DX500, DX680, DX700 DX780, DX800

Maintenance manual
Maintenance manual DX500/DX680/DX700/DX780/DX800

2 (62) C 05434--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Maintenance manual

PREFACE

Congratulations on your choice of Sandvik drilling rig.

This manual describes the maintenance of DX500/DX680/DX700/DX780/DX800 drilling
rigs. Only those who have been given proper training are allowed to operate and service
the rig. The operator shall also read and fully understand the contents of the Operator’s
Manual, Maintenance Manual and the Safety Instructions.
The manual gives you such information on the structure and operation of the rig that is
necessary for correct maintenance.
For demanding maintenance and repairs, we recommend that you contact your nearest
authorized Sandvik Service. Our maintenance personnel have the skills and special tools
required for the most demanding tasks.
Through correct use and by following the maintenance instructions, you can expect a high
degree of utilization and long operating life of your rig.
55055051-- B

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Maintenance manual DX500/DX680/DX700/DX780/DX800

CONTENTS

1. INTRODUCTION TO MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1. Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2. Recommended operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3. Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2. SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.1. Warning labels on the equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.2. Warning of injury risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3. Warning of damage to equipment or property . . . . . . . . . . . . . . . . . . . 12
2.4. Read the user or maintenance instructions . . . . . . . . . . . . . . . . . . . . . 12
2.5. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.6. Refuelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.7. Pneumatics maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.8. Rock drill’s pressure accumulators maintenance . . . . . . . . . . . . . . . . 15
2.9. Hydraulics maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.10. Electric system maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.11. Battery maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.12. Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3. IMPORTANCE OF PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.1. General notes on maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2. First service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4. PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.1. Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.2. Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.2.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.2.2. Rock drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.2.3. Chain feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.2.4. Rod handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.2.5. Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.2.6. Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.2.7. Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.2.8. Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.2.9. Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.2.10. Air circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.2.11. Dust collector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

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DX500/DX680/DX700/DX780/DX800 Maintenance manual

1. INTRODUCTION TO MACHINE
1.1. Intended use
The DX drilling rig is intended for use at construction sites and quarries. It is a hydraulic
drill rig that drills vertical, inclined, and horizontal holes 45 to 127 mm (1 3/4” to 5”) in
diametre using 32, 38, 45 or 51 mm (1 1/4”, 1 1/2” , 1 3/4” or 2”) extension rods. The
maximum hole depth is 29 metres when 14 foot ( 45 mm) MF steels are used.

1.2. Recommended operating conditions

D Ambient temperature . . . . . . . . . . . . . . . . . . -- 30_C ... + 50_C
D Maximum altitude from sea level . . . . . . . . max. 3,000 m
D Before use in exceptional conditions, contact Sandvik’s engineering department.

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Maintenance manual DX500/DX680/DX700/DX780/DX800

1.3. Components
FRONT

1. Rock drill
2. Feed
3 1
4 3. Rod handler
4. Boom

1. Rock drill
6 1. Low pressure accumulator
4 2 2. High pressure accumulator
7 3. Body cylinder
4. Rotation motor
5. Spacer
6. Gear housing
7. Flushing housing
1
5 3
2. Feed
1. Hose reel
1
2. Pito
3. Movable suction head
6
4. Carriage
5 5. Feed gear
6. Feed beam
2 4 7. Stinger

3
7

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3. Rod handler

1. Upper end of rod handler

2. Lower end of rod handler
1 3. Rod gripping cylinder
4. Gripper transfer cylinder
5. Rod feed cylinder
3

4. Boom

3 1. Boom lift cylinder

8 7 2. Boom knee cylinder
3. Feed extension cylinder
4 4. Feed swing cylinder
5. Feed tilt cylinder
6. Rear boom
7. Boom arm
8. Cradle
2 1 9. Cross piece
9
5 6

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Maintenance manual DX500/DX680/DX700/DX780/DX800

MIDDLE

1. Cabin
4 2. Crawler base
3
2 3. Receivers
1
4. Drilling hydraulics

1. Controls

1. Roof panel
2. Pressure gauges
1 3. Rod handling control
4. Tramming control
5. Left hand panel
6. Drilling control
7. Boom control
8. Right hand panel

2
6
3 7
8
4

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2. Crawler base
2 1 1. Final drives
2. Oscillation cylinders
3. Idler wheels
4. Track frames
5. Track rollers

3 4 5
3. Receivers
1. Hydraulic oil tank
1
2. Fuel tank

4. Drilling hydraulics

1. Pumps
2. Valve blocks
3. Drilling joystick

3 2 1

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Maintenance manual DX500/DX680/DX700/DX780/DX800

REAR

1. Powerpack
2. Air system
1 2 3 4 3. Dust collection system
4. Shank lubrication unit

1. Powerpack
1. Diesel engine
1
2. Compressor
5 3. Hydraulic pumps
4. Side pump
5. Transfer gear

2. Air circuit
2 1. Compressor
2. Oil/air receiver
3. Air filter
3 4. Dust collector

1 4

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3. Dust collection system

1. Dust collector
2. Primary cyclone
3. Suction head
4 4. Suction hose
1

3
4. Shank lubrication unit
1. Oil tank
2. Pump unit
3. Water separator
4. Lubrication air valve

1
4

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Maintenance manual DX500/DX680/DX700/DX780/DX800

2. SAFETY INSTRUCTIONS
2.1. Warning labels on the equipment
All the warning labels on the device will be presented in the instructions chapter dealing
with the warning labels.

