DX500, DX680, DX700 DX780, DX800

Operator’s manual
Operator’s manual DX500/DX680/DX700/DX780/DX800

2 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

PREFACE

Congratulations on your choice of Sandvik drilling rig.

This manual describes the use of DX500/DX680/DX700/DX780/DX800 drilling rigs. Only
those who have been given proper training are allowed to operate the rig. The operator
shall also read and fully understand the contents of the User Manual and the Safety
Instructions.
The manual gives you such information on the structure and operation of the rig that is
necessary for correct use and maintenance. It also guides you in performing the
maintenance each shift. Periodical maintenance is explained in the Maintenance
Instructions.
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

B 05068--4 en 0807/PIR 3 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

1. INTRODUCTION TO MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1. Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2. Recommended operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3. Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2. SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.1. Operator safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2. Main safety hazards in use or maintenance work . . . . . . . . . . . . . . . . 15
2.3. Dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.3.1. Protection from dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.3.2. Dust collector system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.4. Warning sign locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.5. Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.6. Symbol plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.7. Centre of gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.8. Gradient angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.8.1. Tramming and parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.8.2. Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.9. Danger areas during tramming and drilling . . . . . . . . . . . . . . . . . . . . . . 26
2.9.1. Tramming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.9.2. Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.10. Manners and conditions of operation where the rig is not
allowed to be operated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.10.1. Risk factors for personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.10.2. Risk factors for rig and working site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.11. Noise level and noise emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.12. Acceleration value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.13. Safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.14. Location and use of fire extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.15. Emergency stops and stopping devices . . . . . . . . . . . . . . . . . . . . . . . . 30
2.15.1. Emergency stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.15.2. Safety wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.16. Automatic stop functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.17. Tramming stop device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.18. Dual tramming prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.19. System for stopping drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

4 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

3. OPERATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.1.1. Left hand panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.1.2. Drilling control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.1.3. Drilling pressure gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.1.4. Rod handling control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.1.5. Right hand panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.1.6. Boom control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.1.7. Roof panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.1.8. Engine control display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.1.9. Remote control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.1.10. Air conditioning unit (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.2. Operation in cold weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.3. Main switch and fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.3.1. Main switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.3.2. Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.4. Welding of the rig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.5. Routine checks before starting a shift . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.6. Starting diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.6.1. Engine running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.6.2. Stopping engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.7. Tramming instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.7.1. Before tramming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.7.2. Tramming position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.7.3. Tramming from cabin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.7.4. Oscillation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.7.5. Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.7.6. Tramming with remote control, and using winch . . . . . . . . . . . . . . . . . . 74
3.7.7. Tramming to another drilling site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.7.8. Moving to the next hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.8. Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.8.1. Releasing the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

B 05068--4 en 0807/PIR 5 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

3.9. Drilling instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

3.9.1. Principle of percussive drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.9.2. Shank lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3.9.3. Drilling equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.9.4. Safety considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
3.9.5. Loading drill rods into cassette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
3.9.6. Positioning and support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3.9.7. Collaring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
3.9.8. Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
3.9.9. Drilling parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3.9.10. Adding drill rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3.9.11. Ending drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
3.10. Turning feed to horizontal drilling position . . . . . . . . . . . . . . . . . . . . . . 99
3.10.1. Turning to horizontal drilling to the right . . . . . . . . . . . . . . . . . . . . . . . . . 99
3.11. Transporting the rig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3.11.1. Driving onto transport wagon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3.12. Storing instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3.13. Lifting methods and lifting points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3.14. Extra equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3.14.1. Flushing automatics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4. OPERATOR TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

6 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s 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.

B 05068--4 en 0807/PIR 7 (108)

Operator’s 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
3. Body cylinder
7
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

8 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

3. Rod handler

1 1. Upper end of rod handler

2. Lower end of rod handler
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

B 05068--4 en 0807/PIR 9 (108)

Operator’s 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

10 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

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

B 05068--4 en 0807/PIR 11 (108)

Operator’s 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
3. Hydraulic pumps
5
4. Side pump
5. Transfer gear

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

4
1

12 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

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

B 05068--4 en 0807/PIR 13 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

2. SAFETY INSTRUCTIONS
2.1. Operator safety instructions

Operation, maintenance, and adjustments are only allowed to persons

with specific training in operation and maintenance of the equipment.
Read the operating and maintenance instructions before using or
WARNING
servicing the equipment.

Plan your work carefully in advance to avoid possible accidents and

injuries. The operator must be familiar with the functions of the
equipment before using or servicing the equipment.
WARNING

The operator must always wear required personal protection, such as

safety helmet, protective overall, safety boots, hearing protectors,
safety goggles, etc.
WARNING

The drilling equipment must always be kept clean of oil and dirt. Service
operations should be carried out only when the rig is stopped. Use the
correct tools suitable for the work. Replace or repair faulty tools and
CAUTION
equipment. Make sure that there are no unauthorized persons in the
working area when you carry out service and repair work.

If you have to weld the rig, disconnect the alternator cables or open the
.. main switch before starting to weld. Consider also the fire and explosion
risk caused by welding. Make sure that the rig and its surroundings are
WARNING clean and fire-- safe.

The compressor air/oil receiver is pressure vessel and it is no allowed to

be repaired without proper authorization.

WARNING

Always have a fire extinguisher at hand, and learn how to use it. Have the
extinguisher inspected and serviced regularly according to the local
regulations.
CAUTION

When operating in confined conditions the exhaust gases and dust must
be directed in such a way that they do not return to the working area and
create a hazard.
WARNING

14 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

2.2. Main safety hazards in use or maintenance work

Make sure that there are no unauthorized persons in the working area
during drilling or tramming.

WARNING

Hazardous moving and rotating parts (boom, feed, drilling rig, hatches,
and grills). MAKE SURE THAT THERE ARE NO PERSONS IN THE
DANGER ZONE.
WARNING

Keep an eye on the movements of the drilling equipment if you are

working near the rig. Especially watch out for the rotating drill rod.
WARNING

Hazardous boom movement. Make sure that the boom is properly

supported before servicing the hydraulic system.
WARNING

Observe the balance of the rig. Never exceed the specified inclination
Max. angles when parking, tramming, or drilling.

WARNING

Slipping, tripping or falling hazard. Keep stairs, steps, handrails,

handles, and work platforms clean of oil, dirt, and ice.

WARNING

Danger of high pressure air streams. The air streams can cause serious
personal injuries. Release the pressure before opening filling caps or
pneumatic connections.
WARNING

Danger of high pressure oil jets. High pressure oil jets can cause serious
personal injuries. Release the pressure in the hydraulic circuit before
opening caps or connections.
WARNING

B 05068--4 en 0807/PIR 15 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

2.3. Dust

Drilling creates dust, which may stay at the drilling site and its surroundings even when
you are not drilling.
Dust may be so fine that it cannot be seen. The fine unseen dust is very dangerous if
breathed by the operator.

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

2.3.1. Protection from dust

-- Always use a respirator approved by the respirator manufacturer for the job you
are doing when outside the cabin. Make sure that the respirator is in good
condition.
-- Always keep the cabin door closed.
-- Keep the cabin clean. Clean the cabin with a vacuum cleaner daily.
-- Change the cabin air filter regularly. Use only original spare parts.

2.3.2. 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 when 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.
You should use the DustMizer --system, which keeps dusting at a more reduced level and
is available as optional equipment.
Using the correct drilling parameters and keeping the drilling equipment in good condition
reduces the amount of created dust.

Safe use of the machine requires skilled maintenance personnel trained

by Sandvik, and using only original spare parts. The daily and periodical
checks and maintenance must be carried out according to the
CAUTION
instructions.

