition key (A) is turned to position 1, the fuel pump starts and runs for 2 minutes, in which
time the fuel system bleeds automatically.

5.11.5. Fuel tank

Fill the tank with clean fuel only; it is extremely important to keep the fuel storage tank clean and also
to drain the water and clean it regularly.
Clean the area surrounding the filling tube carefully before opening the fuel tank cap. This is to prevent
dust and other impurities from entering the tank.
Keep the filling pump valve clean. When using the hand pump, ensure cleanliness of the pump suction
hose and filling tank intake port.
Before re-filling, clean the electric filling pump valve and protect it from dirt.
Do not keep the tank cap open when using the electric pump.
Drain water from the fuel tank regularly (once a week) and clean the tank at the intervals specified in
the maintenance instructions.
Replace the breather at the intervals specified in the maintenance instructions or if it is wetted with
fuel (due to overfilling).
Fill the fuel tank at the end of the day to remove moist air from the tank. This prevents the water from
condensating. Do not fill the tank to the brim since the fuel expands as it warms and could cause the
tank to overflow.

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5.11.6. Replacing the fuel tank breather

Replace the fuel tank breather (1).

The breather must be replaced earlier than
specified if it becomes wetted with fuel (due to
overfilling).

5.11.7. Cleaning the fuel tank

Clean the fuel tank.

Empty the tank into a receptacle using the drain
valve. Clean, rinse, and dry the tank thoroughly.
Replace the door seal if necessary.
Ensure that the tank is clean before filling it.

5.12. Dust collector system

5.12.1. Condition of suction hoses and connections

Check that there are no leaks in the dust collec-

tor intake line hoses and connections. Reshape
any depressed hoses so that they are round.
Replace any damaged hoses.

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5.12.2. Condition of the filter cartridges

Dust emission from the dust collector air outlet

indicates a damaged filter cartridge. Replace a
damaged cartridge immediately, since the pas-
sage of dust through the damaged cartridge
causes wearing of the dust collector blower
wheel. The cartridges have threaded fittings at
the upper end.
Check the condition of the filter cartridges. If
necessary, clean the cartridges with com-
pressed air via the maintenance shaft on the
side of the dust collector.

The compressed air nozzle must be kept at a safe distance from

the filter cartridges to prevent them from becoming damaged.

5.12.3. Operation of pulse jet cleaning

Three blow-out valves are fitted to the dust col-

lector pulse jet cleaning line. When the pulse jet
cleaning is on, each blow-out valve takes turns
to blow compressed air into the filter cartridges.
The operation can be checked by monitoring the
blow-out valve operation. Normally, the LED on
the blow-out valve is lit when the valve is acti-
vated. When the blow-out valve blows com-
pressed air into the filters, a blowing sound is
heard.

5.12.4. Integrity of the dust collector

Check the integrity of the dust collector. When

the integrity of the dust collector housing is suf-
ficient, the dust connector does not suck in par-
ticles through the cracks on the maintenance
shaft nor from other inappropriate places. Re-
place the door seal if necessary.

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5.12.5. The condition of the fine separator’s impact plate.

Check the condition of the impact plate steel

grate on the opening inside the fine separator.
If there is a hole in the part, replace the part.

5.12.6. Condition of the coarse separator’s skirt rubber

Check the condition of the skirt rubber at the

opening of the coarse separator. A damaged
skirt rubber reduces the effect of the dust col-
lector system. If the rubber is worn or otherwise
damaged, replace it.

5.12.7. Condition of the coarse separator’s rubber lining

Check the condition of the rubber lining inside

the coarse separator by opening the coarse
separator cover. If there is a hole in the rubber
lining, replace it with a new rubber lining.

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5.12.8. Condition of the suction head rubbers

Check the condition of the skirt rubber on the

opening of the suction head and the rubber seal
in the suction head. Replace any damaged
parts.

5.12.9. Moving suction head cylinder lubrication

Add grease to the grease nipples of the moving

suction head cylinder.

5.12.10. Operation of the cut-off cylinder / butterfly valve

Add grease to the cut-off cylinder grease nip-

ples. Grease the shaft of the butterfly valve.

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5.12.11. Operation of the cut-off cylinder / butterfly valve

Check the operation of the cut-off cylinder / but-

terfly valve. In normal operation, the cylinder
opens the butterfly valve when percussion is in-
itiated. When the percussion is disengaged, a
spring closes the butterfly valve.

5.13. Main electrical system

5.13.1. Checking the condition of electrical cables and connections

1. Check the condition of electrical cables.

2. Check the condition and fastening of electrical connections.

Replace any faulty cables or connectors. If necessary, contact Sandvik Mining and Construction Oy's
service division.

5.13.2. Checking electrical cabinets and boxes

1. Check that the electrical cabinet doors and box covers are closed securely.
2. Check the fastening of electrical cabinet and box connectors.
3. Check the integrity and tightness of sealing bushings on the electrical cabinets and boxes.
4. Check that possible water holes are not clogged.

Repair any faults and deficiencies. If necessary, contact Sandvik Mining and Construction Oy’s
service division.

5.13.3. Checking the fastening of electrical cables

1. Check the fastening of electrical cables.

2. Check that the cables are not chafed or stretched from the fastening sites.

Firmly attach any loose cables. Repair other faults and deficiencies. If necessary, contact Sandvik
Mining and Construction Oy's service division.

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6. LUBRICANTS AND CAPACITIES

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6. LUBRICANTS AND CAPACITIES

6.1. General

All fluids and greases mentioned in this instruction are hazardous to health and to the
environment.
ENVIRONMENT POLLUTION HAZARD!
Dispose of all fluids and greases in accordance with local
regulations.

6.1.1. Choosing the oil

Oil is chosen according to the properties of the oil and the application.

Choosing the oil according to its properties

- viscosity
- stability of properties throughout the service life
- water separation ability
- anti-oxidation and anti-foaming properties
- health effects
- environmental effects

Check the original oil type from the machine card or the
maintenance instructions.

Choosing the oil according to the application

The following issues must be considered:

- Sandvik's oil recommendation
- the component manufacturer's oil recommendation (e.g. diesel engine, transmission)
- environmental/site-specific/safety requirements
- biodegradable oils
- less flammable fluids

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Mistakes in choosing and using oil

Components may be damaged if

- a wrong oil type has been chosen
- a wrong oil viscosity has been chosen
- the recommended oil change interval is exceeded.

Oil must be changed at certain intervals because the properties of the oil and its additives deteriorate
and are lost as the oil ages.
Observe the colour and clearness of the oil. Water and other
impurities in the oil can cause malfunctions in the hydraulic
system and serious component damage (e.g. of rock drills). If
the oil is light grey or dull, change the oil. Find the cause of the
oil impurity.

6.1.2. Oil viscosity

SAE classification (engine oils)

(SAE = Society of Automotive Engineers) Viscosity indicates the oil's ability to flow. Viscosity is
measured at a high and low temperature and is indicated as an SAE grade, e.g. SAE 40. For
multigrade oils, e.g. 5W-40, the first value (5W) indicates the viscosity at low temperatures, and the
second value (40) indicates the oil viscosity when it is hot.

ISO classification (industrial oils)

(ISO = International Organization for Standardization) The viscosity of industrial oils is determined
by the ISO-VG standard (ISO 3448). The ISO grade number indicates the oil viscosity at +40 °C,
expressed in centistokes (cSt, kinematic viscosity). For example, oil graded as ISO-VG 68 has a
viscosity of 68 cSt at + 40 °C.

Too low viscosity causes

- Breaking of the lubrication film between contact surfaces. The resulting metal-to-metal contact
between surfaces causes rapid wear and increases the need for maintenance.
- Internal leaks in components, which reduces efficiency.

Too high viscosity causes

- Flow losses in the system, thus also reducing efficiency.

- Increase in the load on the seals due to increased return line pressure.
- For certain rock drills, wear of the rotation shaft and thrust bearing due to increased return line
pressure.
- Too thick oil increases the risk of cavitation in pumps.

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6.2. Hydraulic system

The oil viscosity recommendations are based on the operating temperature of the oil.
Never mix different types of hydraulic system oils. Mixing can
damage the hydraulic components.

The selected hydraulic oil must be high quality and must retain its properties in fluctuating temperature
conditions. Furthermore, it should contain additives typical of high performance hydraulic oils.
When choosing the viscosity of the oil to be used, the temperature of the drilling environment is
important. Pay attention to temperature fluctuation.
When choosing the oil, consider the following:
1. Check or estimate the operating temperature of the oil.
2. The viscosity of oils at their operating temperature should be close to 60 cSt, and any variation
in continuous use should remain within the range 50–110 cSt.
The following variation limits are permitted temporarily (but not constantly):
- 110–200 cSt as a result of a low temperature peak, or
- 30–50 cSt as a result of a high temperature peak
The values indicated in the tables should be considered first and foremost. In each case it must
always be ensured that the product in question has the required properties.
3. If the drilling environment temperature does not vary greatly, it is most recommended to use
single-grade oils which undergo minimal viscosity variation during use.
4. If the drilling conditions are such that single-grade oils do not remain within the given viscosity
limits, a multigrade oil should be chosen.
5. The oil should be changed once a year unless heavy use requires more frequent changes. This
change interval recommendation is based on the the extent that the oil ages and gathers moisture
over a one-year period.

For arctic conditions (temperatures below –20 °C), synthetic oils are recommended.

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6.2.1. Engine oils in the hydraulic system

Only use high-quality oils.

Classification Operating temperature

(SAE)
Multigrade oil
°C -30 -20 -10 0 +10 +20 +30 +40 +50 +60 +70
°F -22 -4 +14 +32 +50 +68 +86 +104 +122 +140 +158
5W--20
5W--30
10W--30
10W--40

Single-grade
oil
10W
20W--20
SAE 30
SAE 40

Synthetic oil
5W--30

Recommended temperature range

Temporarily allowed temperature range
Lowest permitted starting temperature

Table: Viscosity/temperature table

Oils and fluids suitable for hydraulic systems are, e.g.