! DANGER
DANGER
Immediate danger related to a feature of the device,
causing serious injury or death if the proper safety
precautions are not taken.
Hazardous voltage.
WARNING
Can cause severe
injury or death. A dangerous or unsafe manner of operation that may
Disconnect main cause serious injury or death if the proper safety
supply cable before
servicing. precautions are not taken.
GB ID = 207 241 08

2.2. Warning of injury risks

A dangerous or unsafe manner of operation that may cause serious injury or death (injury
or health risk) if the proper safety precautions are not taken.

Dangerous boom movement. The boom movement can cause serious

injury or health risk. Do not enter the danger zone of the machine during
drilling or tramming.
WARNING

2.3. Warning of damage to equipment or property

These warnings are designed to instruct the operator how to use the equipment so that
material damage can be avoided.

Risk of damage. Welding current can damage electric devices and circuit
boards. Disconnect the battery terminals and circuit boards before
welding the equipment.
CAUTION

2.4. Read the user or maintenance instructions

These instructions are used when it is forbidden to operate the equipment before
receiving proper training or reading the information in the manuals

Do not use the equipment unless you have been given proper training.
Read the operating instructions before using the equipment. The
operator must know the operating, maintenance, and safety instructions
CAUTION
of the equipment, as well as the local safety instructions of the mine,
before using the equipment.

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2.5. General
Our recommendation is that records be kept on services and wearing part replacements.
Regular maintenance at correct intervals increases reliability, economy, and safety of the
equipment.
Even maintenance work can be dangerous, unless caution is observed. Everybody
involved in maintenance work should understand the possible hazards, and use safe
working methods. Before starting any maintenance or repair work, read the
manufacturer’s instructions and follow them.

The person responsible for maintenance and repairs should be clearly defined.
-- Do not do any work that you are not authorized to do.
-- Inform the users of the equipment of the start of special and maintenance work.
-- Ensure the area around the rig is clear and safe before commencing maintenance
work.
-- If the equipment or a part of it has been stopped for maintenance or repair, make
sure that it cannot be started accidentally.
D Turn main switch off
D Remove ignition key
D Put a DANGER DO NOT START warning sign on the main switch. The sign must
only be removed by a person who is fully aware of the situation.
-- Clean and wash the equipment regularly, and always before maintenance and
repair work.
-- Before starting to clean the equipment with water, high-pressure washer, steam,
or other cleaning methods, protect all such openings and other points that can
cause danger or become broken. Electric motors, switchgear cabinets and and
electric boxes especially need to be protected.
-- If required, ensure suitable and safe ladders or working platforms are available for
repair and maintenance work.
-- Do not use parts of the equipment as steps. If maintenance work must be done high
up, or in an otherwise dangerous place or position, use necessary safety devices
to prevent falling.
-- All platforms, steps, grips, rails, ladders, and other similar parts must be kept clean
of oil, dirt, snow, and ice to prevent accidents caused by slipping.
-- Always use the correct tools for the maintenance task.
-- Before commencing maintenance or repair work ensure vehicle is on level ground,
with both tracks chocked.

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Maintenance manual DX500/DX680/DX700/DX780/DX800

-- Pay special attention to the exhaust piping and the exhaust gas cleaning system.
Ensure sufficient ventilation.
-- Overheating indicates a fault. Stop the engine and repair the fault before more
serious damage is caused. Make sure that the engine radiator is not covered, and
that it is not clogged.
-- When checking engine coolant level, stop the engine and allow it and the radiator
to cool down. If an overheated engine must be stopped, allow the radiator to cool
down before checking coolant level. If there is no time for that, use thick gloves and
protective clothing when opening the radiator filling cap. Stand to the side, turn your
face away, and open the cap a little. Wait until the pressure is released and coolant
stops running out, then open the cap slowly.
-- When replacing heavy parts, use correct lifting apparatus and techniques.

2.6. Refuelling
The following precautions must be observed when refuelling
-- Do not fill the fuel tank when the engine is running.
-- Take care not to spill fuel on hot surfaces.
-- Refuelling should be done in a well ventilated space.
-- Smoking is strictly forbidden.
-- Open flame, and sparks are dangerous when refuelling.
-- Wipe off spilled fuel before starting the engine.
-- Keep the fuel nozzle in contact with the fuel tank. Arrange earthing to prevent
sparking caused by static electricity.
-- The cabin heater must be switched off.
-- The fuel tank cap must be taken back when the tank is filled.

2.7. Pneumatics maintenance

The pneumatic circuit must be depressurised before any repairs are made.
-- Make sure that the pneumatic system completely pressureless before starting
maintenance or repair work on the compressor.
-- The system pressure must not be adjusted higher than specified by the
manufacturer. Increasing the pressure does not increase the performance of the
equipment.

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DX500/DX680/DX700/DX780/DX800 Maintenance manual

2.8. Rock drill’s pressure accumulators maintenance

-- The pressure accumulators of the rock

drills are pressurized with nitrogen gas N2.
Before removing the accumulators,
release the pressure by opening the filling
valve. Do not pressurize the accumulators
over the specified filling pressure. Follow
the instructions for pressure accumulator
maintenance and repair.