16 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

2.4. Warning sign locations

4 5

6 7 2

B 05068--4 en 0807/PIR 17 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

WARNING ! WARNING
DO NOT OPERATE THIS VEHICLE UNLESS YOU: 17_
1. Have read the operator’s / service manual. 24_
2. Understand and observe all cautions and warnings.
3. Have been fully trained. 22_
24_
Do not work under the boom when drilling. 20_
Before tramming turn the boom to a tramming position. DX
Before tramming turn feedrail to a horizontal position. 19_
Before removing oscillation cylinders or performing any maintenance Roll over hazard.
under the unit, securely position the footpiece against a solid surface Can cause severe
and support main frame rear end, and the boom is safely blocked.
injury or death.
The track oscillation cylinders must be locked when the crawler is
being hosted or transported on a vehicle.
When drilling:
S do not exceed given
Never operate with less than three (3) rope coils remaining on the
winch drum.
gradient angles
S keep oscillation
EN ID= 233 040 78 cylinders locked
1 1

! DANGER SAFETY ! WARNING

INSTRUCTIONS
G Fasten seat belt. max 20˚ max 20˚
G Do not operate Roll over hazard.
with doors open and Can cause severe
unlatched. injury or death.
Hazardous voltage. G Stop engine when When tramming:
Can cause severe servicing, adjusting S keep boom in
injury or death. tramming position
and refueling.
Be extremely careful S do not exceed
when approaching GDo not leave given gradient
power lines or running when angles
cables. unattended.
EN ID = 232 898 48 EN ID = 233 045 08
EN ID = 233 038 88

1 1 1

1, 3, 8

18 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

! WARNING ! WARNING ! WARNING

High pressure air Hazardous moving

injection hazard. Hazardous boom and rotating parts.
Can cause severe motion.
Can cause severe
injury. Can cause bodily injury.
Relieve pressure injury.
Do not enter work-
before removing Secure boom ing range with
filler plug or before servicing machine in opera-
fittings. hydraulic system. tion.
EN ID = 232 482 66 EN ID = 207 339 48 EN ID = 207 329 38

3 4 5

WARNING WARNING

! WARNING

Danger of getting
tangled in the drilling Danger of burn injuries.
Roll over hazard.
rod. Can cause severe injury. Can cause severe
Can cause severe injury Do not touch the hot injury or death.
or death. surfaces of the rig. Water tank must
Do not install the drilliin be locked in
rod into a rotating shank operating position
during tramming
or rod and drilling.
EN ID = 550 306 99 EN ID = 233 458 08
EN ID = 550 317 32

4 7 2

WARNING!
DO NOT ENTER
MACHINE OPERATING
DISTANCE!

EN ID = 232 247 08

B 05068--4 en 0807/PIR 19 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

2.5. Type plate

55055051-- B

20 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

2.6. Symbol plates

Main switch, carrier

If towing is required, tramming motors must

be released.

Lifting from marked points only.

Fuel tank / filling.

Compressor’s pressure regulator.

Main fuses

B 05068--4 en 0807/PIR 21 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

Engine air filter

High noise level. Wear hearing protection

when the diesel engine is running.

To equalize thermal tensions, allow the diesel

engine to idle 3 minutes before stopping.

Disconnect the battery cables or turn the main

switch off and disconnect connectors from the
ECM before welding the rig. See chapter
Welding of the rig.

CHECK COMPRESSOR
OIL LEVEL BEFORE Checking compressor oil level
STARTING THE ENGINE.

Never operate with less than three (3) rope

coils remaining on the winch drum.

22 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

2.7. Centre of gravity

Centre of gravity with boom arm cylinder in maximum length and arm in horizontal position
and the feed against the transport support.

1350

1200

1100

B 05068--4 en 0807/PIR 23 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

2.8. Gradient angles

On slippery surfaces, e.g. ice or smooth rock, safe tramming and drilling
gradients are much smaller than on surfaces with good grip.

WARNING

Water tank must be locked in operating position during tramming and

drilling.

WARNING

2.8.1. Tramming and parking

In gradients over 20_, winch must be used.

WARNING

Keep the boom in forward position and the feed against the transport
support.

WARNING

Do not exceed given gradient angles.

Max. 20_
Max. 20_

24 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

2.8.2. Drilling
The diagram below shows the maximum gradient angles in all directions when drilling in
different boom positions.

17_

24_

24_ 22_

20_

19_

Upper carriage extra turn (optional)

Roll over hazard. Can cause severe injury or death. Do not exceed given
gradient angles.
Observe extreme caution when drilling with upper carrier turned to the
WARNING side and the boom at its extreme position.

B 05068--4 en 0807/PIR 25 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

2.9. Danger areas during tramming and drilling

2.9.1. Tramming

3m
3m

3m

3m

2.9.2. Drilling
6m

6m
3m
6m

26 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

2.10. Manners and conditions of operation where the rig is not

allowed to be operated
2.10.1. Risk factors for personnel

D Operator does not have sufficient training

D Unauthorized persons are present in the working area
WARNING
D Safety systems are deficient or out of order
D The field is charged
D Transportation of persons
D Use of rig for lifting purposes

2.10.2. Risk factors for rig and working site

D Risk of terrace cave--in under the rig

CAUTION D Risk of loose boulders falling on the rig
D Icy or otherwise slippery drilling site
D Drilling near overhead power lines with a danger of contact with live
lines
D Insufficient lighting

2.11. Noise level and noise emission

The measurement of the noise emission and the noise level at the operator’s positions
have been measured in accordance of European Standard Drill Rigs -- Safety EN 791.

D Sound pressure level at the operator’s position . . . . LpA 80 dB (A)

ISO 11201--1995
D Sound power level emitted by the machinery
(when drilling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LwA 126 dB (A)
ISO 4872--1978

2.12. Acceleration value

The measurement of the acceleration value at the operator’s positions have been
measured in accordance of European Standard Drill Rigs -- Safety EN 791. Acceleration
value does not exceed 0,5 m/s2.

B 05068--4 en 0807/PIR 27 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

2.13. Safety equipment

Check the emergency stop buttons and safety equipment for proper
operation and condition at the beginning of each shift and always after
tramming.
WARNING

Fire extinguisher
Emergency stop buttons
Safety rope
Tramming prevention device (cabinet door open)
Dual tramming prevention
Back up alarm
Rear view mirror
Anti--slip strips
R.O.P.S./F.O.P.S. cabin
Cabin noise insulation < 80 dBA
Roof hatch (emergency exit)
Warning signs
Rig tilt angle indicators
Rear jack warning light

28 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

2.14. Location and use of fire extinguisher

The fire extinguisher is mounted to the side wall of the cabin.

Read the operating instructions on the fire extinguisher bottle. Make

sure that the extinguisher gauge needle is not in the red sector. If the
needle points at red, the extinguisher must be serviced at once by
WARNING authorized service.

In case of fire:
1. Stop the engine.
2. Take the extinguisher from its holder.
3. Turn the extinguisher a few times up and down to mix the contents.
4. Pull the safety pin and take the hose from its holder.
5. Stand firmly, take a good grip of the hose, and direct it towards the heart of the fire.

6. Spray the chemical by squeezing the extinguisher handle. As soon as the fire dies,
stop spraying to save extinguishing power for possible reignition.
7. The extinguisher bottle must always be filled by authorized service after use.

B 05068--4 en 0807/PIR 29 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

2.15. Emergency stops and stopping devices

2.15.1. Emergency stops

Always ensure free access to the emergency stops.

WARNING

Check the operation of the emergency stops daily.

WARNING

When any of the emergency stop buttons is depressed, the engine stops at once and all
functions with it. The indicator light in panel lights up. The engine cannot be started until
the emergency stop button has been released.

Emergency stop
indicator light

Emergency stop Emergency stop

button button

30 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

Emergency
stop button

Emergency
stop button

2.15.2. Safety wire

If the safety wire is pulled hard enough, or if it loosens, drilling and rod handling functions
stop, as well as the dust collector. The engine remains running. Resetting is done by
pushing the safety wire reset button.
Before resetting the device, check that the rod handling and drilling
controls are not in any operating position.

WARNING

1. Feed safety wire

2. Safety wire reset button

B 05068--4 en 0807/PIR 31 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

2.16. Automatic stop functions

The engine stops automatically if

1. hydraulic oil level in tank drops too low; indicator light in panel lights up.
2. compressor temperature rises above 115_C; indicator light in panel lights up.