• Shell Rimula R3 (engine oil)

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6.2.2. Hydraulic oils

DIN 51524, ISO 6743-4

Viscosity cSt Operating temperature

(40 °C)
°C -30 -20 -10 0 +10 +20 +30 +40 +50 +60 +70
°F -22 -4 +14 +32 +50 +68 +86 +104 +122 +140 +158
32
46
68
100
150

Recommended temperature range

Temporarily allowed temperature range
Lowest permitted starting temperature

Table: Viscosity/temperature table

Oils and fluids suitable for hydraulic systems are, e.g.

• Shell Tellus S (hydraulic oil)

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6.2.3. Biodegradable hydraulic oils

Sandvik sets the same high technical quality requirements for biodegradable oils as are set for
conventional mineral oils. In addition, the oils must be environmentally friendly in terms of the following
quality requirements:
• biodegradability
• toxicity
• use and disposal.

The international standard ISO 15380 specifies the requirements for environmentally acceptable
hydraulic fluids.

Viscosity cSt Operating temperature

(40 °C)
°C -30 -20 -10 0 +10 +20 +30 +40 +50 +60 +70
°F -22 -4 +14 +32 +50 +68 +86 +104 +122 +140 +158
46
68

Recommended temperature range

Temporarily allowed temperature range
Lowest permitted starting temperature

Table: Viscosity/temperature table

Instructions for changing biodegradable oils are provided in the manual "Biodegradable Hydraulic
Oils – Changing instructions for biodegradable hydraulic oils", Sandvik instruction 130.
When biodegradable oils (optional) are used, Sandvik factory
fill oils are SHELL NATURELLE HFE 46 or HFE 68 (synthetic
ester). The guarantee is valid only when these olis are used.

Oils and fluids suitable for hydraulic systems are, e.g.

• Shell Naturelle HFE (biodegradable hydraulic oil, synthetic ester)

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6.2.4. Fire retardant hydraulic fluids

Sandvik sets the same high technical quality requirements for less flammable hydraulic fluids as are
set for conventional mineral oils. In addition, the oils must be non-flammable, with self-extinguishing
properties. A range of fire retardant fluids are available on the market, the properties of which differ
greatly.
In risk-prone conditions, Sandvik recommends use of fluids that comply with the ISO 6743-4 HFD
standard for synthetic fluids.
However, for safety, performance and environmental reasons
Sandvik does not allow mixing of different hydraulic oils/fluids.

These fluids must be compatible with the majority of metals and seal materials.
Sandvik uses fire retardant and biodegradable HFD fluids as factory-fill oils: Fuchs Plantoflux 68-AT-
S (Tampere plant) and Condat D68 (Lyon plant). Sandvik recommends these fluids for use in drilling
rigs. Since the availability of these fluids can be limited in certain market areas, Sandvik also approves
the following alternative:
• Quintolubric 888-68 (Quaker Chemicals)

Sandvik factory fill oils are totally miscible with the fluid mentioned above. Thus, the factory filled oil
can be changed as necessary in connection with the rig start-up inspection without flushing the
hydraulic system. Sandvik does not approve continuous mixing of hydraulic fluids.
The guarantee is valid only if the recommended fluids are used.

Oils and fluids suitable for hydraulic systems are, e.g.

• Fuchs Plantoflux 68-AT-S (less flammable hydraulic fluid)

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6.3. Rock drill shank lubrication

6.3.1. Shank lubrication with oil

Use only recommended shank lubrication oils. Using water-

based lubricants for this purpose is forbidden.

The oil recommendations are based on the ambient temperature.

Viscosity cSt Ambient temperature

(40 °C)
°C -30 -20 -10 0 +10 +20 +30 +40 +50 +60 +70
°F -22 -4 +14 +32 +50 +68 +86 +104 +122 +140 +158
32
68
100
150
220
320

Recommended temperature range

Table: Viscosity/temperature table

Examples of rock drill oils:

SHELL Torcula
ESSO (EXXON) Arox
GULF Gulf Rock Drill Oil
MOBIL Almo
BP Energol RD-E
TEXACO Rock drill lube

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6.3.2. Shank lubrication with grease

The grease used must provide sufficient lubrication properties at high temperatures.

NLGI grade 2
Penetration, beaten, 25 ºC, ASTM D 217, 0.1 mm 265–295
Operating temperature range, °C –30...+210
Dropping point, ASTM D 2265, °C > +260
Corrosion protection, ASTM D 1743, SKF EM- Approved
COR, classification
Water flushing test, ASTM D 1264, 79ºC, % wt. <3
loss
Oxidation, ASTM D 942, psi decrease / 100 hours <5
Evaporation, ASTM D 2595, 100 ºC, wt % <2

Table: Recommendations

High mechanical durability.

Suitable for heavy shock loads as well as high vibration and oscillatory conditions.

Grease type Manufacturer

VISO 808-2 VISO
MOBILITH SHC220 MOBIL
ALMAGARD 3752 LUBRICATION ENGINEERS
ALBIDA HLS 2 SHELL
SYNTEC GREASE TEBOIL

Table: Recommended greases

6.4. Diesel engine

6.4.1. API engine oil classification

The API (American Petroleum Institute) diesel engine oil classification has two-letter designations,
the first letter being “C”. The current classification designations for four-stroke diesel engines are API
CG-4, API CH-4, API CI-4 ja API CJ-4. The higher the second letter in the alphabet, the higher the
oil quality.

6.4.2. Fuel sulphur content

A fuel sulphur content exceeding 0.5 % can affect the oil selection and the length of oil change
intervals. For more information, refer to the engine manufacturer’s maintenance instructions.
For the engine oil selection, refer to the engine manufacturer’s
maintenance instructions.

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Caterpillar

• API CJ-4 multigrade oil (recommended oil)

• API CI-4 multigrade oil that meets Caterpillar ECF-1-a or ECF-2 specifications (acceptable oil)
• API CH-4 multigrade oil that meets Caterpillar ECF-1-a or ECF-2 specifications (acceptable oil)
• API CG-4 multigrade oil that meets Caterpillar ECF-1-a or ECF-2 specifications (acceptable oil)

Classification Ambient temperature

(SAE)
°C -40 -30 -20 -10 0 +10 +20 +30 +40 +50 +60
°F -40 -22 -4 +14 +32 +50 +68 +86 +104 +122 +140
SA E 0W -- 20
SA E 0W -- 30
SA E 0W -- 40
SA E 5W -- 30
SA E 5W -- 40
SA E 10 W -- 30
SA E 15 W -- 40

Recommended temperature range

6.5. Compressor

6.5.1. Gardner Denver compressor

Mineral-based engine oil or synthetic compressor oil can be used in the compressor.
Never mix different types of oil. Mixing may damage the
compressor.

When changing the oil type, the compressor circuit must be flushed with new oil:
1. Drain the oil from the compressor circuit.
2. Fill the compressor circuit with new oil and run the compressor to warm it up.
3. Drain the oil from the compressor circuit.
4. Replace the oil filter and oil separators.
5. Fill the compressor circuit with new oil.

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Mineral-based engine oil

Mineral-based engine oil can be used in the compressor. The flash point of the oil must be over 180
°C. The lowest allowable viscosity at the operating temperature is 7 cSt.
If the operating temperature is continuously over 90 °C, the oil
change interval for mineral-based oils is 250 engine hours (500
engine hours for synthetic compressor oils).

The mineral-based engine oil recommendations are based on the ambient temperature.

Classification Ambient temperature

(SAE)

SAE SW - 20
SAE 10W
SAE 20W - 20
SAE 10 - 30

Recommended temperature range

Temporarily allowed temperature range

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Synthetic compressor oil

If the operating temperature is continuously over 100 °C

(ambient temperature over 40 °C) or below –20 °C (in arctic
conditions), synthetic compressor oil must be used.

The synthetic compressor oil recommendations are based on the ambient temperature.

ISO VG Ambient temperature

Viscosity cSt
(40 °C)
°C -40 -30 -20 -10 0 +10 +20 +30 +40 +50 +60
°F -40 -22 -4 +14 +32 +50 +68 +86 +104 +122 +140
32
46

Recommended temperature range

Temporarily allowed temperature range

Recommended synthetic oils:

- Shell Corena AS 46
- Mobil Rarus SHC 1025
- Esso Cetus Pao 46
- BP Enersyn RC-S46

6.6. Classifications for transmission and driveline oils

6.6.1. Quality classifications

API classification

The API (American Petroleum Institute) transmission oil recommendations are API GL-1...API GL-5.
The higher the last digit, the higher the EP additive level is.
For example, API-GL-5 is an EP oil with a high additive level, suitable for hypoid gears.

ISO 12925-1 classification

ISO (International Organization for Standardization) industrial transmission oil recommendations are
ISO 12925-1 type CKB... ISO 12925-1 type CKD. The higher the third letter, the more additives there
are in the oil.
For example, ISO 12925-1 type CKD. Lubricants with oxidation resistance, anti-corrosion, anti-foam,
pressure resistance, and anti-wear properties. Improved thermal/oxidation resistance properties
enable use at high temperatures.

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6.6.2. Viscosity classifications

SAE classification (transmission)

SAE (Society of Automotive Engineers) Viscosity indicates the oil's ability to flow. Viscosity is
measured at a high and low temperature and is indicated as an SAE grade, e.g. SAE 90. For
multigrade oils, e.g. 75W-90, the first value 75W indicates the viscosity at low temperatures, and the
second value 90 indicates the oil viscosity when it is hot.

ISO classification (industrial oils)

( ISO = International Organization for Standardization) The viscosity of industrial lubricants is

determined by the ISO-VG standard (ISO 3448). The ISO grade number indicates the oil viscosity at
+ 40 °C, expressed in centistokes (cSt, kinematic viscosity). For example, oil graded as ISO-VG 150
has a viscosity of 150 cSt at + 40 °C.

6.7. Transmission oils (surface rigs)

6.7.1. Tracks

Track idler wheels (1)

Track rollers (2)
Engine oil SAE 5W-20 or 10W-30
Tramming gear (3)
Oils that meets the following requirements: API
1 2 3
GL-5, SAE 80W-90, or synthetic SAE 75W-90.

6.7.2. Transfer gearbox Stiebel

Transfer gearbox Stiebel (4)

DP and DX series, refer to the technical manual
“Carrier; oil recommendations for the Stiebel
transfer gearbox”. 4
Oils that meets the following requirements: ISO
12925-1 type CKD (synthetic oil).
ISO VG 100, ambient temperature –35...+60 °C
ISO VG 220, ambient temperature –25...+80 °C
E.g. Shell Omala HD 220

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6.7.3. Winch

Winch
Oils that meet the following requirements: API
GL-5, SAE 80W-90, or synthetic SAE 75W-90.