2.9. Hydraulics maintenance

Maintenance, repair, and installation of hydraulic equipment must only be carried out
experienced hydraulics experts.
-- Do not attempt any such repairs that you do not fully understand.
-- Never do any repair work on the hydraulic circuit if the system is pressurized.
-- Do not use the drilling equipment if the system has a hose leakage.
-- Always stop the engine and the powerpack before tightening or repairing a leaking
hose connection.
-- Do not try to locate a leak from a hose or a connection by feeling with your hand.
The high-pressure oil spray from the leak can penetrate the skin and cause a
serious injury. A high-pressure oil spray can also start a fire.
-- Avoid direct skin contact with oil. Prevent oil from getting into your eyes; use eye
protection.
-- Do not work under a device or component that is held up only by the hydraulics.
Use separate supports in conjunction with maintenance and repair.
-- Do not remove boom cylinders or their non-return valves unless the boom, the
feed, and the rock drill are properly supported.
-- Pipe connections, hose lengths, and hose types must correspond with the
specifications. When replacing or repairing hoses, use original Sandvik spare parts
or hoses and fittings recommended by the manufacturer. Ensure that the pressure
ratings of the hoses and connecting fittings correspond with the working pressures.
-- Any alterations require a written authorization from the manufacturer.

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Maintenance manual DX500/DX680/DX700/DX780/DX800

2.10. Electric system maintenance

-- Work on electric equipment or materials is only be carried out by qualified
electricians, or assistants under their supervision and control, observing
electrotechnical regulations.
-- The local electrotechnical and electric safety regulations must always be
observed.
-- Always use only original electric components.
-- If disturbances in electric supply occur, stop the rig or device at once.
-- Voltage must be cut off from the parts of the equipment or device that are to be
checked, serviced, or repaired, if the regulations so require. Check that the
disconnected parts are dead, and then lock the main switch or arrange a work
earthing if necessary.
-- Check the electric devices of the equipment regularly. Faults, such as loose wires
and damaged insulation must be repaired at once.
-- Check the operation of earth fault protection every week. This is done by pressing
the test button. If no cut-off takes place, the protective device must be repaired
before starting any devices connected to it.
-- When handling high-voltage components, remember that capacitors may have an
electric charge, even if the voltage is cut off. Short the capacitors with an earthing
rod.
-- Before making any changes on the electric devices, Sandvik’s electric engineering
department must be consulted, and a written authorization received, to ensure the
operation of the device does not change.

Working on live components

-- If the component must be live, a fellow worker must be standing by to cut off voltage
at the emergency or main switch in an emergency situation. Follow the electric
safety regulations.
-- Use a red-and-white safety chain and warning signs to encircle the working area.
-- Use only insulated tools.
-- Observe special caution.

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2.11. Battery maintenance

Always wear eye protection, protective overalls, and protective gloves when
servicing batteries.
-- Always disconnect the negative (-) pole first, and then the positive (+) pole. Always
connect the positive pole (+) first, and then the negative (-) pole.
-- To prevent sparking when connecting a battery charger, pull the charger supply
cord or switch the charger off before connecting the charging wires to the battery
terminals. Open the battery cell caps slightly during charging to allow the
generating gases to escape.
-- The acid in the battery burns skin, eats holes in clothing, and can cause blindness
if it gets in the eyes. If you get battery acid on your skin, flush the spot at once with
water. Use sodium bicarbonate to neutralize the acid if it gets in the eyes. Flush the
eyes with water, and call a doctor.
-- When servicing batteries, remember that lead-acid batteries generate (during
charging and discharging) oxygen and hydrogen which form a highly explosive
mixture. A spark or an open flame can cause an explosion. If necessary, ventilate
the battery compartment properly before disconnecting or connecting the cables.
-- To prevent explosion, the electrolyte level must be maintained and checked
regularly. Add distilled water, if required, before starting, never immediately after
use. With a high enough electrolyte level, the cells have less space for gases.
-- Use an flashlight when checking electrolyte levels, never an open flame.
-- The battery terminals should never be shorted as sparks can cause the battery to
explode.
-- Do not test electric devices by making the contact with the battery terminal.

2.12. Welding
Before starting to weld, determine the material to be welded, and the welding method and
fillers. Contact Sandvik Service, if necessary.
-- Do not repair steering equipment by welding.
-- Never repair a boom or boom components or cylinders by welding (Special
materials are used in booms that cannot be welded using normal methods).
-- Welding must be left to qualified personnel.
-- Disconnect both cables from the battery before starting to weld. The welding
voltage can damage electric devices.
-- Use a protective mask when welding.
-- Arrange adequate ventilation.
-- Arrange protection against fire.
-- Place the grounding cable as close as possible to the welding spot.

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Maintenance manual DX500/DX680/DX700/DX780/DX800

3. IMPORTANCE OF PERIODIC MAINTENANCE

Properly done and correctly timed periodic maintenance guarantees the reliability of the
equipment. The purpose of periodic maintenance is to have the rig checked regularly and
thus ensure a high level of serviceability. This will prevent costly damages and downtime
which cuts productivity. Neglected maintenance means extra costs!
It is important to do the daily service routines carefully. Any possible faults must be
repaired at once or reported to the persons in charge. The daily routines include
lubricating, checking, and adjusting. Every new operator must be able to manage the daily
service routines.
Periodic maintenance instructions are based upon the diesel engine’s running
hours and the rock drill’s percussion hours.