The engine first drops to idling speed and stops after a short delay if:
3. engine oil pressure drops too low. At the same time the indicator light on the user
panel goes on and the control display displays a notice.
4. engine cooling water level drops too low. At the same time the control display
displays a notice.

Oil pressure

Cooling water level

32 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

2.17. Tramming stop device

The rig is equipped with a device that prevents tramming when the cabin door is open.
The device also stops the rig if the door is opened during tramming.
When remote control is used, the door can be open.

2.18. Dual tramming prevention

Fast tramming speed

Simultaneous tramming from cabin and
with remote control is prevented. Slow tramming speed
Tramming mode is selected in the cabin
with the right hand panel switch S7.
Tramming with remote control
(slow tramming speed) indicator
light goes on

2.19. System for stopping drilling

The rig is equipped with a system for stopping drilling via a safety wire (see 2.15.2.).
In addition, a function can be enabled that stops rotation and drilling when the cabin door
is opened.
This function releases the magnetic locking of the joystick and brings the joystick to the
centre position.
The function can be enabled by disengaging the loop coupler (see the wiring diagram).

B 05068--4 en 0807/PIR 33 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

3. OPERATION INSTRUCTIONS
3.1. Controls

17 44

13
18 77
12

22
66
33
15
15 19
14 19
55
16
8

99 10
11
11
11

34 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

1. Left panel Selector switches for drilling--related functions

2. Rod handling panel Rod handling, control levers
3. Right panel Start, oscillation, auxiliary tramming functions etc
4. Roof panel Indicator lights, gauges, washers, and lights
5. Joystick Drilling control
6. Pilot control valves Boom control
7. Pressure gauges Drilling pressure gauges
8. Adjusting valve Feed pressure
9. Pilot control valves Tramming control
10. Adjusting valve Adjustment of half flushing flow
11. Adjusting valve Rotation speed
12. Display unit TIM
13. Sight TIM
14. Regulating valve Adjustment of water amount in water injection
15. Foot pedal Thread greasing
16. Hand throttle Adjustment of engine running speed
17. Connector Engine programming / Service monitoring
18. Emergency stop
19. Emergency stop

B 05068--4 en 0807/PIR 35 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

3.1.1. Left hand panel

S108 S23 S45 S16 S46

Percussion--feed follow--
S108 Upper carriage left (extra up off = max. percussion,
turn) S23 indicator light goes on
H42

Percussion--feed
follow--up on
Upper carriage right
(extra turn) Forced flushing if S18 is
ON
NOTE! When using the upper carriage extra turn (S108), the extra turn has to be
made all the way to one of the extremes.
Water injection or
DustMizer liquid mixed
S45 Extra S16 with flushing air

Off

DustMizer liquid into dust Water injection or

collector DustMizer liquid mixed
with flushing air during
percussion on
S46 Suction off

Dust collector on / off

Dust collector on =
indicator light goes on

36 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

S243 S24 S17 S18

S24 Anti--jamming automatics

S243 Close guiding pito on (rotation pressure)

Anti--jamming
Open guiding pito
automatics off
Blow--down automatics,
Flushing control
if dust collector (S46) is
S17 automatics on S18 on, max. flushing

Flushing control Blow--down automatics

automatics off off and flushing off

Blow down automatics, if

Power extractor on dust collector (S46) is
on, half flushing

B 05068--4 en 0807/PIR 37 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

3.1.2. Drilling control

1 Fast feed (S21)

2 Max. percussion pressure (S22)

3 Percussion off/on (S19)

4 Magnetic lock release (S20)

fast feed

drilling/perc.-- feed down

feed follow--up
1/2
perc.

thread loos- full power

perc. off fast rotation ening with percussion
feed up fast
rotation 1/2 perc.
rotation

fast feed

Fast feed goes on every time button 1 is depressed.

WARNING

38 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

3.1.3. Drilling pressure gauges

Rotation Feed
Percussion Flushing
Stabilizer
(optional)

B 05068--4 en 0807/PIR 39 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

3.1.4. Rod handling control

Rod to cassette

Upper Upper
gripper open gripper close

Rod to drilling centre

Suction head down

Lower
Lower gripper close
gripper open

Suction head up

Threading close

Pito open Pito close

Threading open

40 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

3.1.5. Right hand panel

S2
S3
S7
S5
S700

S2 Ignition key S3 Emergency stop

STOP

I Control current on
START

S5 S700 TIM off

Signal horn

Flame start TIM on

S7 Fast tramming

Slow tramming

Tramming with remote

control (slow) indicator
light goes on

Risk of overturning. Can cause serious injuries or death. The controls in

the cabin do not work when the switch S7 is in the remote control
position.
WARNING

B 05068--4 en 0807/PIR 41 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

H27 S26
S25

Left track oscillation locked, both indicator

lights off
S25 H27

Both tracks unlocked, indicator lights on

H26
Right track oscillation locked, both indicator
lights off

Risk of overturning. Can cause serious injuries or death. During drilling

one track must be kept locked.

WARNING

If both indicator lights are not on when the switch S25 is in the middle
position, there is a fault within the control system. Check the control
system and repair the fault before use.
CAUTION

When the ignition key (switch S2) is in the STOP position, both tracks are
locked and their indicator lights are off.
CAUTION

S26
Oscillation forwards, cabin tilts forwards.
Indicator light for unlocked track comes on.

Oscillation backwards, cabin tilts backwards.

Indicator light for unlocked track comes on.

42 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

S35

S15 S104

Rear jack up,

Front ground jack up S15 indicator light goes off
S35 H23

Rear jack down,

Front ground jack down
indicator light goes on

Close noise killer

S104
H104 The indicator light turns
on when the rock drill is
against the front limiter

Open noise killer

B 05068--4 en 0807/PIR 43 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

3.1.6. Boom control

Lower end of feed forwards

Lower end of Lower end of feed right

feed left

Lower end of feed backwards

Boom front arm up

Boom rear arm up

Boom rear arm down

Boom front arm down

Feed down

Upper carriage left Upper carriage right

Feed up

44 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

3.1.7. Roof panel

B 05068--4 en 0807/PIR 45 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

Compressor temperature Hydraulic oil temperature

Fuel amount *

*The indicator light starts flashing when there is approx. 60--80 litres of fuel left in the tank.
The warning can be acknowledged by pressing the button. Using the diesel engine when
the fuel level is low is not recommended.

46 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

H10 H9 H8 H7 H6

H5 H4 H3 H2 H1

H10 Hydraulic oil return filter H9 Hydraulic oil level

indicator light indicator light

H8 Hydraulic oil temperature

H7 Charging indicator light
indicator light

H5 Hydraulic oil pressure

H6 Extra
filter indicator light

H4 Emergency stop indicator H3 Compressor

light temperature indicator light

H2 Engine error warning light H1 Inlet heater

B 05068--4 en 0807/PIR 47 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

3.1.8. Engine control display

48 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

B 05068--4 en 0807/PIR 49 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

S13 S10 S6

H99 S14 H94

H99 S13 Tramming lights

Central lubrication

Spotlight for pressure

S14 S10 gauges
Drilling lights

Spotlight for pressure

gauges plus cabin light
Shank lubrication
Hydraulic oil preheating,
working, green indicator
S6 indicator light goes on
light
H93
H41

Shank lubrication
disturbance (stops
H94 drilling) or shank
lubrication oil level low,
red indicator light

50 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

S92

The engine idle revolution speed is 1400 rpm.

S92 It can be adjusted between 1400 ---- 2200 rpm with the hand
lever (when percussion or flushing is NOT on).
If percussion or flushing is used the revolution speed will be
automatically adjusted to 2200 rpm.

The engine idle revolution speed is 1400 rpm.

It can be adjusted between 1400 ---- 2200 rpm with the hand
lever (when percussion or flushing is on).
When percussion or flushing is used again, the revolution speed
will rise to the value set with the hand lever.