6.8. Drill steel thread grease

Recommended lubrication grease:

Sandvik Coromant thread grease

6.9. Lubrication grease

The hardness of greases is indicated by the NLGI grade, which indicates the grease’s penetration
value as determined in laboratory tests. The NLGI grade can be 000, 00, 0, 1, 2, 3, 4, 5, or 6. Number
2 indicates the so-called normal hardness for a bearing grease. The higher the figure, the harder the
grease. The hardness grade of a grease is usually indicated after the product name.

6.9.1. General lubrication greases

Never use the greases listed below for lubricating the shank of
a rock drill!

Alvania EP Grease 2
SHELL
Retinax HDX
Beacon EP 2
ESSO
Beacon Q 2
Gulfcrown Grease EP 2
GULF
Gulflex Moly
Mobilux EP 2
MOBIL
Mobilgrease Special
Energrease LS-EP 2
BP
Energrease L 21 M
Marfax All Purpose
TEXACO
Molytex Grease 2
Speeroll AP 2
CASTROL
Castrol MS 1 Grease

Table: Recommended lubrication greases from different manufacturers

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6.9.2. Sandvik (SKF) central lubrication system greases

Use the recommended lubricants or corresponding products from other manufacturers.

Operating temperature NLGI grade Example

Below 0 °C 00 Shell Grease Centra W
Mobil Chassis LBZ
Esso Fliessfett S 420 (EGL 3818)
Above 0 °C 0-2 Teboil Solid 0 (NLGI 0)
Shell Grease Central W1 (NLGI 1)
Esso Beacon EP 2 (NLGI 1)
Shell Retinax EP 2 (NLGI 2)
Shell Alvania EP 2 (NLGI 2)

Mixing different grease types is strictly prohibited. Verify the

grease type from the greasing system instructions.

6.9.3. Greases for Lincoln central lubrication system

Operating temperature NLGI grade Example

Below 0 °C 0-1 Esso Beacon EP1
Teboil Solid 0
Mobil Grease XHP220
Mobil Chassis LBZ
Above 0 °C 1-2 Teboil Solid 2 NLGI - 2
Esso Beacon EP2 NLGI - 2
Shell Retinax EP2 NLGI - 2
Shell Alvania EP2 NLGI - 2
Mobil Grease XHP222 NLGI - 2

Table: Recommended lubrication greases from different manufacturers

Mixing different grease types is strictly prohibited. Verify the

grease type from the greasing system instructions.

6.10. Engine coolant

Engine coolant is a mixture of water and corrosion preventing agents/anti-freeze agent. To prevent
corrosion and to elevate the boiling point of the coolant, the mixture must be used in the cooling
system throughout the year.
When choosing the corrosion preventing agents/anti-freeze agent for the engine coolant, refer to the
engine manufacturer's maintenance manual.
Engine coolant must be changed at certain intervals. The characteristics of the coolant and its
additives weaken and are lost as the coolant ages. Refer to the engine manufacturer's maintenance
manual.

Do not mix different coolants. Mixing coolants can lead to

clogging the cooler's duct and seriously damage the engine.

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6.10.1. Caterpillar engines

The cooling system is filled at the factory with a prepared mixture of water and Caterpillar Extended
Life Coolant. Cat ELC is a red ethylene glycol based fluid. Only this same Cat ELC fluid or distilled
water can be added to the cooling system.

Anti-freezing to temperature °C / ELC fluid percentage of ELC concentrate percentage of

°F volume (%) volume (%)
-37 °C / -34 °F 100
-52 °C / -62 °F 80 20 (ELC concentrate added)

Table: Coolant mixing ratio

Boiling prevention 1 bar with Water percentage of vol- Cat ELC fluid percentage of vol-
cooler cap to temperature °C / °F ume (%) ume (%)
129 °C / 265 °F 50 50
132 °C / 270 °F 40 60 (ELC concentrate added)

6.11. Compressor oil and refrigerant for the air conditioning unit

Refer to the manual for the air conditioning unit.

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6.12.
FILLING QUANTITIES
dp1500i

A Fuel tank 680 L 180 U.S. gal

B Hydraulic oil tank 390 L 103 U.S. gal
A
C Cooling system 65 L 17,2 U.S. gal
D Engine oil 40 L 10,6 U.S. gal
E Transmission gear 5,2 L 1,4 U.S. gal
F Winch 3,0 L 1,6 U.S. pt
G Shank lubrication tank 56 L 14,8 U.S. gal B
H Final drive 2,0 L 2,0 U.S. qts
I Track roll 0,3 L 0,6 U.S. pt
J Idler wheel 0,2 L 0,4 U.S. pt
Filling capacities

K Compressor air receiver 19 L 5,0 U.S. gal

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I
H

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MAINTENANCE MANUAL dp1500i
Item Quantity 50h 250h 500h 1000h 1500h 3000h
Fuel (filled when nee- 680 L( 180 U.S. gal)
ded)
Hydraulic oil 390 L (103 U.S. gal) X X
Engine coolant 65 L (17,2 U.S. gal) X
Engine oil 40 L (10,6 U.S. gal) X X X X X
Transmission gear 5,2 L (1,4 U.S. gal) X X
Winch oil 3,0 L (1,6 U.S. pt) X X
Shank lubrication oil 56 L (14,8 U.S. gal)
(added when neces-
sary)
Final drive oil 2,0 L (2,0 U.S. gal) X X
Track roll oil (added 0,3 L (0.6 U.S. pt)
when necessary)
Idler Wheel oil (added 0,2 L (0,4 U.S. pt)
when necessary)
Compressor oil 19 L (5,0 U.S. gal) X X X X

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7. ADDITIONAL INSTRUCTIONS

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7. ADDITIONAL INSTRUCTIONS

7.1. Towing

WARNING
ACCIDENT HAZARD!
Could cause death or severe injury.
Always exercise great caution when towing the rig.
Make sure that the brakes of the towing vehicle are in proper
condition and that they are efficient enough to stop both
vehicles in an emergency.
Only use a fixed bar for towing. Do not use a rope or cable for
towing the rig.
Before towing, release the brakes of the rig to be towed.
A winch is not allowed to be used for towing.

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7.1.1. Releasing the brakes

If the rig needs towing, the tramming engines must be put in neutral. Make sure that the rig is not
able to move by itself on a slanted surface. Connect a rigid tow bar to tow the rig.

When the tramming engines are in neutral, there are no brakes

available for the rig.

The rig must be attached to the towing rig before the brakes are
released.

Figure: Symbol plate

1 1

You need an 13 mm spanner to open and tighten the bolts.

The correct tightening torque is 20 Nm.
1. Remove two hexagonal screws (1) from the cover (2).
2. Remove the cover (2), turn it around, and reattach it with bolts (1) as shown in the figure.

Note that the procedures must be performed on both tramming gears.

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After the brakes are released, the towing must be performed with a rigid towing bar. The tramming
speed during towing must not exceed 3.5 km/h.
The tramming gear must be engaged before detaching the rig
from the towing rig.

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7.2. Transport

WARNING
TIPPING HAZARD! The tipping of the rig can cause personal
injury or material damage. Never exceed the specified maximum
inclination angles. Before tramming the rig onto a transport
platform or ship, move the booms, boom supports, feeds, and
cabin / safety canopy (if fitted) to the transport position.

• When tramming the rig onto or from a transport platform, use suitable ramps. This must always be
done on level ground.
• Always use low tramming speed and observe great caution, especially when leaving the ramps and
approaching the platform.
• When tramming along the ramps, the rig must be balanced with boom movements and oscillation
(if provided).
• Lock the oscillation valve (if the rig is equipped with oscillation) before transport.
• Lower the jacks onto the transport platform before transport.
• Lower the booms as far down as possible. Anchor the booms and feed to the transport platform
before transport.
• Fasten the rig to the platform with straps and chains so that it cannot move during transport.

Take the rig dimensions into consideration when planning the

transport route.

Max. 20°

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7.3. Lifting

Always follow the appropriate local legislation and safety

regulations concerning lifting safety.

Consider the rig's total weight, which is indicated on the rig's

type plate and in the technical data section.

For more details on the correct use of lifting equipment, please

refer to the Load Lifting section of the General Safety
Instructions.

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Lifting points are marked with hook symbols.

• Use only an appropriate type of lifting device, with sufficient lifting capacity. Neither the rig nor its
components may be lifted with devices other than those designed for lifting purposes. Do not use,
for instance, a loader for lifting.
• The weight of the load must be known, and the capacity of the lifting device, as specified by the
manufacturer, must not be exceeded.
• Lifting routes should be chosen so that the load is not moved over persons or locations where
persons could be present.
• Check that the lifting device is in good condition.
• The lifting wires and chains must be checked regularly. Damaged wires and chains must be marked
clearly and removed from use immediately.
• Make sure that the load is properly attached and balanced. To check the fastening and balance, lift
the load by just a few centimeters initially. Do not continue lifting until you are certain that the
fastening and balance are good.
• Never wrap the lifting wires or chains around the lifting hook. Always fasten wires or chains
according to the manufacturer's instructions.

WRONG RIGHT

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7.4. Storage

Storage conditions:

The temperature of the storage location should

be 0 °C…35 °C. The rig must be protected
against direct sunlight and rain.
NOTE! The relative humidity of the air
C F
30 86
must be below 90%.
20 68
10 50
0 32
max 90 %

Rig

• Wash the rig if it has been in use or has been transported by sea. Use high-pressure steam washing.
• Empty the water circuit and blow some anti-freeze agent into it (an anticorrosive agent).
• Lubricate the rig (all greasing points).
• Lift the rig with the jacks.
• Tilt the feed's front end downward.
• Empty the rock drill's pressure accumulators and prominently hang a sign to this effect (the pressure
accumulators must be filled before the drilling rig is used).
• All hydraulic cylinder piston rods must be protected with grease.
• Empty the water separator.
• Replace all lubricants and fluids, which may have deteriorated in use.
• Protect all electrical devices from corrosion so that there will be no contact failures.