3.1. General notes on maintenance work

1. Always shut off the rig before maintenance work. Prevent accidental starting by
turning the main switch off or remove the ignition key.
2. Make sure that the rig will not move.
3. Clean the rig before maintenance.
D Do not use solvents containing aromatic or chlorinated hydrocarbons for washing
the drilling rig. Also petroleum--based fuels like petrol, gasoline, kerosine, diesel
fuel etc. can not be used for washing. Depending on chemicals they can cause
deterioration, cracking and softening of material in rubber and plastic.
4. Ensure that
D tools;
D spare parts: and
D materials (oils, lubricants etc.) needed are ready at hand
5. Carefully clean around the filling caps before refuelling or topping up of oils.
6. Always check the cleanliness of the oil used when changing oil or replacing the
filter. A large amount of impurities (e.g. clogged filter) may be a sign of a fault that
must be repaired at once before it causes serious damage.
7. Beware of hot surfaces and hot oils. Dispose of used oil and filters according to the
local regulations.
8. All guards and covers must be re--installed after maintenance work.

Change / Replace This symbol indicates that local environmental

regulations must be observed when disposing of used
components/liquid. Refer to General safety instructions, section
CAUTION ‘ENVIRONMENTAL PROTECTION DURING MAINTENANCE’.

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3.2. First service

The following steps should be carried out during the first week of use (in addition to the
normal scheduled services):
Adjust the drilling pressures according to rock conditions.
After the first five shifts (50 h)

CHECK / CLEAN AND CHANGE /

TEST
LUBRICATE
FLUSH REPLACE
S SERVICE

AFTER THE FIRST FIVE SHIFTS (50 hours)

Tighten the engine mounting, air intake and exhaust manifold bolts.
Check air suction hoses and connections.

Change compressor oil and oil filter.

Tighten the triple pump mounting flange bolts.

Check tightening torques of all bolts in rock drill.

Tighten all loosened connections and bolts.

Tighten bolts of expansion pins in cylinders (oscillation) correct tightness
290 Nm.
Check V--belts

Diesel engine:
Contact the local Caterpillar dealer for commissioning the engine. Caterpillar “Engine
Service Delivery Record” must be filled at that time.

CHECK / CLEAN AND CHANGE /

TEST
LUBRICATE
FLUSH REPLACE
S SERVICE

AFTER THE FIRST 200 h

Change transfer gearbox oil.

AFTER THE FIRST 500 h

Diesel engine valve clearances inspect / adjust 1)

1) Refer to cat engine operation and maintenance manual to get the detailed instructions.

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Maintenance manual DX500/DX680/DX700/DX780/DX800

4. PERIODIC MAINTENANCE

4.1. Schedule

CHECK / CLEAN AND CHANGE /

TEST
LUBRICATE
FLUSH REPLACE
S SERVICE

DIESEL ENGINE OPERATING HOURS when

INTERVAL completed

DAILY 50 200 600 1200 1800 2400 3600 Y= N=

GENERAL
Yes Note

Operation of emergency stop switches and

buzzer

Working lights

Tramming lights

Function of the gauges

Possible oil leaks

Clean the rig

Operation of warning and shut down system

Tighten bolts of expansion pins in cylinders

(oscillation ) correct tightness 290 Nm

Operation of warning and shut down sensors

Tightness of all electrical connections

Replace the vapour capsule in electric box

Fire extinguisher testing and refilling

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CHECK / CLEAN AND CHANGE /

TEST
LUBRICATE
FLUSH REPLACE
S SERVICE

DIESEL ENGINE OPERATING HOURS when

INTERVAL completed

DAILY 50 200 600 1200 1800 2400 3600 Y= N=

ROCK DRILL
Yes Note

Tightness of mounting between carriage / rock

drill

Possible oil leaks

Tightness of flushing housing bolts

Condition of hoses and connectors

Condition of flushing housing seals (during

drilling)

Percussion hour meter reading

Operation of shank lubrication

Tie rod tightness

Condition of accumulator filling valves/caps

Accumulator pressures

Shank, chuck, flushing housing, connecting

piece and rotation bushing

Rotation motor and accumulator bolt tightness

Tightness of bolts in the rear cover,

intermediate gear

NOTE! The service interval of the

rock drill is 500 percussion hours.

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CHECK / CLEAN AND CHANGE /

TEST
LUBRICATE
FLUSH REPLACE
S SERVICE

DIESEL ENGINE OPERATING HOURS when

INTERVAL completed

DAILY 50 200 600 1200 1800 2400 3600 Y= N=

CHAIN FEED
Yes Note

Tension and condition of feed chain

Rod greasing device

Lower sprocket

Feed gear sprockets

Greasing points

Rock drill carriage/feed rail clearance

Retainer centralizer

Feed gear oil (DX500, DX680)

DAILY 50 200 600 1200 1800 2400 3600 Y= N=

ROD CHANGER
Yes Note

Greasing points

Rod changer jaws and cylinder mountings

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CHECK / CLEAN AND CHANGE /

TEST
LUBRICATE
FLUSH REPLACE
S SERVICE

DIESEL ENGINE OPERATING HOURS when

INTERVAL completed

DAILY 50 200 600 1200 1800 2400 3600 Y= N=

BOOM
Yes Note

Greasing points

Weldings of boom and cradle

Mountings of hydraulic cylinders

Cradle clearances

DAILY 50 200 600 1200 1800 2400 3600 Y= N=

CARRIER
Yes Note

Tension of tracks

Transfer gear oil

Oscillation shafts

All grease nipples

Electrolyte and connections in batteries

Condition and mounting of winch rope

Operation of brakes

Final drive oil

Winch oil

Mountings of hydraulic cylinders

All weldings

Cabin air filters (inner circulation and intake

filter)