B 05068--4 en 0807/PIR 51 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

PS8 S8 S9 PS9

SM6--7

PS8 PS9
Windscreen wiper Roof screen wiper
intermittent intermittent

S8 SM6--7

Windscreen washer Roof screen washer

Windscreen wiper Windscreen washer

S9

Roof screen washer

Roof screen wiper

52 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

3.1.9. Remote control panel

S620

S613

S605

S604
S611 S601/H601

S611 Mushroom button Emergency stop

S601 Selector switch Power on/off,
spring return to middle position
H601 Indicator light Control current on in remote control panel
S620 Selector switch Oscillation locking; left locked / both unlocked / right
locked, switch keeps selected position
S605 Control lever Control of oscillation / ground jack, spring return to
middle position
S613 Control lever Winch control, maintains selected position, activated
when button at joystick (S604) top is depressed
S604 Joystick Tramming control, spring return to middle position,
activated when button at joystick top is depressed

B 05068--4 en 0807/PIR 53 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

S605 Control lever Oscillation forwards

Ground jack Ground jack

up down

Oscillation backwards

S613 Control lever Unwinding; rope maintains tension which

is set by pressure relief valve during tram-
Activated ming forward
when button
at top of
joystick
(S604) top is
depressed.
Winding Unwinding

Winding; rope tightens to tension set with

pressure relief valve, and keeps the ten-
sion during tramming backward

S604 Joystick
Forward
Depress
button

Right forward Left forward

Right forward Left forward

Left reverse Right reverse

Left reverse Right reverse

Reverse

54 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

3.1.10. Air conditioning unit (optional)

1. Fan switch
-- the switch is used to select one of the three fan speeds
-- the same fan is used for both ventilation and heating
-- ventilation works only when the fan is switched on (switch positions 1--3)
2. Operating switch of the heater
3. Air supply selector switch
-- opens and closes the air supply hatch
-- outside air can be drawn through a filter or cabin air can be recirculated
4. Operating switch of the ventilator / adjuster switch of the thermostat
-- switches on ventilation
-- used to set the correct temperature for the cabin
5. Filter for recirculated air

4
6
5

B 05068--4 en 0807/PIR 55 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

6. Nozzles
-- by changing the direction of the nozzles, the warm or cold air supplied by the fan
can be directed in the desired direction
7. Air filters, 2 pcs
-- located in the rear wall of the cabin
-- filters impurities out of the air
-- clean with pressurized air and change the filter cartridges regularly; service
intervals depend on the quality of the outside air but check the filters at least twice
a year -- in spring and in autumn
8. Exhaust air openings

56 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

Instructions for use

D Warm weather
-- Close the air supply hatch by turning the air supply switch (3) all the way to the end
position.
-- Switch off the heater by turning the heater switch (2) to the left--hand end position.
-- Switch on ventilation by turning the operating switch (4) to the right. Adjust the
thermostat if necessary.
-- Select the fan speed with the fan switch (1).
D Misty windows
-- Close the air supply hatch by turning the switch (3) to the right--hand end position.
-- Switch on ventilation by turning the switch (4) to the right. Adjust the thermostat if
necessary.
-- Switch on the heater by turning the heater switch (2) to the right as far as
necessary.
-- Select the fan speed with the switch (1).
D Cold weather
-- Close the air supply hatch by turning the switch (3) to the right--hand end position.
-- Switch on the heater by turning switch (2) to the right as far as necessary.
-- Switch off ventilation by turning switch (4) to the left--hand end position.
-- Select the fan speed with the switch (1).

B 05068--4 en 0807/PIR 57 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

How to make the most of the air conditioning

D Fan speed and air temperature are easy to adjust. Never use a higher fan speed
than necessary. If it feels cold in the cabin, always choose a lower fan speed before
adjusting the thermostat.
D Adjust the direction of the air nozzles to make the air flow feel as comfortable as
possible. Never direct the air flow towards yourself.
D Keep the indoor air recalculation switched on and the door closed. This ensures
the ventilation works most efficiently and problems of outside noise, exhaust
gases, dust etc. are avoided.
D Do not keep the cabin temperature too low. Keep in mind that your body does not
appreciate extreme variations of temperature. Test which temperature difference
is best for you. It is recommended that the indoor temperature is not more than
5--7_C below the outdoor temperature. Adjust the temperature according to what
you feel is comfortable, not according to the thermometer reading. Since
ventilating reduces humidity in the air, misty windows can be avoided by keeping
both ventilation and heating switched on.
D Moist air is difficult to breathe. The ventilator reduces the humidity in the cabin air
and makes you feel more comfortable.

3.2. Operation in cold weather

If the temperature is below 0_C, clear off ice from all steps and handles on the rig.
Note the instructions for engine cold start in the section on starting the diesel engine.
To warm up the hydraulic oil, turn the switch S6 on roof panel to the position for hydraulic
oil heating. Turn the switch back to the middle position when the oil has warmed up.
The speed of the oil cooler blower is adjustable. It may be advisable to lower the blower
rotating speed during winter.

Hydraulic oil heating,

indicator light goes on

58 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

A diesel fuel heater for warming up engine coolant, hydraulic oil, and cabin temperature
is available as an option.
In cold conditions, it is necessary to warm up engine coolant and hydraulic oil before
starting.

3.3. Main switch and fuses

3.3.1. Main switch
Main switch is located behind the rig.
3.3.2. Fuses
The main fuses (1 pc, 100A and 2 pcs, 50 A) are beside the diesel engine.

B 05068--4 en 0807/PIR 59 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

The other fuses F1 -- F17 (20 pcs) are inside the main switchgear.

F1 --- F 17 (20 pcs)

60 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

3.4. Welding of the rig

Never repair a boom or boom components or cylinders by welding.

CAUTION

There are electrical / electronic components which could damage when

welding the rig. The following procedure must be followed when welding
on the rig.
CAUTION

1. Stop the engine. Turn the switched power to the STOP position.
2. Open the main switch.
3. Disconnect the J1/P1 and J2/P2 connectors from the ECM. Move the harness to
a position that will not allow the harness to accidentally move back and make
contact with any of the ECM pins. ECM is beside the diesel engine.
4. Connect the welding ground cable directly to the part that will be welded. Place the
ground cable as close as possible to the weld in order to reduce the possibility of
welding current damage to bearings, hydraulic components, electrical / electronic
components, and ground straps.
5. Protect the wiring harness from welding debris and spatter.
6. Use standard welding practices to weld the materials.

J1/P1

J2/P2

B 05068--4 en 0807/PIR 61 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

3.5. Routine checks before starting a shift

Points to check before starting engine

Walk around inspection.
2 Check engine oil (1). The oil level
must be between ”add” and ”full”
marks.
5 Check engine coolant level (2),
tightness of radiator hoses and
connections.
Check tightness and condition of
v--belts (3).
Drain water separator (4).

Check water pump for leaks.

3 4
1 Check oil level in transfer gear (5).
The oil level should be between the
dipstick markings.

Check the hydraulic oil level.

Check the fuel amount.

62 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

Check compressor oil level.

Check oil level in shank

lubricator.

Check feed chain tightness and

condition.

B 05068--4 en 0807/PIR 63 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

ROCK DRILL HL510

Check visually mounting between

carriage / rock drill. Bolts A, B, C.
If bolt(s) are loosen or broken see
Maintenance manual.

B A C

ROCK DRILL HL510

2 Check visually flushing housing

bolts 3 pcs.
If bolt(s) are loosen or broken see
Maintenance manual.
1
3

ROCK DRILL HL650, HL710, HL800

Check visually mounting between

carriage / rock drill. Bolts A, B, C.
If bolt(s) are loosen or broken see
Maintenance manual.

B A C

ROCK DRILL HL 650, HL710, HL800

Check visually flushing housing

2 bolts 4 pcs.
4 If bolt(s) are loosen or broken see
Maintenance manual.

3
1

64 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

Check percussion hour meter

reading.

15...35 mm
Check track tension. The track is
correctly adjusted when the upper
stretch slack is 15--35 mm.

Check air suction hoses and

connections.

B 05068--4 en 0807/PIR 65 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

3.6. Starting diesel engine

Always make sure before starting that there are no unauthorized
persons in the danger areas of the engine and the drilling rig, and that no
controls are in the operating position.
WARNING

Starting cold engine

1. Turn the ignition key (switch S2) into position 1. Wait until the indicator lights blink
(c. 2 seconds).
2. Inlet heater operates automatically (indicator light H1 illuminates). When indicator
light goes off turn the ignition key into the START position. Do not run the starter
motor longer than 30 seconds at a time.