RISK OF DAMAGING THE RIG!

Too high a humidity level in the storage location could damage
the rig.
Ensure that the storage space does not collect water, that the
humidity will not become too high, and that the location is
otherwise protected from the elements.
Protect the electrical connections in accordance with set of
instructions 571: “Protecting electrical and electronic
components and connectors with protective agents”.

Proceed as specified in set of instructions 571, and use a suitable protective agent to protect, for
example, the following points:
- coupling box connections
- screw terminals of the multi-pole switches
- battery terminals
- multi-pole switch coupling contacts
- contacts of the connecting caps of magnetic valves, pressure switches, and corresponding parts
(fill the caps with grease)

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7.5. Filling the lubricant reservoir of the pumping unit

The lubricant reservoir of the pumping unit is filled through the filling connector equipped with a filter.
1. Ensure that the area surrounding the pumping unit is clean. Impurities in the system prevent its
trouble-free operation and cause damage when they reach the lubrication point.
2. Remove the lid from the lubricant container (1) and press the follower plate (2) tightly to the
container on top of the lubricant. The follower plate is not used with fluid lubricants, as it would
not float on the surface of such lubricants.
3. Place the container lid (3) on top of the lubricant container. Fasten the container lid to the container
with the wing screws (4).
4. Insert the pump (5) through the container lid into the follower plate’s central unit (6).
5. Connect the lubricant hose (7) to the pump.
6. Fill the lubricant hose by pumping by hand.
7. Connect the quick connector (8) to the lubricant hose.
8. Connect the quick connector to the pumping unit filling connector (9).
9. Fill the lubricant reservoir of the pumping unit by pumping slowly by hand.
10. The filling of the lubricant reservoir can be monitored with the level indicator (10). To prevent
overfilling, the pumping unit is equipped with a safety valve (11).
11. Turn the pump handle (12) to a vertical orientation to discharge the pressure so it passes to the
lubricant container.
12. Disconnect the quick connector from the pumping unit filling connector.
13. Fasten the protecting cap (13) of the pumping unit filling connector.
14. Fasten the protecting cap (14) of the filling device quick connector.
The filter (15) of the filling connector must be cleaned regularly
and replaced if necessary.

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12

5
8

14 4

10 3
11
6
15 2

13 1
9

The working stroke of the filling pump is about 90 degrees. The pressure is released when the handle
is turned so that it is vertical.

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7.6. Seat adjustment

Adjust the position of the seat and armrest panels to suit you.

4
2 3

5
6

Figure: Operator's seat adjustments

1 Distance adjustment
2 Backward tilt adjustment
3 Forward tilt adjustment
4 Backrest tilt adjustment
5 Dampening adjustment
6 Turning the seat
7 Seat heating switch Optional

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7.6.1. Adjusting the armrest panels

3
4

Figure: Armrest adjustments

1 Height adjustment of the armrest

panel
2 Width adjustment
3 Tilt adjustment
4 Armrest forward–backward The armrest can be adjusted forward and backward by
adjustment. opening the small knurled thumb screw.
The height adjustment (1) of the armrest panels can be locked. Other adjustments can´t be locked.

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7.7. Cabin's vacuum cleaner

Use the vacuum cleaner daily.

Starting vacuum-cleaning

1. Drive the mobile suction head of the feed against the ground.
2. In the user interface, under the Rig settings window, go to the Maintenance tab (Menu → Rig
settings → Maintenance).
3. Under Vacuum cleaner select Start.
4. Lift up both armrest panels.
5. Pull out the vacuum cleaner hose (2) from behind the plastic cover (1).
6. Open the vacuum cleaner's lever valve (3).

1 2 3

Stopping vacuum-cleaning

1. Close the vacuum cleaner's lever valve (3).

2. Place the vacuum cleaner's hose (2) back behind the plastic cover (1).
3. Lower the armrest panels.
4. In the user interface, under Vacuum cleaner select Stop.

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7.8. Filling the fuel tank with the electric pump

6
Location of the electric fuel filling pump (1).

1. Tram the rig next to a fuel storage tank and

2 3 4 5
shut down the diesel engine.
Leave the ignition key in position I.
2. Open the door on the right-hand side of the rig.
3. Take the fuel filling hose from the bracket (5)
on the door.
4. Ensure that the suction end (4) of the hose is
clean.
Clean the suction end if necessary.
5. Insert the suction end into the fuel storage tank
from which you are going to fill the rig's fuel
tank, ensuring that the end of the hose goes
below the fuel level.
6. Press the fuel filling pump switch (2).
The pump (1) starts and the indicator light (3)
comes on.
7. The pump stops when the fuel tank is full or
when the filling pump switch (2) is pressed
again.
8. Lift the filling hose out of the tank and place it
in the bracket (5) on the door.
Ensure that no fuel is spilled from the suction
end (4) of the filling hose onto the ground, by
using, for example, a suitable cloth.
9. Close the door.

If you keep the filling pump switch depressed, the overfill

prevention system is bypassed and the fuel tank can overflow.

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7.9. Filling the hydraulic oil tank with the electric pump

Location of the electric hydraulic oil filling pump

(1). 1

1. Tram the rig next to a hydraulic oil storage tank

2 3 4 5
and shut down the diesel engine.
Leave the ignition key in position I.
2. Open the door on the right-hand side of the rig.
3. Take the hydraulic oil filling hose from the
bracket (4) on the door.
4. Ensure that the suction end (5) of the hose is
clean.
Clean the suction end if necessary.
5. Insert the suction end into the hydraulic oil
storage tank from which you are going to fill the
rig's hydraulic oil tank, ensuring that the end of
the hose goes below the oil level.
6. Press the hydraulic oil filling pump switch (3).
The pump (1) starts and the indicator light (2)
comes on.
7. The pump stops when the hydraulic oil tank is
full or when the filling pump switch (3) is
pressed again.
8. Lift the filling hose out of the tank and place it
in the bracket (4) on the door.
Ensure that no hydraulic oil is spilled from the
suction end (5) of the filling hose onto the
ground, by using, for example, a suitable cloth.
9. Close the door.

If you keep the filling pump switch depressed, the overfill

prevention system is bypassed and the tank can overflow.

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7.10. Filling the water tank with the electric pump

Location of the electric water filling pump (1).

1. Tram the rig next to a water storage tank, and

2 3 4
shut down the diesel engine.
Leave the ignition key in position I.
2. Open the door on the right-hand side of the rig.
3. Remove the water filling hose from the bracket
(4).
4. Ensure that the suction end of the hose is
clean.
Clean the suction end if necessary.
5. Insert the suction end into the water storage
tank from which you are going to fill the rig's
water tank, ensuring that the end of the hose
goes below the water level.
6. Press and hold the water filling pump switch
(3).
The pump (1) starts and the indicator light (2)
comes on (the water filling pump runs only
when the switch (3) is held down).
7. Once the rig's water tank is full, stop the pump
by releasing the button (3).
The pump will not stop by itself when the water
tank is full.
8. Lift the filling hose out of the tank and place it
in the bracket (4) on the door.
9. Close the door.

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7.11. Water heater

7.11.1. General

The water heater operates only when the rig’s main switch is in the “ON” position (power on).
The rig’s main switch may not be switched off when the heater is activated or in use. The rig’s main switch turns
off the power to the whole electrical system; the heater and timer are switched off too.
When the rig’s main switch has just been turned on, all indicators on the display flash – the timer must
be re-programmed. In this condition, the heater cannot be used.
When the ignition key is in the running position (power on), the display show the day and time. When
the power is switched off, the clock disappears from the display within 15 seconds.

7.11.2. Orientation of the heater

Switching on

W hen the heater is switched on using the switch or timer, the heating symbol appears on the display;
the combustion air fan and water pump start up, the heater plug is activated, and the preheating phase
commences.

Start-up

After the preheating phase of approximately 60 seconds, the fuel metering pump starts and supplies
fuel to the combustion chamber. A flame is ignited. The combustion air fan speed is slowly increased
along with the fuel metering pump’s impulse frequency, which is also steplessly increased through
the ‘MEDIUM’ and ‘HIGH’ stages up to the ‘POWER’ stage (9500 W).
The heater plug is switched off after the post-glow phase. If the flame does not ignite (the flame sensor
does not recognise the flame), the second start attempt commences. If the flame still does not ignite,
the heater switches to faultmode and stops after the cool-down cycle.

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Heating operation

After start-up, the heater operates at the ‘POWER’ setting of 9500 W until the water temperature
exceeds the set temperature (e.g., 72 °C), at which point the control unit, controlled by the
temperature sensor, switches the heater to the ‘HIGH’ setting
- or the maximum operating time set for the ‘POWER’ stage (2 hours) is reached.
Depending on the heat demand, the heater then switches to the ‘HIGH’, ‘MEDIUM’, or ‘LOW’ setting
or, if required, to the control break. After the water temperature reaches 55 °C, the cabin heater blower
is switched on.
During the individual control stages, the coolant/water can reach a maximumtemperature of 85 °C.
• If the heat demand is 9500 W or higher, the heater operates at the ‘POWER’ setting.
• If the heat demand is 7500Wor higher, the heater alternates between the ‘HIGH’ and ‘POWER’
settings. If the water cools to below 60 °C due to high heat demand, the heater switches again to
‘POWER’ and then back to ‘HIGH’ after the temperature exceeds 72 °C.
• If the heat demand is between 7500 W and 3200 W, the heater alternates between the ‘HIGH’ and
‘MEDIUM’ settings.

If the heat demand is between 3200 W and 1500 W, the heater alternates between the ‘MEDIUM’
and ‘LOW’ settings.
If the heat demand is 1500 W or lower, the heater operates at the ‘LOW’ setting. If the heat demand
is so low that the water temperature reaches 85 °C, the heater switches to control break: the flame
is extinguished and, after a cool-down cycle of 210 seconds, the heater stops. Only the water pump
stays on until the heater is restarted. When the water has cooled to about 70 °C, the heater starts
again, at the ‘MEDIUM’ setting.

Operating instructions

If you want to warm up the cabin, you need to open the cabin heater water valve to the position ”warm”.
The cabin heater blower should be set to slow speed (low power consumption).
If standard switches are used for connecting the heater, their current rating must be at least 1 A.