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Maintenance manual DX500/DX680/DX700/DX780/DX800

CHECK / CLEAN AND CHANGE /

TEST
LUBRICATE
FLUSH REPLACE
S SERVICE

DIESEL ENGINE OPERATING HOURS when

INTERVAL completed

DAILY 50 200 600 1200 1800 2400 3600 Y= N=

DIESEL ENGINE
Yes Note

REFER TO CAT ENGINE

OPERATION AND MAINTENANCE
MANUAL TO GET THE DETAILED
INSTRUCTIONS.
Walk around inspection

Engine oil

Radiator hoses and connections S

Water pump for leaks

Coolant temperature

Engine coolant 1)

V--belts

Operation of air filter service indicator

Air intake lines and connections

Radiator core

Engine oil filter

Crankcase breather

Cylinder head grounding

Alternator

Air filter

Air filter safety cartridge

Intercooler and hoses

Valve clearances*

1) Check the coolant antifreeze mixture before cold season.

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DX500/DX680/DX700/DX780/DX800 Maintenance manual

DAILY 50 200 600 1200 1800 2400 3600 5000 N=

DIESEL ENGINE
Note

Belt tensioner

Thermostat of cooling system

Crankshaft vibration damper

Engine mounts

Starter motor*

Turbo charger*

Water pump*

* Contact Caterpillar dealer

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Maintenance manual DX500/DX680/DX700/DX780/DX800

CHECK / CLEAN AND CHANGE /

TEST
LUBRICATE
FLUSH REPLACE
S SERVICE

DIESEL ENGINE OPERATING HOURS when

INTERVAL completed

DAILY 50 200 600 1200 1800 2400 3600 Y= N=

FUEL
Yes Note

Fuel amount

Fuel filter indicator

Drain the water trap from the water separator

Drain the condensate water from the tank

Fuel filter

Fuel water separator

Breather

Fuel tank
DAILY 50 200 600 1200 1800 2400 3600 Y= N=
HYDRAULICS
Yes Note

Hydraulic oil

Radiator core

Temperature sensor

Breather

Oil pressure filter

Oil return filter

Operation of oil level indicator

Hydraulic oil tank

Anti--jamming valve strainer

1) Every 2400 engine operating hours or 1 year

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CHECK / CLEAN AND CHANGE /

TEST
LUBRICATE
FLUSH REPLACE
S SERVICE

DIESEL ENGINE OPERATING HOURS when

INTERVAL completed

DAILY 50 200 600 1200 1800 2400 3600 Y= N=

AIR CIRCUIT
Yes Note

Compressor oil

Oil filter service indicator

Operation of air filter service indicator

Air intake line and connections

Air filter

Air filter safety cartridge

Oil filter

Alarm and shut down temperature switches

Oil regeneration line strainer and orifice

Oil separators

Oil receiver

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Maintenance manual DX500/DX680/DX700/DX780/DX800

CHECK / CLEAN AND CHANGE /

TEST
LUBRICATE
FLUSH REPLACE
S SERVICE

DIESEL ENGINE OPERATING HOURS when

INTERVAL completed

DAILY 50 200 600 1200 1800 2400 3600 Y= N=

DUST COLLECTOR
Yes Note

Suction hoses and connections

Condition of filter elements, change if

necessary

Precyclone rubbers

Fine collector reflector rubber

Movable suction head cylinder

Suction head rubbers

Condition of fine collector rubber elbow

Operation of closing cylinder and suction

control flap mechanism
DAILY 50 200 600 1200 1800 2400 3600 Y= N=
TIM
Yes Note

Laser receiver window

Greasing points

Measuring accuracy

Tightness and mounting of components and

connections

Mechanical condition

Breathers

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DX500/DX680/DX700/DX780/DX800 Maintenance manual

4.2. Instructions
4.2.1. General
EVERY 50 HOURS

Clean the rig.

EVERY 200 HOURS

Check the operation of warning

! and shut down system. (See Tech-
nical manual: Electric system)

EVERY 600 HOURS

Tighten bolts of expansion pins (1)

in oscillation and boom cylinders
1 1 correct tightness 290 Nm.

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Maintenance manual DX500/DX680/DX700/DX780/DX800

EVERY 1,200 HOURS

Check the operation of warning
and shut down sensors.

Warning devices:
-- Filter indicators, hydraulic oil
pressure filter, hydraulic oil return
filter and compressor oil filter.
-- Engine coolant temperature
-- Hydraulic oil temperature
-- SLU --oil level sensor and oil
pump

Stopping devices:
-- Compressor temperature
-- Hydraulic oil level
-- Engine oil pressure

Check the tightness of all electrical

connections.

Replace the vapour capsule in

electric box.

EVERY 2,400 HOURS

Test the fire extinguisher and

refilling.

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DX500/DX680/DX700/DX780/DX800 Maintenance manual

4.2.2. Rock drill

EVERY 50 HOURS

Check condition of accumulator

filling valves/caps.

Check accumulator pressures.

See Pressure accumulators
manual.