START

H5

S2 H1

3. Do not use hand throttle before engine runs smoothly.

4. If engine does not start turn the ignition key into position STOP and wait 3
minutes. Then operate again as points 1 and 2.
Wait 30 seconds before starting to drill. Compressor output begins 30
seconds after starting.
CAUTION

When the rig is started in cold weather, the pressure filter indicator light
(H5) may illuminate a few minutes before going off.
CAUTION

Using ether as starting aid is forbidden.

CAUTION

5. Other starting aids are recommended in temperatures below --18_C. Preheating

engine coolant and/or use of extra batteries may be necessary.
The engine cannot be started by towing.

CAUTION

66 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

Points to check when engine is running

Check compressor temperature.

Check coolant temperature (1).

1, 2

Check engine oil pressure (2).

Pressure should be 3--4 bar.

Check the tramming lights.

Check the working lights.

S13 S14

Check the function of the gauges.

B 05068--4 en 0807/PIR 67 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

Check operation of shank

lubrication.

Check the operation of emergency

stop switches and buzzer.

68 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

Check service indicators of

compressor and engine air filters.

Water separator / fuel filter:

-- Check the reading of the gauge
when the engine is running at full
speed.
-- Replace the filter element when
the needle is between 7 and 8
(inHG).
-- Never let the engine run when
the reading is over 9!

Check compressor oil filter service

indicator (1).

B 05068--4 en 0807/PIR 69 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

Check condition of dust collector

filters.

Check flushing housing seal

leakage control drain holes (1).
Check during drilling.

Check possible oil leaks.

Check during drilling.

Check that the rig has no oil leaks.

70 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

3.6.1. Engine running

The main health risks of the exhaust fumes of a diesel engine are
nitrogen oxides and carbon monoxide. GOOD VENTILATION MUST
ALWAYS BE ENSURED WHEN THE ENGINE IS RUN INDOORS.
WARNING

Check the following:

D The engine temperature warning light should be off. If the light goes on, stop the
engine at once.
D The engine oil pressure should show normal values (3--4 bar).
D Observe the other warning lights as well.
D Do not let the engine idle unnecessarily.

Never leave the rig running unattended.

CAUTION

3.6.2. Stopping engine

Before stopping the engine, allow it to idle for three minutes to equalize
thermal stresses.
CAUTION

Stop the engine by turning the ignition key into 0 position.

In danger situations the engine can also be stopped with one of the
emergency stop buttons.
CAUTION

Never turn the main switch off when the engine is running. This may
damage the alternator or the voltage regulator.
CAUTION

B 05068--4 en 0807/PIR 71 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

3.7. Tramming instructions

3.7.1. Before tramming
Check the following:
D Boom is in tramming position.
D Rear jack is up.
D There is enough space around the rig.
3.7.2. Tramming position
D Move the boom to tramming position (boom forward).
D Tilt the feed backwards until it rests against the transport bracket. Check that
hoses or cables are not squeezed and the feed does not collide with
anything.

Tramming position

3.7.3. Tramming from cabin

D Oscillation lock is kept open when tramming in normal conditions.
D Control tramming with the proper levers.
D The carrier hydraulic system is connected so that the left lever controls the left track
and the right lever the right track.
D Two tramming speeds are available: fast (rabbit symbol) and slow. Speed is
selected with the switch S7 in right hand panel. As a general rule, fast speed should
be used when the conditions are good and slow speed when moving between
holes, and in difficult terrain.
D To start the rig moving, push both control levers slowly forwards. The position of
the levers determines the tramming speed. Push the levers fully forwards if you
want to use maximum speed. When you want to reverse, pull the levers
backwards.
D If the rig lacks power in the fast speed range, centralize the tramming levers and
shift to slow speed range with the selector switch S7.

72 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

D If you want to turn right, push the left lever forward and centralize the right lever.
D For faster turning, push the left lever forward and pull the right lever backward. In
this situation, the selector switch S7 must be in the slow range.
D The selector switch S25 is used for separately locking the oscillation of the tracks.

3.7.4. Oscillation
Oscillation locking is usually kept opened during tramming. This guarantees the best
possible comfort and minimizes the stresses on the frame.
Roll over hazard. Can cause severe injury or death. Never exceed given
gradient angles.
When oscillation is unlocked, always keep the boom in the tramming
WARNING position and upper carriage aligned with tracks.

When tramming in uneven terrain, use oscillation to keep the rig as horizontal as possible.
This guarantees proper lubrication for the diesel engine, and the best possible balance
of the rig.
If only one track has to be driven over an obstacle, use oscillation to maintain balance.
Avoid sudden falling from the obstacle.

3.7.5. Stopping
D The rig is equipped with two drive gears with hydraulic motors. These units
incorporate spring--operated multiplate brakes that are released with hydraulic
pressure. The system is connected so that the brakes are always applied
automatically when the tramming control levers are in the middle position. The
brakes are released automatically when pressure is directed to drive motors.
D The tramming control levers should not be centralized too abruptly when the rig is
moving.

B 05068--4 en 0807/PIR 73 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

3.7.6. Tramming with remote control, and using winch

When the rig is steered with remote control, extreme caution must be
observed. The operator must stay outside the danger area (3 metres) on
the left side or behind of the rig. When tramming backwards operator
WARNING must not stay behind the rig. If the rig is used in a slope the operator
MUST NEVER STAY ON THE DOWNHILL SIDE OF THE RIG!

3m

Danger area

Safe area when using remote control

D Turn the selector switch S7 in control panel into the remote--control position.
D When the control current is switched on to the remote control panel, the rig can only
be controlled by remote control.
D If the remote control panel is disconnected from its socket, the emergency stop
circuit becomes activated and prevents the use of the rig. If you want to use the
rig with the remote control cable disconnected, a bypass plug must be inserted into
the socket.
D When tramming the rig with remote control, only the slow speed range is available.
D Oscillation forwards/backwards is controlled with the control lever S605.
D With the selector switch S620, oscillation of the tracks can be locked separately.

74 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

Using winch
Roll over hazard. Can cause severe injury or death. The specified max.
gradient angles (for drilling and tramming) are not allowed to be
exceeded when using winch.
WARNING

D Winch unwinding/winding is controlled by turning the control lever S613 left/right

while depressing the push button at the top of the joystick S604.
Fasten the winch wire rope to a firm point uphill.

WARNING

Make sure that the winch wire rope is not left under the ground jack.

WARNING

Never operate with less than three (3) rope coils remaining on the winch
drum.

WARNING

D The wire rope tensions automatically is during unwinding when the control lever
S613 is pushed forwards while depressing the push button at the top of the joystick
S604. The wire rope is kept tight during tramming forwards.
D The wire rope tensions automatically during winding when the control lever S613
is pulled backwards while depressing the push button at the top of the joystick
S604. The wire rope is kept tight during tramming backwards.
D The tension of the wire rope can be adjusted with a pressure relief valve located
on the left side of the rig, at the dust collector. A pressure gauge is provided for
making adjustments.

3.7.7. Tramming to another drilling site

D Before starting the engine, make ensure the tramming levers are in the middle
position.
D Start the engine as instructed earlier.
D Move the boom to the tramming position.
D Lift the rear jack up, if the rig is equipped with one.

3.7.8. Moving to the next hole

D Lift the boom upwards.
D Run the feed high enough to ensure that it does not hit the ground when you move
the rig.
D Select slow speed range with the switch S7 in the the right hand panel.

B 05068--4 en 0807/PIR 75 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

3.8. Towing
Extreme caution must always be observed when towing the rig.

WARNING

Make sure that the brakes of the towing vehicle are effective enough to
stop both vehicles under all circumstances.

WARNING

Do not try to start the rig by towing.

CAUTION

3.8.1. Releasing the brakes

If the rig is to be towed, the driving motors must be disconnected. Before doing so, make
sure that the rig cannot move by itself.