Heating operation at high altitudes

Below 1500 m:
- No restrictions on the use of the heater.
Above 1500 m:
- Short--term heating operation is allowed -- e.g., when crossing amountain pass or during a break.
F or long--term usage -- e.g., winter camping -- the supplying of fuel should be adjusted for the altitude.
For more information, please consult the distributor.

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7.11.3. Control and safety equipment

The flame and maximum temperature are monitored by the flame sensor and the overheating switch,
respectively. Both affect the control unit, which switches the heater off if a fault occurs.
• If the flame does not ignitewithin 105 seconds after the fuel supply is started, a new start attempt
commences. If the flame does not ignite during the second attempt within 75 seconds from the start
of the fuel supply, the heater switches to faultmode and stops after the cool--down cycle. After a
certain number of unsuccessful start attempts, the heater’s fault interlock is activated.
• If the flame extinguishes by itself during the heating operation, a new start attempt is automatically
triggered. If the flame does not ignite within 105 seconds after the fuel supply is started, the heater
switches to faultmode (stops after the cool--down cycle). The fault mode can be deactivated by
switching the heater off and then on again.
• If overheating occurs (lack of water, air in water circuits, poor water circulation), the overheating
switch (see the wiring diagram, item 1.5) activates, the fuel supply is switched off, and the heater
switches to fault mode (stops after the cool--down cycle). Once the cause of the overheating has
been eliminated, the heater can be restarted by switching it off and then on again (after it has cooled
down). After a certain number of unsuccessful start attempts, the heater’s fault interlock is activated.
• If the voltage drops below about10 V / 20 V or exceeds 15 V / 30 V, the heater switches to fault
mode.
• The heater will not start if the heater plug is faulty or the electrical connection to the fuel metering
pump is interrupted.
• The combustion air fan motor with stepless speed control is constantly monitored. If a fault occurs
(i.e., if the combustion air fan does not start, the motor stops, or its speed falls below 40% of the
desired speed), the heater switches to fault mode after a delay of 60 seconds.

7.11.4. Operation of the timer

6 7 8 9 10 11

1 2 3 4 5

1 Setting the time 2 Preset selection

3 Heating 4 Setting backwards
5 Setting forwards 6 Preset location number
7 Day of the week (abbreviation) 8 Radio remote control symbol
9 Time 10 Temperature display symbol
11 Heating

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Setting the time and day of the week

Press briefly and the time is displayed. When you press the button longer, the time display

starts to flash. Set the time with buttons and . The set time is stored when the time display

stops flashing after the time is set.

The display of the day starts flashing. Set the day of the week (= current day) with and .

The setting is stored when the display stops flashing.

If the ignition is on, the display remains on screen. When the ignition is switched off, the display
disappears after about 15 seconds.

Changing the time and day settings

Press until the time display starts flashing. Set the time as described above. If only the time is

to be changed (not the day of the week), the day setting can be skipped by pressing . After the

day is set (if necessary), the duration for which the display of the day flashes can be shortened by
pressing .

Heating operation without pre-selection, ignition off

Pay attention to the heating symbol .

Switching on the heater

Press briefly. The heating symbol and remaining heating time are displayed. The default

heating duration setting is 120 minutes. This can be shortened to the desired duration either for a
single heating period or permanently.

Switching off the heater

Press briefly. The heating symbol disappears. The cool-down cycle commences.

Changing the heating duration for single heating period

After switching on the heater: decrease or increase the duration with or , respectively

(max. 120 min).

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Changing the heating duration permanently

The heater is off.

Depress (for about 3 sec) until the heating duration flashes on the display. Release . Set

the desired heating duration with and . The new heating duration is stored when the

display disappears. Note! This duration setting will be stored in the presets!

Heating operation without pre-selection, ignition on

Press briefly. The heating symbol is displayed. The heater operates (i.e., is on) as long as the

ignition is on. When the ignition is switched off, the heater operates for 15 minutes (post--heating
period), after which it switches off. The post--heating period can be increased or decreased for this
single heating period with or The heating can be switched off by pressing

Pre-selection of the heater start-up

Programming and activating a preset

Press repeatedly until the desired preset (1, 2, or 3) flashes on the display.

Press or briefly.

Then, set the desired switch-on time with and

Once the time display stops flashing, the time setting is stored. The day starts flashing, at which point
the desired day can be set with and When the switch-on time changes to the current

time display, both switch--on time and switch-on day are stored.
The preset number on the display shows the active preset. If no preset number is shown, no preset
is activated – the heater is not set for preset start-up! This can be selected by pressing until the

preset number 3 disappears (= empty location).

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8. MAINTENANCE CARDS

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 8.

270 (304)
8.1.
TIER4 8 10 19

5
1 Engine secondary fuel filter (2 pcs) 886 618 49
dp1500i

2 Engine oil filter 550 558 74

A
3 Engine primary fuel filter / Water separator 551 987 18
4 Compressor oil filter 818 937 49
5 Hydraulic return oil filters (2 pcs) 867 272 89
6 Hydraulic oil pressure filter 872 701 09
7 Breathers (2 pcs) 850 794 09
14 12 13
8 Engine air filter 551 875 29 B
9 Compressor air filter 551 933 92
10 Engine air filter safety cartridge 560 408 22
11 Compressor air filter safety cartridge 551 933 96 7
Maintenance label

12 Cabin air filters (inner, 3 pcs) 550 999 05

13 Cabin air filter (outer) 550 999 10 C13 Tier4
14 Cabin recirculation air filter 551 711 50
15 Compressor oil separators (2 pcs) 551 844 29
MAINTENANCE CARDS

16 Dust collector filters (20 pcs) 880 211 99 C

17 Polygroove flat belt 551 810 38
18 Filling cap 551 796 27
19 Fuel filter 551 861 92 17

FILLING QUANTITIES
A Fuel tank 680 L 180 U.S. gal E
B Hydraulic oil tank 390 L 103 U.S. gal
D
C Cooling system 65 L 17,2 U.S. gal
D Engine oil 40 L 10,6 U.S. gal
E Transmission gear 5,2 L 1,4 U.S. gal

ID: 666 1 en 2011-08-23

3 2 1 J
F Winch 3,0 L 1,6 U.S. pt
G Shank lubrication tank 56 L 14,8 U.S. gal I
H
H Final drive 2,0 L 2,0 U.S. qts
I Track roll 0,3 L 0,6 U.S. pt
J Idler wheel 0,2 L 0,4 U.S. pt
F

Copyright © Sandvik Mining and Construction

K Compressor air receiver 19 L 5,0 U.S. gal

18 15
16 6
Sandvik reserves the right to change the
service parts or this information without G K
further notice. Please, cross-check part
numbers and quantities from the Spare 4
Part manual.
Sandvik Mining and Construction Oy
Pihtisulunkatu 9, P.O. Box 100
Please remember!
FIN-33311 Tampere, Finland The warranty is not valid if other than
Tel. +358 205 44 121 9 11
Fax. +358 205 44 120 GENUINE SANDVIK SPARE PARTS
STICKER ID = 552 084 89 have been used in the equipment.
MAINTENANCE MANUAL
MAINTENANCE MANUAL dp1500i
8.2. Maintenance program

Maintenance program
Maintenance card hours
Drilling rig engine hours
250 500 1000 1500 3000
250 6250 12250 18250 24250 X
500 6500 12500 18500 24500 X
750 6750 12750 18750 24750 X
1000 7000 13000 19000 25000 X
1250 7250 13250 19250 25250 X
1500 7500 13500 19500 25500 X
1750 7750 13750 19750 25750 X
2000 8000 14000 20000 26000 X
2250 8250 14250 20250 26250 X
2500 8500 14500 20500 26500 X
2750 8750 14750 20750 26750 X
3000 9000 15000 21000 27000 X
3250 9250 15250 21250 27250 X
3500 9500 15500 21500 27500 X
3750 9750 15750 21750 27750 X
4000 10000 16000 22000 28000 X
4250 10250 16250 22250 28250 X
4500 10500 16500 22500 28500 X
4750 10750 16750 22750 28750 X
5000 11000 17000 23000 29000 X
5250 11250 17250 23250 29250 X
5500 11500 17500 23500 29500 X
5750 11750 17750 23750 29750 X
6000 12000 18000 24000 30000 X

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8.3. Instructions for reading maintenance cards

1 2 3 4 5 6

1 Maintenance card heading Hour type and amount

2 Maintenance procedure column Maintenance procedure to be performed
3 Symbol column Symbol representing the maintenance procedure
4 Page number column Maintenance manual page for additional information on
the maintenance procedure
5 Check column Enter a cross here when the maintenance procedure is
completed
6 Notes column Enter any notes on the maintenance procedure here

Maintenance card symbol descriptions

Adjust Check
Change/Replace Lubricate

Drain Measure

Service Clean

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8.4. Maintenance performed according to diesel engine hours

8.4.1. Every 50 hours

DIESEL HOURS – EVERY 50 HOURS

MAINTENANCE PROCEDURE NOTES
BOOM
Check the tightness of bolts and nuts 128

Check the zoom tube wiper ring 129

Check the fastening of the boom to the

136
carrier
Lubricate the greasing points 139

FEED
Check the tightness of bolts and nuts 141

Clean the cables 141

Check the wear and condition of the ca-

142
bles
Check the fastening and tightness of
143
the cables
Check the feed cylinder guide clearan-
149
ces
Check the clearance of the rock drill
carriage and hose reel carriage and the 151
condition of the slide pieces
Lubricate the PITO centraliser cylinder 155

Lubricate the greasing points 156

ROD HANDLER
Check the tightness of bolts and nuts 157

Check the condition of the roller Pito 158

Lubricate the rod handler 159

HYDRAULIC ROCK DRILL

Check the tightness of the bolts be-
tween the carriage and rock drill, as well 165
as the flushing housing bolts
Check the condition of the flushing
166
housing seals
Check the shank, chuck, flushing hous-
166
ing, coupling, and rotation bushing

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DIESEL HOURS – EVERY 50 HOURS

MAINTENANCE PROCEDURE NOTES
Check the condition of the pressure ac-
cumulator’s filling valves and cover 179
plugs
Check the pressure of the pressure ac-
180
cumulators
CARRIER
Wash the rig 183

Lubricate the oscillation axle 189

Lubricate the oscillation cylinder pins. 190

Check the electrolyte level and battery

192
cable connections
Check the mounting and condition of
192
the winch cable
DIESEL ENGINE
Clean the radiator core. 197

Clean the intercooler 198

CABIN
Check the operation of the cabin door
204
switch
HYDRAULIC SYSTEM
Clean the radiator core. 205

PNEUMATIC SYSTEM
Check the intake air line and connec-
210
tions
Clean the radiator core 215

SLU SHANK LUBRICATION UNIT

Drain the condensation water from the
215
oil tank
Empty the shank lubrication return tank 216

FUEL SYSTEM
Drain condensed water and deposit
218
from the fuel tank
DUST COLLECTOR SYSTEM
Check the condition of the suction ho-
222
ses and connections
Check the condition of the filter car-
223
tridges

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DIESEL HOURS – EVERY 50 HOURS
MAINTENANCE PROCEDURE NOTES
Check the operation of the pulse jet
223
cleaning
Check the integrity of the dust collector. 223

Check the condition of the fine separa-

224
tor’s impact plate.
Check the condition of the coarse sep-
224
arator skirt rubber
Grease the moving suction head cylin-
225
der
Grease the cut-off cylinder and butterfly
225
valve

When completed:
Date ....................................................... Diesel hours ...........................................
Approved ...............................................