REMOVE FLUSHING HOUSING

max.1 mm max.1 mm
Check shank adapter.
The shank must be changed if the
2 mm bevel of the striking head or
1 mm of the splines is worn out or
Manufacturing 2 mm any other wear limit is execed.
Reject 1 mm

Check bearings of the flushing

housing.
The bearings must be changed if
the wear indication--groove has
worn out from any area as shown
in the picture.

Check coupling.
Pull the coupling out from the rota-
tion bushing. Check and replace, if
the edges of the inner teeth are
worn sharp.

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Maintenance manual DX500/DX680/DX700/DX780/DX800

EVERY 50 HOURS

Check rotation bushing.

Check the teeth and the bearing
surface for wear. Replace the
rotation bushing when the shoulder
A (see picture) is worn down to the
surface.

Check chuck.
The chuck inside the rotation
bushing must be changed if the
wear is over 1 mm (picture) or if
there are hairline cracks. The
chuck is changed by the hydraulic
press and punch.

Check front bearing of the gear

housing
The bearings must be changed if
the lubrication pocket has worn out
from any area as shown in the
picture.

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DX500/DX680/DX700/DX780/DX800 Maintenance manual

ASSEMBLE FLUSHING HOUSING

ROCK DRILL HL510 EVERY 50 HOURS

Tightening of flushing housing bolts
(3 pcs).
2 1. Lubricate the threads and the
nut faces with grease.
2. Pretighten to 150 Nm (15 kpm).
1 Correct tightening order is (1--2--3).
3 3. Final tightening torque is 300
Nm (30 kpm). Same tightening
(150 Nm) 300 Nm order (1--2--3) should be used.
ROCK DRILL HL650, HL710, HL800 EVERY 50 HOURS

Tightening of flushing housing bolts

(4 pcs).
1. Lubricate the bolt and nut
threads with grease.
2
2. Pretighten all four bolts to
4 300 Nm (30 kpm). Correct
tightening order is 1--2--3--4.
3. Final tightening torque is 600
3 Nm (60 kpm). Same tightening
1
order (1--2--3--4) should be
used.
(300 Nm) 600 Nm

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Maintenance manual DX500/DX680/DX700/DX780/DX800

ROCK DRILL HL 510 EVERY 50 HOURS

Check tie rods tightness.
Check the tightness of each bolt
by using 10  higher torque
than specified.
2
The joint being tested is loose if
the wrench turns. In this case
3
loosen all tie rod bolts.
Loosen also bolts between
carriage / rock drill.
1
1. Lubricate the threads and the
nut faces with grease.
4 2. Pretighten to 200 Nm (20 kpm).
Correct tightening order is
(200 Nm) 400 Nm 1--2--3--4.
3. Final tightening torque is 400
Nm (40 kpm). Same tightening
order (1--2--3--4) should be used.
ROCK DRILL HL650, HL710, HL800 EVERY 50 HOURS
Check tie rods tightness.
Check the tightness of each bolt
by using 10  higher torque
than specified.
The joint being tested is loose if
2 the wrench turns. In this case
loosen all tie rod bolts.
3 Loosen also bolts between
carriage and rock drill.
1. Lubricate the threads and the
nut faces with grease.
4 1 2. Tighten first slightly the rear
nuts (A) to bottom.
3. Pretighten the front nuts (B) to
B 200 Nm (20 kpm). Correct
tightening order is 1--2--3--4.
A
4. Final tightening torque is 400
(200 Nm) 400 Nm Nm (40 kpm). Same tightening
order (1--2--3--4) should be used.

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DX500/DX680/DX700/DX780/DX800 Maintenance manual

ROCK DRILL HL510 EVERY 50 HOURS

Check tightness of mounting
between carriage / rock drill.
Check the tightness of each bolt
by using 10  higher torque
than specified.
The joint being tested is loose if
the wrench turns. In this case
loosen all bolts between
carriage / rock drill.
1. Pretighten bolts A to 100 Nm
(10 kpm).
B A C 2. Pretighten bolts B to 100 Nm.
(100 Nm) 400 Nm
3. Pretighten bolts C to 100 Nm.
4. Tighten bolts A to 400 Nm
(40 kpm).
5. Tighten bolts B to 400 Nm.
6. Tighten bolts C to 400 Nm.

ROCK DRILL HL650, HL710, HL800 EVERY 50 HOURS

Check tightness of mounting
between carriage and rock drill.
Check the tightness of each bolt
by using 10 % higher torque
than specified.
The joint being tested is loose if
the wrench turns. In this case
loosen all bolts between
carriage and rock drill.
1. Pretighten bolts A to 300 Nm
(30 kpm).
B A C 2. Pretighten bolts B to 300 Nm.
(300 Nm) 600 Nm 3. Pretighten bolts C to 300 Nm.
4. Tighten bolts A to 600 Nm
(60 kpm).
5. Tighten bolts B to 600 Nm.
6. Tighten bolts C to 600 Nm.