When the driving motors are disconnected, the rig has no brakes.

WARNING

Before disconnecting the motors (brakes), connect the rig to the towing
vehicle.

WARNING

Symbol sign

76 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

1 1

2
2 1

You need a 13 mm spanner to remove and fasten the screws.

The tightening torque of the screws is 20 Nm.
D Remove the two hex. head screws (1) from the cover (2).
D Remove the cover (2), turn it upside down, and fasten it back with the screws (1)
as shown.
Note that these procedures must be done on both driving gears.
When the brakes have been released, a rigid towing bar must be used. The max. towing
speed for the rig’s is 3.5 km/h.
Before disconnecting the rig from the towing vehicle, the driving gears
must be reconnected.

WARNING

B 05068--4 en 0807/PIR 77 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

3.9. Drilling instructions

3.9.1. Principle of percussive drilling

PERCUSSION

FEED
ROTATION

There are four main functions in percus-

sive drilling:

D Percussion, enabling drill bit

penetration into rock.
FLUSHING D Feed, keeping drill bit in tight
contact with rock.
D Rotation, turning drill bit into a
new position before next impact.
D Flushing, cleaning the hole of
drill cuttings and cooling the
drilling equipment.

The impact energy generated by the rock

drill piston is transferred to the rock
through the drill steels and the drill bit.

78 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

Percussion

The percussion power transmitted

through the drill string is a combination
of impact force and impact frequency.
This power is directly controlled by the
level of percussion PRESSURE.

One of the basic issues in drilling is the

energy transfer capacity of the drilling
equipment. There is a maximum kinetic
energy that can be transferred with
drilling equipment of a certain size.
When the energy transfer capacity of
the equipment is exceeded, equipment
damage increase rapidly.

The percussion power used depends

on the ground being drilled. If the rock
is soft, use pressure in the low end of
the range. If the rock is hard, you can
use pressure from the upper end of the
range.

Percussion pressure setting is usually a

compromise of penetration rate and
equipment durability.

B 05068--4 en 0807/PIR 79 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

Feed

The purpose of feed is to keep the shank in

tight contact with the rock drill and the drill bit
in tight contact with the rock.

When percussion pressure is increased, feed

pressure should also be increased. Correct
feed force depends on percussion pressure,
rock type, hole depth, and the size and type
of the drilling equipment.

Fractured rock should be drilled using low

percussion pressure and low feed pressure.

Optimal feed pressure can be obtained by

”looking” and ”listening”
LOOK for:
--smooth forward drifter movement
(no jumping or shaking about of the
feed cradle)
-- smooth rotation of the drill steel
(constant RPM)
-- tight shank joint (coupling not over-
heating/turning blue/smoking)
-- steady penetration rate
LISTEN for:
-- ”solid” percussion sound (not a ”rat-
tling” or vibrating sound)

Increased feed force does not increase the

penetration rate -- it will only increase bit
wear and cause hole deviation, bend rods
and cause higher than normal rotation
pressures.

Too little feed force results in the bit not being

in firm contact with the rock being drilled. If
this is allowed to happen, the percussion
energy will rebound back up the drill steel
(instead of going into the rock) causing
damage to the drill string, the rock drill and
the feed cradle.

80 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

Rotation

The main function of rotation in

percussion drilling is to turn the drill bit
to a new position after each blow from
the piston. Optimum rotation speed
depends on bit geometry, bit size and
rock drillability (hardness, abrasiveness,
etc.), and the other main functions of
drilling.

Too low rotation speed result in energy

losses due to recutting of the rock chips
and low penetration rates. The cuttings
come out of the drilled hole as grindings
rather than chips.

Too high rotation speed result in

excessive bit wear because the rock is
broken by rotation rather than
percussion. Higher than required drill bit
rotation speeds also lead to excessively
tightened couplings, causing uncoupling
problems.

B 05068--4 en 0807/PIR 81 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

Flushing

The purpose of flushing is to remove

rock cuttings from the drilled hole.
Flushing air travels to the bottom of the
hole through the drill string and the
holes in the drill bit. The rock cuttings
mix with the flushing air are blown out
of the drilled hole through the space
between the drill string and the hole
wall.

Poor flushing leads to a low penetration

rate (increased recutting), decreased
drill steel life, increased bit wear and an
increased possibility of jammed rods.

82 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

3.9.2. Shank lubrication

The purpose of shank lubrication is to lubricate the rotation mechanism and shank of the
rock drill. The pump unit pumps oil to the rock drill through the plastic tube inside the
compressed air tube. The compressed air distributes the oil to the lubrication points.

Oil tank

P T

Pump unit

Air

Flawless operation of shank lubrication is essential. Inadequate

operation quickly causes serious damage on the rock drill.
CAUTION

The operating panel has a green and a red indicator light. The green light indicates that
shank lubrication is operational. The red light indicates a malfunction in shank lubrication
and, at the same time, the drilling control lever returns to its middle position. The red light
also indicates low oil level in the oil tank, but in this case, the drilling control lever is not
returned to its center position.

Shank lubrication working

H93 green indicator light

Shank lubrication disturbance (stops

H94 drilling) or shank lubrication oil level low,
red indicator light

Always make sure that the shank lubrication oil you use meets the
specifications. Choose correct oil viscosity according to ambient
temperature.
CAUTION

B 05068--4 en 0807/PIR 83 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

3.9.3. Drilling equipment

Shank

Impact energy and rotation torque of rock

drill is transferred to drilling equipment
through shank.

Coupling sleeve

Coupling sleeves connect extension rods

to one another.

Extension rods

Both ends of an extension rod have

identical threads. Rod length is usually
10--12 ft. (300 -- 360 cm).

MF rods

MF rods have a male thread in one end

and a female thread in the other. Rod
lengths are the same as for extension
rods.

Drill tubes

Tube equipment have threads as in MF

rods. Drill tubes have large--diameter
flushing holes. Guide tubes are used in
difficult drilling conditions.

Drill bits

Button bit is the most common drill bit

type. Its advantages are good penetration
rate, durability, and easy resharpening.
Various types of button bits are available
for different drilling conditions.

84 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

Example of the use of different drilling equipment. Guide tube and special bit is used when
straight holes are required and the drilling conditions are difficult.

Shank Shank Shank

Coupling sleeve

MF rod MF rod
Extension rod

Coupling sleeve

Guide tube
MF rod

Extension rod

Drill bit

Drill bit Drill bit

B 05068--4 en 0807/PIR 85 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

3.9.4. Safety considerations

Note all matters concerning safety.

CAUTION

Always check the drilling site visually before starting the powerpack and
starting to drill.

WARNING

Make sure that all control levers are in the middle position before starting
the powerpack.

WARNING

Make sure that there are no unauthorized persons in the drilling area
before moving the boom or starting to drill.

WARNING

3.9.5. Loading drill rods into cassette

D Position the boom/feed into almost horizontal position.

D Clean the rod threads.
D Place a rod and its sleeve between the Pito jaws and close the jaws.
D Run the rock drill forwards and thread the shank into the sleeve.
D Open the jaws a little, and run the rock drill so far backwards that the rod still is
between the jaws.
D Move the grippers to the drilling centre and close the gripper jaws to guide the rod
(do not grip it with the jaws).
D Run the rock drill further backwards, to a position where the rod can be taken into
the cassette without hitting upper or lower end structures.
D Close the gripper jaws, and thread the shank out of the drill rod sleeve.
D Move the grippers to the cassette and open the jaws.
D You can load six drill rods into the cassette as described above.

86 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

3.9.6. Positioning and support

Positioning is started by running the feed

upwards with the feed transfer cylinder to
bring the boom’s point of support as far
down as possible.

Positioning is first done close to the

intended angle without pressing the stinger
against the ground. The angle is left a little
short of the desired position because the
angle will change when the feed is driven
down and the rig is supported into the
drilling position. Final positioning is done
with feed transfer to place sufficient weight
on the stinger. Note that on an inclined site
the feed must be on the downhill side.

If the boom position changes when the

stinger is down, you should always use two
movements simultaneously to correct the
positioning. This is to avoid unnecessary
stresses on the drilling equipment.