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8.4.2. Every 250 hours

DIESEL HOURS – EVERY 250 HOURS

MAINTENANCE PROCEDURE NOTES
BOOM
Check the tightness of bolts and nuts 128

Check the zoom tube wiper ring 129

Check the fastening of the boom to the

136
carrier
Lubricate the greasing points 139

FEED
Check the tightness of bolts and nuts 141

Clean the cables 141

Check the wear and condition of the ca-

142
bles
Check the fastening and tightness of
143
the cables
Check the feed cylinder guide clearan-
149
ces
Check the clearance of the rock drill
carriage and hose reel carriage and the 151
condition of the slide pieces
Lubricate the PITO centraliser cylinder 155

Lubricate the greasing points 156

Check the Pito centraliser jaws 153

ROD HANDLER
Check the tightness of bolts and nuts 157

Check the condition of the roller Pito 158

Lubricate the rod handler 159

Check the rod changer jaws 158

HYDRAULIC ROCK DRILL

Check the tightness of the bolts be-
tween the carriage and rock drill, as well 165
as the flushing housing bolts
Check the condition of the flushing
166
housing seals
Check the shank, chuck, flushing hous-
166
ing, coupling, and rotation bushing

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DIESEL HOURS – EVERY 250 HOURS

MAINTENANCE PROCEDURE NOTES
Check the condition of the pressure ac-
cumulator’s filling valves and cover 179
plugs
Check the pressure of the pressure ac-
180
cumulators
CARRIER
Wash the rig 183

Lubricate the oscillation axle 189

Lubricate the oscillation cylinder pins. 190

Check the electrolyte level and battery

192
cable connections
Check the mounting and condition of
192
the winch cable
Check the tramming gear oil 187

Check the idler wheel oil 188

Clean the battery and its terminals 193

DIESEL ENGINE
Clean the radiator core. 197

Clean the intercooler 198

Change the oil and replace the filter 196

Check the engine earth terminal 197

Check the hoses and connections 198

CABIN
Check the operation of the cabin door
204
switch
HYDRAULIC SYSTEM
Clean the radiator core. 205

PNEUMATIC SYSTEM
Check the intake air line and connec-
210
tions
Clean the radiator core 215

Check the operation of the air filter

212
maintenance indicator

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DIESEL HOURS – EVERY 250 HOURS
MAINTENANCE PROCEDURE NOTES
SLU SHANK LUBRICATION UNIT
Drain the condensation water from the
215
oil tank
Empty the shank lubrication return tank 216

FUEL SYSTEM
Drain condensed water and deposit
218
from the fuel tank
Replace the fuel filter / water separator
219
cartridge
Replace the fuel filter 220

DUST COLLECTOR SYSTEM

Check the condition of the suction ho-
222
ses and connections
Check the condition of the filter car-
223
tridges
Check the operation of the pulse jet
223
cleaning
Check the integrity of the dust collector. 223

Check the condition of the fine separa-

224
tor’s impact plate.
Check the condition of the coarse sep-
224
arator skirt rubber
Grease the moving suction head cylin-
225
der
Grease the cut-off cylinder and butterfly
225
valve
Check the condition of the coarse sep-
224
arator’s rubber lining
Check the condition of the suction head
225
rubbers
Check the operation of the cut-off cyl-
226
inder / butterfly valve
MAIN ELECTRICAL SYSTEM
Check the condition of electrical cables
226
and connections
Check the electrical cabinets and box-
226
es
Check the fastening of electrical cables 226

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When completed:
Date ....................................................... Diesel hours ...........................................
Approved ...............................................

250h Filter kit (ID 552 094 27) including following filters

Item ID Quantity
Engine secondary fuel filter 886 618 49 2
Primary fuel filter / water separator 551 987 18 1
Engine oil filter 550 558 74 1

250 hours

Item Quantity
Engine oil 40 L (10,6 U.S. gal)

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8.4.3. Every 500 hours

DIESEL HOURS – EVERY 500 HOURS

MAINTENANCE PROCEDURE NOTES
BOOM
Check the tightness of bolts and nuts 128

Check the zoom tube wiper ring 129

Check the fastening of the boom to the

136
carrier
Lubricate the greasing points 139

Check the condition of the cylinder pins. 135

Check the mounting of the hydraulic

136
cylinders.
Check the boom and cradle welds. 136

Check the pressures of the pressure

137
accumulators
FEED
Check the tightness of bolts and nuts 141

Clean the cables 141

Check the wear and condition of the ca-

142
bles
Check the fastening and tightness of
143
the cables
Check the feed cylinder guide clearan-
149
ces
Check the clearance of the rock drill
carriage and hose reel carriage and the 151
condition of the slide pieces
Lubricate the PITO centraliser cylinder 155

Lubricate the greasing points 156

Check the Pito centraliser jaws 153

ROD HANDLER
Check the tightness of bolts and nuts 157

Check the condition of the roller Pito 158

Lubricate the rod handler 159

Check the rod changer jaws 158

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DIESEL HOURS – EVERY 500 HOURS

MAINTENANCE PROCEDURE NOTES
HYDRAULIC ROCK DRILL
Check the tightness of the bolts be-
tween the carriage and rock drill, as well 165
as the flushing housing bolts
Check the condition of the flushing
166
housing seals
Check the shank, chuck, flushing hous-
166
ing, coupling, and rotation bushing
Check the condition of the pressure ac-
cumulator’s filling valves and cover 179
plugs
Check the pressure of the pressure ac-
180
cumulators
CARRIER
Wash the rig 183

Lubricate the oscillation axle 189

Lubricate the oscillation cylinder pins. 190

Check the electrolyte level and battery

192
cable connections
Check the mounting and condition of
192
the winch cable
Check the tramming gear oil 187

Check the idler wheel oil 188

Clean the battery and its terminals 193

Check the mounting of the track batch-

184
es
Check the cylinders (oscillation) expan-
189
sion pin screws.
Check the welds 193

DIESEL ENGINE
Clean the radiator core. 197

Clean the intercooler 198

Change the oil and replace the filter 196

Check the engine earth terminal 197

Check the hoses and connections 198

Clean the diesel engine 194

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DIESEL HOURS – EVERY 500 HOURS
MAINTENANCE PROCEDURE NOTES

Replace the air filter 195

Check the tightness and condition of

198
the V-belt
Check the condition of the starter motor 199

Check the condition of the water pump 200

Check the engine protection 201

Check the alternator 202

CABIN
Check the operation of the cabin door
204
switch
HYDRAULIC SYSTEM
Clean the radiator core. 205

Check the return pressure sensor 206

Check the temperature sensor 206

Replace the hydraulic oil tank breather 207

Replace the oil pressure filter 207

Replace the oil return filters (2 pcs) 208

PNEUMATIC SYSTEM
Check the intake air line and connec-
210
tions
Clean the radiator core 215

Check the operation of the air filter

212
maintenance indicator
Replace the air filter 211

Change the compressor oil 212

Replace the oil filter 213

SLU SHANK LUBRICATION UNIT

Drain the condensation water from the
215
oil tank
Empty the shank lubrication return tank 216

FUEL SYSTEM
Drain condensed water and deposit
218
from the fuel tank

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DIESEL HOURS – EVERY 500 HOURS

MAINTENANCE PROCEDURE NOTES
Replace the fuel filter / water separator
219
cartridge
Replace the fuel filter 220

Replace the fuel tank breather 222

DUST COLLECTOR SYSTEM

Check the condition of the suction ho-
222
ses and connections
Check the condition of the filter car-
223
tridges
Check the operation of the pulse jet
223
cleaning
Check the integrity of the dust collector. 223

Check the condition of the fine separa-

224
tor’s impact plate.
Check the condition of the coarse sep-
224
arator skirt rubber
Grease the moving suction head cylin-
225
der
Grease the cut-off cylinder and butterfly
225
valve
Check the condition of the coarse sep-
224
arator’s rubber lining
Check the condition of the suction head
225
rubbers
Check the operation of the cut-off cyl-
226
inder / butterfly valve
MAIN ELECTRICAL SYSTEM
Check the condition of electrical cables
226
and connections
Check the electrical cabinets and box-
226
es
Check the fastening of electrical cables 226

When completed:
Date ....................................................... Diesel hours ...........................................
Approved ...............................................