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Maintenance manual DX500/DX680/DX700/DX780/DX800

EVERY 200 HOURS

Check pressure accumulator bolts
tightness.
Check the tightness of each bolt
by using 10 % higher torque
than specified.
The joint being tested is loose if
3 2 the wrench turns. In this case
loosen all pressure accumulator
bolts.
1. Lubricate the bolt threads with
grease.
2. Pretighten all four bolts to 100
Nm (10 kpm). Correct tightening
1 4 order is 1--2--3--4 (4--bolt
accumulator).
(100 Nm) 200 Nm
3. Final tightening torque is 200
Nm (20 kpm). Same tightening
order (1--2--3--4) should be
used.
ROCK DRILL HL 510 EVERY 200 HOURS
Check rotation motor bolts
tightness.
Check the tightness of each bolt
by using 10  higher torque
than specified.
The joint being tested is loose if
the wrench turns. In this case
1 3
loosen all bolts of rotation
motor.
1. Lubricate the bolt threads with
grease.
4 2 2. Tighten all four bolts to 80 Nm
(8 kpm). Correct tightening order is
80 Nm 1--2--3--4.
Check rotation motor bolts
tightness.

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DX500/DX680/DX700/DX780/DX800 Maintenance manual

ROCK DRILL HL650, HL710, HL800 EVERY 200 HOURS

Check rotation motor bolts
tightness.
Check the tightness of each bolt
by using 10 % higher torque
than specified.
(100 Nm) The joint being tested is loose if
3 the wrench turns. In this case
150 Nm
2 loosen all bolts of rotation
motor.
1. Lubricate the bolt threads with
grease.
2. Pretighten all four bolts to 100
1 4 Nm (10 kpm). Correct tightening
order is 1--2--3--4.
3. Final tightening torque is 150
Nm (15 kpm). Same tightening
order (1--2--3--4) should be
used.
ROCK DRILL HL650, HL710, HL800 EVERY 200 HOURS
Check idler gear shaft bolts
tightness.
(100 Nm) 200 Nm Check the tightness of each bolt
by using 10 % higher torque
than specified.
The joint being tested is loose if
the wrench turns. In this case
loosen all bolts of idler gear
shaft.
1. Lubricate the bolt threads with
grease.
2. Install the washers (new) and
the bolts. Pretighten the bolts to
100 Nm (10 kpm). Final tightening
torque is 200 Nm (20 kpm).

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Maintenance manual DX500/DX680/DX700/DX780/DX800

ROCK DRILL HL 510 EVERY 200 HOURS

Check rear cover bolts tightness.
(100 Nm) 200 Nm Check the tightness of each bolt
by using 10  higher torque
than specified.
The joint being tested is loose if
3 2
the wrench turns. In this case
loosen all bolts of rear cover.
1. Lubricate the bolt threads with
1 4 grease.
2. Pretighten all four bolts to 100
Nm (10 kpm). Correct tightening
order is 1--2--3--4.
3. Final tightening torque is 200
Nm (20 kpm). Same tightening
order (1--2--3--4) should be used.
ROCK DRILL HL650, HL710, HL800 EVERY 200 HOURS
Check rear cover bolts tightness.
Check the tightness of each bolt
by using 10 % higher torque
than specified.
The joint being tested is loose if
the wrench turns. In this case
loosen all bolts of rear cover.
1. Lubricate the bolt threads with
grease.
2. Install the washers (new) and
(200 Nm) 400 Nm the bolts.
2. Pretighten all four bolts to 200
Nm (20 kpm). Correct tightening
order is 1--2--3--4.
3. Final tightening torque is 400
Nm (40 kpm). Same tightening
order (1--2--3--4) should be used.

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DX500/DX680/DX700/DX780/DX800 Maintenance manual

4.2.3. Chain feed

EVERY 50 HOURS

Lubricate all the greasing points

(see the Technical manual).

Check rock drill carriage / feed rail

clearance.

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Maintenance manual DX500/DX680/DX700/DX780/DX800

EVERY 200 HOURS

Check condition of the retainer

centralizer jaws (1).

Check feed gear oil level (2).

(DX500, DX680)

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DX500/DX680/DX700/DX780/DX800 Maintenance manual

4.2.4. Rod handler

EVERY 50 HOURS

Lubricate all the greasing points

(see the Technical manual).

Check visually the condition of the

rod changer jaws and cylinder
mountings.

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Maintenance manual DX500/DX680/DX700/DX780/DX800

4.2.5. Boom
EVERY 50 HOURS
Grease all the greasing points.

EVERY 600 HOURS

Check the weldings of boom and

cradle.

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DX500/DX680/DX700/DX780/DX800 Maintenance manual

EVERY 600 HOURS

Check the mountings of hydraulic

cylinders (1).

Tighten bolts of expansion pins in

cylinders correct tightness 290 Nm.

EVERY 1,200 HOURS

1

Check clearance of the cradle (1).

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Maintenance manual DX500/DX680/DX700/DX780/DX800

4.2.6. Carrier
EVERY 50 HOURS
2
Grease the oscillation shafts (1).

Grease the oscillation cylinder pins

(2).
1

Check the condition and mounting

of winch rope (1).

IF ANY OF THE ILLUSTRATED

DEFECTS ARE DETECTED, THE
WIRE ROPE MUST BE
REPLACED. For more detailed
information on checking and
discarding a wire rope, see ISO
standard 4309.

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DX500/DX680/DX700/DX780/DX800 Maintenance manual

EVERY 50 HOURS

Check the electrolyte and

connections in the batteries.

EVERY 200 HOURS

2
1

Check the final drive oil level.

1. Oil filling plug
Oil level 2. Oil checking and draining plug

When checking oil level the drain

plug must be in position (ref. fig.).

Check the operation of brakes.

Check oil level in the winch.