The drilling rig has correct final position

when it has three points of support. One of
the points is the stinger and the other ones
are either the ends of the tracks or the rear
jack together with one of the tracks.

The tramming levers must be kept in the middle position during drilling.
Make sure that nobody touches the levers.

WARNING

B 05068--4 en 0807/PIR 87 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

3.9.7. Collaring
D Run the drill bit close to the ground surface.
D Close the Pito jaws. They act as rod centralizer.
D Lift the movable suction head up, if necessary, to see the drill bit during collaring.
D During collaring half flushing can be used (S18). During drilling maximum flushing
has to be used.
Before collaring, the drilling conditions are selected with the switches S17, S18, S23, S24
and S46 in the left panel.

S23 Percussion--feed S46

follow--up off = max. Suction off
percussion, indicator
light goes on
Dust collector on / off
Percussion--feed Dust collector on =
follow--up on indicator light goes on

Forced flushing if
S18 is ON

S17
Flushing control
automatics on

Flushing control
automatics off
Blow--down automatics,
Power extractor on S18 if dust collector (S46) is
on, max. flushing

Blow--down automatics off

and flushing off
S24 Anti--jamming
automatics on Blow down automatics,
(rotation pressure) if dust collector (S46) is
on, half flushing

The switch S18 is used for selecting

flushing pressure (max./off/half). Flush-
Anti--jamming
ing starts with percussion pressure
automatics off
switch or switch S23.

88 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

Start collaring in the following order:

1. Rotation. Rotation is started by moving the joystick left; rotation speed increases
as the joystick is moved further to the left.
2. Percussion. Half--power percussion starts simultaneously with rotation, when the
joystick is moved to the left. Flushing will also start if the switch S18 is not in the
middle position.
3. Feed. Feed starts when the joystick is pushed forwards; feed speed increases as
the joystick is pushed further forward. When the joystick is pushed far enough, it
will lock into the drilling position and percussion--feed follow--up starts. Locking is
released by pressing the button S20 (4).
NOTE: If the drill bit slides off the starting point, lift the bit up and restart with a lower feed
speed. Make sure that the hole starts straight.

3.9.8. Drilling
Feed pressure is adjusted with the pressure relief valve in the cabin.
With underfeed, the rock drill and the feed chain tend to shake. With considerable
underfeed, the drilling noise becomes clinking because of loosened rod string joints.
With overfeed, the rock drill and the feed chain jerk forwards. Considerable overfeed may
cause hole, or even drill rod, bending.
Both underfeed and overfeed cause heating of rod string joints and damage the threads.
Watch during drilling that the drill cuttings are flushed out properly.
If necessary, clear the hole by running the rock drill back and forth with forced flushing
switched on. Observe flushing air pressure during drilling. A rise in the pressure usually
means a blocked drill bit (flushing does not clear the hole). If the amount of cuttings coming
out decreases or stops completely, drilling should be continued cautiously, making sure
that the flushing is working. Run the rock drill upwards preferably without percussion.

B 05068--4 en 0807/PIR 89 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

3.9.9. Drilling parameters

The relation between percussion pressure, feed force, and rotation speed and their
correct setting depend on the type of rock and the hole diameter. The drilling parameters
must always be adjusted when drilling conditions change. The following tables present
basic pressures and some typical cases of incorrect parameter adjustment and the
resulting symptoms. Use the table to make adjustments.

Percussion Rotation Feed Flushing Stabilizer (optional)

DX500 HL 510 Percussion Rotation Feed Flushing

Collaring 90--100 bar 40 bar 30--50 bar 4--9 bar
Drilling 130--160 bar 40--60 bar 80--110 bar 4--9 bar

DX680 HL 650 Percussion Rotation Feed Flushing

Collaring 100 bar 40 bar 30--50 bar 4--9 bar
Drilling 130--170 bar 40--60 bar 80--110 bar 4--9 bar

DX700 HL 710 Percussion Rotation Feed Flushing

Collaring 80 bar 40 bar 30--50 bar 4--9 bar
Drilling 130--170 bar 40--60 bar 80--120 bar 4--9 bar

DX780 HL 800 Percussion Rotation Feed Flushing

Collaring 80 bar 40 bar 30--50 bar 4--9 bar
Drilling 130--180 bar 40--60 bar 80--120 bar 4--9 bar

DX800 HL 800 Percussion Rotation Feed Flushing

Collaring 80 bar 40 bar 30--50 bar 4--9 bar
Drilling 130--190 bar 40--60 bar 80--120 bar 4--9 bar

90 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

FAULT SYMPTOMS

Too high percus- -- Need to increase feed force.

sion pressure
ERCUSSION

-- Shortened life of rock drill and drilling equipment

-- Hydraulic oil overheating.
-- Increased risk of drill rod sticking.
PE

Too low percussion -- Decreased penetration rate. (When drilling into soft
pressure rock, the best penetration rate and longest drilling
equipment life is reached with lower percussion
pressure than when drilling hard rock.)

Too high rotation -- Fast wear of outer edge of drill bit (risk of
speed anti--tapered bit).
ROTATION

-- Fine--grained drill cuttings.

-- Wear of rock drill and rotation mechanism
components.

Too low rotation -- Uneven rotation of drill rod.

speed -- Decreased penetration rate.
-- Increased stresses on drill rod and rotation
mechanism.

B 05068--4 en 0807/PIR 91 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

FAULT SYMPTOMS

Too high feed force -- Sticking rotation (rotation pressure fluctuates).

-- Increased rotation torque (rotation pressure rises),
causing overload on drilling equipment and rotation
mechanism of rock drill.
NOTE! Increase in rotation pressure can also be
caused by drill rod bending or other abnormal
resistance to rotation.
-- Bending of drill rod, faster wear of centralizers and
chuck, increased risk of piston striking shank at an
angle.
-- Changed sound of rock drill.
NOTE! INCREASING THE FEED FORCE OVER A
CERTAIN LIMIT DOES NOT INCREASE PENETRA-
TION RATE.
FEED
D

Too low feed force -- Rock drill jumps and shakes (clinking sound).
-- Front end of chuck and coupling sleeve of drill rod
wear faster.
-- Faces of rock drill body wear faster (maintenance
intervals are shortened).
-- Penetration rate decreases. Rock drill is not in correct
position when piston strikes. Only a small proportion
of impact force is transmitted to rock.
-- Life of drilling equipment is shortened (great tensile
stresses on drilling equipment).

Too low flushing -- Increased risk of jamming.

pressure -- Lower penetration rate.
LUSHING

-- Fine--grained drill cuttings.

FLU

Too high flushing -- Drill bit wear increases.

pressure -- Diesel engine of drill rig is overloaded.

92 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

3.9.10. Adding drill rods

1. When the extension sleeve comes 2. Lighten up feed when the lower edge
close to the Pito jaws, open them of the sleeve is at the upper edge of Pito.
sufficiently to make room for the sleeve.

3. When the sleeve is between the jaws, 4. If the thread is not yet open, hammer
stop drilling. the rod against the hole bottom by
moving the drilling joystick to the right
while pressing button 2 (S22) until the
thread opens.

5. Close the Pito jaws. 6. Thread the shank out of the sleeve.

B 05068--4 en 0807/PIR 93 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

7. Run the rock drill to the rear position 8. Close the gripper jaws.
with fast feed; pull the joystick backwards
and press the button 1 (S21).

9. Spray grease to the threads. 10. Move the rod to the drilling centre.

11. Run the rock drill to the extension 12. Open the upper gripper jaws; at the
sleeve and thread the shank into the same time pressure is released from the
sleeve. lower gripper jaws (i.e. the lower jaws do
not grip the rod, they only guide it).

94 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

13. Thread the lower thread of the rod to 14. Open the gripper jaws completely.
the sleeve in the Pito jaws.

15. Move the grippers from the drilling 16. Close the gripper jaws.
centre to the cassette.

17. Open the Pito jaws. 18. Continue drilling.

19. Close the Pito jaws when the rod
sleeve has passed the jaws.

B 05068--4 en 0807/PIR 95 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

3.9.11. Ending drilling

1. When the hole is near the specified 2. Stop drilling.

depth, lighten up feed. 3. If the threads are not yet loosened,
hammer the rod string against the hole
bottom by moving the drilling joystick to
the right while depressing the button 2
(S22) until the threads loosen.