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500h / 1000h Filter kit (ID 552 094 28) including following filters

Item ID Quantity
Engine secondary fuel filter 886 618 49 2
Primary fuel filter / water separator 551 987 18 1
Engine oil filter 550 558 74 1
Compressor oil filter 818 937 49 1
Hydraulic return oil filter 867 272 89 2
Hydraulic oil pressure filter 872 701 09 1
Hydraulic oil tank breather 850 794 09 1
Engine air filter 551 875 29 1
Compressor air filter 551 933 92 1

500 hours

Item Quantity
Engine oil 40 L (10,6 U.S. gal)
Compressor oil 19 L (5,0 U.S. gal)

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286 (304) Copyright © Sandvik Mining and Construction

ID: 666 1 en 2011-08-23
MAINTENANCE MANUAL dp1500i
8.4.4. Every 1000 hours

DIESEL HOURS – EVERY 1000 HOURS

MAINTENANCE PROCEDURE NOTES
BOOM
Check the tightness of bolts and nuts 128

Check the zoom tube wiper ring 129

Check the fastening of the boom to the

136
carrier
Lubricate the greasing points 139

Check the condition of the cylinder pins. 135

Check the mounting of the hydraulic

136
cylinders.
Check the boom and cradle welds. 136

Check the pressures of the pressure

137
accumulators
The clearances of the zoom tube slide
130
pieces
Check the cradle clearances 138

FEED
Check the tightness of bolts and nuts 141

Clean the cables 141

Check the wear and condition of the ca-

142
bles
Check the fastening and tightness of
143
the cables
Check the feed cylinder guide clearan-
149
ces
Check the clearance of the rock drill
carriage and hose reel carriage and the 151
condition of the slide pieces
Lubricate the PITO centraliser cylinder 155

Lubricate the greasing points 156

Check the Pito centraliser jaws 153

Replace the idler wheel bearings 155

ROD HANDLER
Check the tightness of bolts and nuts 157

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DIESEL HOURS – EVERY 1000 HOURS

MAINTENANCE PROCEDURE NOTES

Check the condition of the roller Pito 158

Lubricate the rod handler 159

Check the rod changer jaws 158

HYDRAULIC ROCK DRILL

Check the tightness of the bolts be-
tween the carriage and rock drill, as well 165
as the flushing housing bolts
Check the condition of the flushing
166
housing seals
Check the shank, chuck, flushing hous-
166
ing, coupling, and rotation bushing
Check the condition of the pressure ac-
cumulator’s filling valves and cover 179
plugs
Check the pressure of the pressure ac-
180
cumulators
CARRIER
Wash the rig 183

Lubricate the oscillation axle 189

Lubricate the oscillation cylinder pins. 190

Check the electrolyte level and battery

192
cable connections
Check the mounting and condition of
192
the winch cable
Check the tramming gear oil 187

Check the idler wheel oil 188

Clean the battery and its terminals 193

Check the mounting of the track batch-

184
es
Check the cylinders (oscillation) expan-
189
sion pin screws.
Check the welds 193

Change tramming gear oil 185

Change the transfer gearbox oil 191

Check the fastening of the cables 193

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MAINTENANCE MANUAL dp1500i
DIESEL HOURS – EVERY 1000 HOURS
MAINTENANCE PROCEDURE NOTES
DIESEL ENGINE
Clean the radiator core. 197

Clean the intercooler 198

Change the oil and replace the filter 196

Check the engine earth terminal 197

Check the hoses and connections 198

Clean the diesel engine 194

Replace the air filter 195

Check the tightness and condition of

198
the V-belt
Check the condition of the starter motor 199

Check the condition of the water pump 200

Check the engine protection 201

Check the alternator 202

CABIN
Check the operation of the cabin door
204
switch
HYDRAULIC SYSTEM
Clean the radiator core. 205

Check the return pressure sensor 206

Check the temperature sensor 206

Replace the hydraulic oil tank breather 207

Replace the oil pressure filter 207

Replace the oil return filters (2 pcs) 208

PNEUMATIC SYSTEM
Check the intake air line and connec-
210
tions
Clean the radiator core 215

Check the operation of the air filter

212
maintenance indicator
Replace the air filter 211

Copyright © Sandvik Mining and Construction 289 (304)

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dp1500i MAINTENANCE MANUAL

DIESEL HOURS – EVERY 1000 HOURS

MAINTENANCE PROCEDURE NOTES

Change the compressor oil 212

Replace the oil filter 213

SLU SHANK LUBRICATION UNIT

Drain the condensation water from the
215
oil tank
Empty the shank lubrication return tank 216

Change the shank lubrication oil receiv-

215
er breather.
Clean the shank lubrication oil receiver. 216

Check the operation of the monitoring

217
unit
FUEL SYSTEM
Drain condensed water and deposit
218
from the fuel tank
Replace the fuel filter / water separator
219
cartridge
Replace the fuel filter 220

Replace the fuel tank breather 222

DUST COLLECTOR SYSTEM

Check the condition of the suction ho-
222
ses and connections
Check the condition of the filter car-
223
tridges
Check the operation of the pulse jet
223
cleaning
Check the integrity of the dust collector. 223

Check the condition of the fine separa-

224
tor’s impact plate.
Check the condition of the coarse sep-
224
arator skirt rubber
Grease the moving suction head cylin-
225
der
Grease the cut-off cylinder and butterfly
225
valve
Check the condition of the coarse sep-
224
arator’s rubber lining
Check the condition of the suction head
225
rubbers

290 (304) Copyright © Sandvik Mining and Construction

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MAINTENANCE MANUAL dp1500i
DIESEL HOURS – EVERY 1000 HOURS
MAINTENANCE PROCEDURE NOTES
Check the operation of the cut-off cyl-
226
inder / butterfly valve
MAIN ELECTRICAL SYSTEM
Check the condition of electrical cables
226
and connections
Check the electrical cabinets and box-
226
es
Check the fastening of electrical cables 226

When completed:
Date ....................................................... Diesel hours ...........................................
Approved ...............................................

500h / 1000h Filter kit (ID 552 094 28) including following filters

Item ID Quantity
Engine secondary fuel filter 886 618 49 2
Primary fuel filter / water separator 551 987 18 1
Engine oil filter 550 558 74 1
Compressor oil filter 818 937 49 1
Hydraulic return oil filter 867 272 89 2
Hydraulic oil pressure filter 872 701 09 1
Hydraulic oil tank breather 850 794 09 1
Engine air filter 551 875 29 1
Compressor air filter 551 933 92 1

1000 hours

Item Quantity
Engine oil 40 L (10,6 U.S. gal)
Compressor oil 19 L (5,0 U.S. gal)
Transmission gear 5,2 L (1,4 U.S. gal)
Final drive oil 2,0 L (2,0 U.S. gal)

Copyright © Sandvik Mining and Construction 291 (304)

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292 (304) Copyright © Sandvik Mining and Construction

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MAINTENANCE MANUAL dp1500i
8.4.5. Every 1500 hours

DIESEL HOURS – EVERY 1500 HOURS

MAINTENANCE PROCEDURE NOTES
BOOM
Check the tightness of bolts and nuts 128

Check the zoom tube wiper ring 129

Check the fastening of the boom to the

136
carrier
Lubricate the greasing points 139

Check the condition of the cylinder pins. 135

Check the mounting of the hydraulic

136
cylinders.
Check the boom and cradle welds. 136

Check the pressures of the pressure

137
accumulators
FEED
Check the tightness of bolts and nuts 141

Clean the cables 141

Check the wear and condition of the ca-

142
bles
Check the fastening and tightness of
143
the cables
Check the feed cylinder guide clearan-
149
ces
Check the clearance of the rock drill
carriage and hose reel carriage and the 151
condition of the slide pieces
Lubricate the PITO centraliser cylinder 155

Lubricate the greasing points 156

Check the Pito centraliser jaws 153

Replacing the feed cylinder seals 155

ROD HANDLER
Check the tightness of bolts and nuts 157

Check the condition of the roller Pito 158

Lubricate the rod handler 159

Check the rod changer jaws 158

Copyright © Sandvik Mining and Construction 293 (304)

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dp1500i MAINTENANCE MANUAL

DIESEL HOURS – EVERY 1500 HOURS

MAINTENANCE PROCEDURE NOTES
HYDRAULIC ROCK DRILL
Check the tightness of the bolts be-
tween the carriage and rock drill, as well 165
as the flushing housing bolts
Check the condition of the flushing
166
housing seals
Check the shank, chuck, flushing hous-
166
ing, coupling, and rotation bushing
Check the condition of the pressure ac-
cumulator’s filling valves and cover 179
plugs
Check the pressure of the pressure ac-
180
cumulators
CARRIER
Wash the rig 183

Lubricate the oscillation axle 189

Lubricate the oscillation cylinder pins. 190

Check the electrolyte level and battery

192
cable connections
Check the mounting and condition of
192
the winch cable
Check the tramming gear oil 187

Check the idler wheel oil 188

Clean the battery and its terminals 193

Check the mounting of the track batch-

184
es
Check the cylinders (oscillation) expan-
189
sion pin screws.
Check the welds 193

Change winch oil. 193

DIESEL ENGINE
Clean the radiator core. 197

Clean the intercooler 198

Change the oil and replace the filter 196

Check the engine earth terminal 197

Check the hoses and connections 198

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MAINTENANCE MANUAL dp1500i
DIESEL HOURS – EVERY 1500 HOURS
MAINTENANCE PROCEDURE NOTES

Clean the diesel engine 194

Replace the air filter 195

Check the tightness and condition of

198
the V-belt
Check the condition of the starter motor 199

Check the condition of the water pump 200

Check the engine protection 201

Check the alternator 202

Replace the air filter safety cartridge 196

CABIN
Check the operation of the cabin door
204
switch
Replace the cabin air filters (interior cir-
204
culation and suction filters)
HYDRAULIC SYSTEM
Clean the radiator core. 205

Check the return pressure sensor 206

Check the temperature sensor 206

Replace the hydraulic oil tank breather 207

Replace the oil pressure filter 207

Replace the oil return filters (2 pcs) 208

Check the operation of the oil level

208
switch.
Clean the hydraulic oil tank 208

Change the hydraulic oil 209

PNEUMATIC SYSTEM
Check the intake air line and connec-
210
tions
Clean the radiator core 215

Check the operation of the air filter

212
maintenance indicator
Replace the air filter 211

Copyright © Sandvik Mining and Construction 295 (304)

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dp1500i MAINTENANCE MANUAL

DIESEL HOURS – EVERY 1500 HOURS

MAINTENANCE PROCEDURE NOTES

Change the compressor oil 212

Replace the oil filter 213

Replace the air filter safety cartridge 212

Replace oil separator 213

SLU SHANK LUBRICATION UNIT

Drain the condensation water from the
215
oil tank
Empty the shank lubrication return tank 216

FUEL SYSTEM
Drain condensed water and deposit
218
from the fuel tank
Replace the fuel filter / water separator
219
cartridge
Replace the fuel filter 220

Replace the fuel tank breather 222

Clean the fuel tank. 222

DUST COLLECTOR SYSTEM

Check the condition of the suction ho-
222
ses and connections
Check the condition of the filter car-
223
tridges
Check the operation of the pulse jet
223
cleaning
Check the integrity of the dust collector. 223

Check the condition of the fine separa-

224
tor’s impact plate.
Check the condition of the coarse sep-
224
arator skirt rubber
Grease the moving suction head cylin-
225
der
Grease the cut-off cylinder and butterfly
225
valve
Check the condition of the coarse sep-
224
arator’s rubber lining
Check the condition of the suction head
225
rubbers
Check the operation of the cut-off cyl-
226
inder / butterfly valve

296 (304) Copyright © Sandvik Mining and Construction

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MAINTENANCE MANUAL dp1500i
DIESEL HOURS – EVERY 1500 HOURS
MAINTENANCE PROCEDURE NOTES
MAIN ELECTRICAL SYSTEM
Check the condition of electrical cables
226
and connections
Check the electrical cabinets and box-
226
es
Check the fastening of electrical cables 226

When completed:
Date ....................................................... Diesel hours ...........................................
Approved ...............................................