A = Oil drain
E = Oil fill

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Maintenance manual DX500/DX680/DX700/DX780/DX800

EVERY 600 HOURS

2
1 Change the final drive oil.
1. Oil filling plug
2. Oil checking and draining plug

Oil level When oil is added, the oil filling and

drain plugs must be in position (ref.
fig.).
When adding the oil, open both
plugs. Oil capacity is 2 L. Ref. Oil
recommendation for quality of oil.

Check that there are no fractures in

the welding seams.

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DX500/DX680/DX700/DX780/DX800 Maintenance manual

EVERY 1,200 HOURS

Change cabin air filters (inner

circulation and intake filter) (1).

Change transfer gear oil (1).

EVERY 2,400 HOURS

Change the winch oil.

Oil is drained out through plug A

and filled/added through plug E.

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Maintenance manual DX500/DX680/DX700/DX780/DX800

4.2.7. Engine
Refer to your engine operation and maintenance manual to get the detailed instructions.

EVERY 50 HOURS

Check air intake lines and

connections.

Clean radiator core.

EVERY 200 HOURS

Change engine oil.

Oil drain plug (1).
Oil fill (2).
Dip stick (3).

Change engine oil filter (4).

Check alternator (5).

5
2 3
1 4

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DX500/DX680/DX700/DX780/DX800 Maintenance manual

EVERY 200 HOURS

Clean the crankcase breather (1).

Clean the air intake filter (1)

2 1
The filter element must be cleaned
or replaced when the service
indicator shows red. The filter
element must be replaced at least
every 600 hours or every 6 months.
The filter element can be
cleaned max. six times. Note that
the filtering capacity and
structure of the element are
weakened after every cleaning.

When the filter element is

cleaned or changed the safety
filter element (2) must be kept in
place.

The safety filter element (2) must

not be cleaned.

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Maintenance manual DX500/DX680/DX700/DX780/DX800

EVERY 600 HOURS

2 1
Change the air intake filter (1).

The safety filter element (2) must

be replaced when the filter element
has been replaced three times, or
at least every 1200 hours.

EVERY 1,200 HOURS

2

Change the safety filter element

(2).

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DX500/DX680/DX700/DX780/DX800 Maintenance manual

EVERY 1,800 HOURS

2 Service radiator hoses and

connections.
S

Change engine coolant (2).

Intercooler and hoses

Check valve clearances.

EVERY 3,600 HOURS

Change thermostat of cooling

system.

Check belt tensioner.

Check crankshaft vibration

dampers.

Check engine mounts.

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Maintenance manual DX500/DX680/DX700/DX780/DX800

EVERY 5,000 HOURS

Check starter motor.

Check turbo charger.

Check water pump.

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4.2.8. Fuel system

EVERY 50 HOURS

Drain fuel tank water trap.

EVERY 200 HOURS

Change fuel prefilter (1).

Change water separator element

(2).

1 2

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Maintenance manual DX500/DX680/DX700/DX780/DX800

EVERY 600 HOURS

3

Change fuel tank breather (3).

EVERY 1,200 HOURS

Clean fuel tank.

4.2.9. Hydraulics
EVERY 50 HOURS
1

Clean the radiator core (1).

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EVERY 600 HOURS

3 Check the temperature sensor (1).

4
Change the oil pressure filter (2).
2

Change the oil return filter (3).

1
Change the breather (4).

EVERY 1,200 HOURS

Change hydraulic oil.

1
Clean hydraulic oil tank.

Check operation of oil level

indicator (1).

Change stabilizer pressure filter

OPTIONAL (only when the rock drill is
equipped with a stabilizer).

EVERY 2,400 HOURS

1

Clean anti--jamming valve strainer

(1).

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Maintenance manual DX500/DX680/DX700/DX780/DX800

4.2.10. Air circuit

EVERY 50 HOURS

Air intake lines and connections.

EVERY 200 HOURS

2 1 Clean the air intake filter (1).
The filter element must be cleaned
or replaced when the service indi-
cator shows red. The filter element
must be replaced at least every
600 hours or every 6 months.
The filter element can be
cleaned max. six times. Note that
the filtering capacity and struc-
ture of the element are weak-
ened after every cleaning.
When the filter element is
cleaned or changed the safety
filter element (2) must be kept in
place.
The safety filter element (2) must
not be cleaned.

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DX500/DX680/DX700/DX780/DX800 Maintenance manual

EVERY 600 HOURS

2 1
Change the air intake filter (1).

The safety filter element (2) must

be replaced when the filter element
has been replaced three times, or
at least every 1,200 hours.

EVERY 600 HOURS

Change the compressor oil filter

(1).

Change the compressor oil (2).

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Maintenance manual DX500/DX680/DX700/DX780/DX800

EVERY 600 HOURS

Check alarm and shut down

temperature switches (1).

EVERY 1,200 HOURS

2
1 Clean the oil regeneration line
strainer (1) and orifice (2).

Change the safety filter element

(2).

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EVERY 2,400 HOURS

Change oil separator elements (1)

1 4 pcs.

Clean oil receiver.

4.2.11. Dust collector

EVERY 50 HOURS

Check precyclone rubbers.

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Maintenance manual DX500/DX680/DX700/DX780/DX800

EVERY 50 HOURS

Check fine collector reflector

rubber.

Grease lubrication points of the

movable suction head.

EVERY 200 HOURS

Check suction head rubbers.

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EVERY 200 HOURS

Check condition of fine collector

rubber elbow.

Check operation of closing cylinder

and suction control flap
mechanism.

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Notes:

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