4. Retract the rod string until the sleeve of 5. Close the Pito jaws to guide the sleeve
the first joint is at the Pito jaws. (sleeve must be free between the jaws).

6. Open the gripper jaws. 7. Move the grippers to the drilling centre.

96 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

8. Close the gripper jaws. 9. Tighten the rod extension sleeve

thread to the rock drill shank.

10. Open the upper gripper jaws; at the 11. Close the Pito jaws.
same time pressure is released from the
lower gripper jaws (i.e. the lower jaws do
not grip the rod, they only guide it).

12. Open the rod string joint at Pito, using 13. Make sure that the rod is at a height
threading function. from where it can be moved into the
cassette.
14. Close the gripper jaws.

B 05068--4 en 0807/PIR 97 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

15. Thread the shank out of the sleeve. 16. Move the grippers from the drilling
centre to the cassette.

D Dismantle the whole rod string as described above.

D To make sure that the lower threads do not open when the rod string is pulled up,
you can push the drilling joystick into the rotating position.
D Avoid pulling the drill bit through the suction head as this might damage the rubber
sealings.
D Lift the feed cautiously up to avoid caving--in of the hole.

98 (108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

3.10. Turning feed to horizontal drilling position

1. Turn the upper carriage in line with the tracks.
2. Run the rock drill and the feed to the extreme forward position.
3. Move the boom forwards to the position shown below.

Make sure that the feed remains front heavy, i.e. its centre of gravity is
forward of the point x.

WARNING

3.10.1. Turning to horizontal drilling to the right

1. Remove the screw (1) and the washer (2) from the lower end of the pin at the piston
rod end of the swing cylinder.

4
3
2
1

B 05068--4 en 0807/PIR 99 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

Keep the feed stinger against the ground to make sure that the feed
cannot move.

WARNING

2. Move the feed swing cylinder so that there is no load on the pin.
3. Remove the sleeve (3) using an M 24 screw as an extractor. Pull the pin (4) out
from below and drive the sleeve (5) off upwards from below.

5 a

4
3

2
1

4. Drive the piston rod forwards up to the ear (a) for horizontal drilling, and insert the
pin. Tighten to the specified torque of 290 Nm.
5. Lift the stinger up from the ground.
6. Turn the feed to the horizontal drilling position by driving the swing cylinder
inwards.

100(108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

3.11. Transporting the rig

3.11.1. Driving onto transport wagon

Move the boom and the feed to the tramming position before driving the
rig onto a transport wagon.
Never exceed the specified gradient angles.
WARNING

Max. 20_

D Suitable access ramps must be used when driving the rig onto and off transport
wagon. Driving must always be done on level ground.
D When driving over the ramps, use oscillation and boom movements to balance the
rig.
D Always use low speed and observe special caution when coming from the ramps
to the platform.
D Before transporting, lower the boom down and firmly support the feed against the
platform.
D Lock the oscillation valve.
D Fasten the rig to the platform from the boom and both ends of the tracks with strong
straps and chains so that the rig cannot shift during transporting.

When planning the transporting route, keep in mind the rig’s

dimensions.
CAUTION

B 05068--4 en 0807/PIR 101 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

3.12. Storing instructions

Environment:
D The storing temperature should be +0...+35_C, and the rig should be protected
from direct sunlight and from rain.
D The humidity of the air should be below 90%.

_C 86F
30
20 68
10 50
0 32
max 90%

Preparations:
D Wash the rig thoroughly if it comes directly from use, or if it has been transported
by sea (use high pressure washer or steam).
D Lubricate all greasing points.
D Empty the pressure accumulators and place warning signs on the rig: ’Pressure
accumulators must be filled before using the rig’.
D Apply protective grease to the piston rods of the cylinders.
D Change all lubricants and fluids that may have deteriorated in use.
D Protect electric devices with corrosion inhibitor to prevent contact failures.

Spray protective grease, Order No. 867 430 49, on the following points:
-- terminal strips
-- battery terminals

Apply protective grease, Order No. 867 429 89, to the following points:
-- multipole connectors
-- connectors at caps of magnetic valves, pressure switches, etc. Fill the caps with
grease.

102(108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

3.13. Lifting methods and lifting points

Always respect the law and all the local safety regulations in lifting work.

WARNING

Keep in mind the total weight of the rig, given in the technical data of
these instructions.

WARNING

3000

B 05068--4 en 0807/PIR 103 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

The lifting points (three) have been marked

with hook symbols.

D The lifting device used must be of the correct type and have sufficient lifting
capacity. The rig or parts of it must not be lifted with any devices that are not
specifically designed for lifting purposes. Do not use, for instance, a loader for
lifting.
D You must always know the exact weight of the load, and never exceed the lifting
capacity specified by the manufacturer of the lifting device.
D The lifting routes should be planned so that the load is not moved over persons or
such places where persons may be present.
D Make sure that the lifting equipment are in proper condition.
D The wire ropes and chains used for lifting must be checked regularly. Damaged
wire ropes and chains must be marked clearly and discarded at once.
D Lift the load only a few centimetres at first to make sure that it is properly fastened
and in balance. Do not continue lifting until you are sure of proper fastening and
balance.
D Never wind the ropes and chains around the hook of the hoist. The lifting ropes and
chains must be fastened according to the manufacturer’s instructions.

INCORRECT CORRECT

104(108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

3.14. Extra equipment

3.14.1. Flushing automatics
The purpose of flushing automatics is to prevent the drill rods from jamming when drilling
through a layer of clay, for instance. The system monitors the amount of air flowing through
the drill bit. If the air flow decreases sufficiently (bit blocked), feed reverses and lifts up the
rod string until the air flow returns to normal.

Rotation Rotation Rotation

Flushing Flushing Flushing

Feed Feed Feed

Sticky layer in
rock

Operation of flushing automatics

B 05068--4 en 0807/PIR 105 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

4. OPERATOR TROUBLESHOOTING

FAULT POSSIBLE REASON / CHECK

Tramming from cabin 1. Cabin door is open.
does not work. Tramming from cabin works only when door is closed.

2. Switch (S7) on right hand panel is in remote control

position.
S7
Fast tramming

Slow tramming

Tramming with remote

control (slow)

Drilling does not work. 1. Drilling safety wire is pulled or wire is loose (the indicator
light goes on). See also adjusting instruction of wire.
Safety wire
reset button
Drilling safety
wire

2. Switch (S7) on right hand panel is in remote control

position.
S7
Fast tramming

Slow tramming

Tramming with remote

control (slow)

106(108) B 05068--4 en 0807/PIR

DX500/DX680/DX700/DX780/DX800 Operator’s manual

FAULT POSSIBLE REASON / CHECK

Rotation and percus- 1. Rotation speed adjusting valve (11) is too much open.
sion do not work.

11

Flushing does not start. 1. Switch S18 on left hand panel is in middle position.
S18
Blow--down automatics, if dust collector
(S46) is on, max. flushing

Blow--down automatics off and flushing off

Blow down automatics, if dust collector

(S46) is on, half flushing

2. If half flushing is selected by switch S18 and half flushing

valve (10) is too much open.

10

Engine stops or engine 1. Gable plug of the remote control panel is disconnected.
does not start.

B 05068--4 en 0807/PIR 107 (108)

Operator’s manual DX500/DX680/DX700/DX780/DX800

FAULT POSSIBLE REASON / CHECK

Percussion does not work. 1. Percussion on / off switch (3) of drilling control joy stick
has been depressed

3 = Percussion off/on (S19)

Drilling control joy stick Disturbance in shank lubrication oil flow. Indicator light
does not lock in drilling (H94) goes on.
position.

H93

Shank lubrication disturbance

H94 (stops drilling) or shank lubrication
oil level low, red indicator light

Ignition current does not 1. Main switch (1) is disconnected.

go on. 2. Main fuse (2) has gone off.

108(108) B 05068--4 en 0807/PIR