1500h / 3000h Filter kit (ID 552 094 29) including following filters

Item ID Quantity
Engine secondary fuel filter 886 618 49 2
Primary fuel filter / water separator 551 987 18 1
Engine oil filter 550 558 74 1
Compressor oil filter 818 937 49 1
Hydraulic return oil filter 867 272 89 2
Hydraulic oil pressure filter 872 701 09 1
Hydraulic oil tank breather 850 794 09 1
Engine air filter 551 875 29 1
Compressor air filter 551 933 92 1
Engine air filter safety cartridge 560 408 22 1
Compressor air filter safety cartridge 551 933 96 1
Cabin air filter EU6-DOP 550 999 05 3
Cabin air filter 30ppi 550 999 10 1
Cabin air recirculation filter 551 711 50 1
Compressor oil separator filter 551 844 29 2

1500 hours

Item Quantity
Engine oil 40 L (10,6 U.S. gal)
Compressor oil 19 L (5,0 U.S. gal)
Hydraulic oil 390 L (103 U.S. gal)
Winch oil 3,0 L (1,6 U.S. pt)

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298 (304) Copyright © Sandvik Mining and Construction

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MAINTENANCE MANUAL dp1500i
8.4.6. Every 3000 hours

DIESEL HOURS – EVERY 3000 HOURS

MAINTENANCE PROCEDURE NOTES
BOOM
Check the tightness of bolts and nuts 128

Check the zoom tube wiper ring 129

Check the fastening of the boom to the

136
carrier
Lubricate the greasing points 139

Check the condition of the cylinder pins. 135

Check the mounting of the hydraulic

136
cylinders.
Check the boom and cradle welds. 136

Check the pressures of the pressure

137
accumulators
The clearances of the zoom tube slide
130
pieces
Check the cradle clearances 138

FEED
Check the tightness of bolts and nuts 141

Clean the cables 141

Check the wear and condition of the ca-

142
bles
Check the fastening and tightness of
143
the cables
Check the feed cylinder guide clearan-
149
ces
Check the clearance of the rock drill
carriage and hose reel carriage and the 151
condition of the slide pieces
Lubricate the PITO centraliser cylinder 155

Lubricate the greasing points 156

Check the Pito centraliser jaws 153

Replace the idler wheel bearings 155

Replacing the feed cylinder seals 155

Copyright © Sandvik Mining and Construction 299 (304)

ID: 666 1 en 2011-08-23
dp1500i MAINTENANCE MANUAL

DIESEL HOURS – EVERY 3000 HOURS

MAINTENANCE PROCEDURE NOTES
ROD HANDLER
Check the tightness of bolts and nuts 157

Check the condition of the roller Pito 158

Lubricate the rod handler 159

Check the rod changer jaws 158

HYDRAULIC ROCK DRILL

Check the tightness of the bolts be-
tween the carriage and rock drill, as well 165
as the flushing housing bolts
Check the condition of the flushing
166
housing seals
Check the shank, chuck, flushing hous-
166
ing, coupling, and rotation bushing
Check the condition of the pressure ac-
cumulator’s filling valves and cover 179
plugs
Check the pressure of the pressure ac-
180
cumulators
CARRIER
Wash the rig 183

Lubricate the oscillation axle 189

Lubricate the oscillation cylinder pins. 190

Check the electrolyte level and battery

192
cable connections
Check the mounting and condition of
192
the winch cable
Check the tramming gear oil 187

Check the idler wheel oil 188

Clean the battery and its terminals 193

Check the mounting of the track batch-

184
es
Check the cylinders (oscillation) expan-
189
sion pin screws.
Check the welds 193

Change tramming gear oil 185

Change the transfer gearbox oil 191

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MAINTENANCE MANUAL dp1500i
DIESEL HOURS – EVERY 3000 HOURS
MAINTENANCE PROCEDURE NOTES

Check the fastening of the cables 193

Change winch oil. 193

Check the condition of the fire extin-

184
guishers
DIESEL ENGINE
Clean the radiator core. 197

Clean the intercooler 198

Change the oil and replace the filter 196

Check the engine earth terminal 197

Check the hoses and connections 198

Clean the diesel engine 194

Replace the air filter 195

Check the tightness and condition of

198
the V-belt
Check the condition of the starter motor 199

Check the condition of the water pump 200

Check the engine protection 201

Check the alternator 202

Replace the air filter safety cartridge 196

Check the condition of the turbocharg-

199
er.
Change the coolant 201

Replace the cooling system thermostat 201

Check the engine brackets 202

Check the crankshaft's vibration damp-

202
er
Check the electronic injector nozzles 203

Check the engine speed and timing

203
sensors
Check the valve clearances. 203

Check the valve rotators 204

Copyright © Sandvik Mining and Construction 301 (304)

ID: 666 1 en 2011-08-23
dp1500i MAINTENANCE MANUAL

DIESEL HOURS – EVERY 3000 HOURS

MAINTENANCE PROCEDURE NOTES
CABIN
Check the operation of the cabin door
204
switch
Replace the cabin air filters (interior cir-
204
culation and suction filters)
HYDRAULIC SYSTEM
Clean the radiator core. 205

Check the return pressure sensor 206

Check the temperature sensor 206

Replace the hydraulic oil tank breather 207

Replace the oil pressure filter 207

Replace the oil return filters (2 pcs) 208

Check the operation of the oil level

208
switch.
Clean the hydraulic oil tank 208

Change the hydraulic oil 209

Check the hydraulic oil thermostats 209

PNEUMATIC SYSTEM
Check the intake air line and connec-
210
tions
Clean the radiator core 215

Check the operation of the air filter

212
maintenance indicator
Replace the air filter 211

Change the compressor oil 212

Replace the oil filter 213

Replace the air filter safety cartridge 212

Replace oil separator 213

Clean the oil receiver. 214

Check the operation of the thermostat 214

SLU SHANK LUBRICATION UNIT

Drain the condensation water from the
215
oil tank

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MAINTENANCE MANUAL dp1500i
DIESEL HOURS – EVERY 3000 HOURS
MAINTENANCE PROCEDURE NOTES

Empty the shank lubrication return tank 216

Change the shank lubrication oil receiv-

215
er breather.
Clean the shank lubrication oil receiver. 216

Check the operation of the monitoring

217
unit
FUEL SYSTEM
Drain condensed water and deposit
218
from the fuel tank
Replace the fuel filter / water separator
219
cartridge
Replace the fuel filter 220

Replace the fuel tank breather 222

Clean the fuel tank. 222

DUST COLLECTOR SYSTEM

Check the condition of the suction ho-
222
ses and connections
Check the condition of the filter car-
223
tridges
Check the operation of the pulse jet
223
cleaning
Check the integrity of the dust collector. 223

Check the condition of the fine separa-

224
tor’s impact plate.
Check the condition of the coarse sep-
224
arator skirt rubber
Grease the moving suction head cylin-
225
der
Grease the cut-off cylinder and butterfly
225
valve
Check the condition of the coarse sep-
224
arator’s rubber lining
Check the condition of the suction head
225
rubbers
Check the operation of the cut-off cyl-
226
inder / butterfly valve
MAIN ELECTRICAL SYSTEM
Check the condition of electrical cables
226
and connections

Copyright © Sandvik Mining and Construction 303 (304)

ID: 666 1 en 2011-08-23
dp1500i MAINTENANCE MANUAL

DIESEL HOURS – EVERY 3000 HOURS

MAINTENANCE PROCEDURE NOTES
Check the electrical cabinets and box-
226
es
Check the fastening of electrical cables 226

When completed:
Date ....................................................... Diesel hours ...........................................
Approved ...............................................

1500h / 3000h Filter kit (ID 552 094 29) including following filters

Item ID Quantity
Engine secondary fuel filter 886 618 49 2
Primary fuel filter / water separator 551 987 18 1
Engine oil filter 550 558 74 1
Compressor oil filter 818 937 49 1
Hydraulic return oil filter 867 272 89 2
Hydraulic oil pressure filter 872 701 09 1
Hydraulic oil tank breather 850 794 09 1
Engine air filter 551 875 29 1
Compressor air filter 551 933 92 1
Engine air filter safety cartridge 560 408 22 1
Compressor air filter safety cartridge 551 933 96 1
Cabin air filter EU6-DOP 550 999 05 3
Cabin air filter 30ppi 550 999 10 1
Cabin air recirculation filter 551 711 50 1
Compressor oil separator filter 551 844 29 2

3000 hours

Item Quantity
Engine oil 40 L (10,6 U.S. gal)
Compressor oil 19 L (5,0 U.S. gal)
Transmission gear 5,2 L (1,4 U.S. gal)
Final drive oil 2,0 L (2,0 U.S. gal)
Hydraulic oil 390 L (103 U.S. gal)
Winch oil 3,0 L (1,6 U.S. pt)
Engine coolant 65 L (17,2 U.S. gal)

304 (304) Copyright © Sandvik Mining and Construction

ID: 666 1 en 2011-08-23
www.sandvik.com