Original instructions

REVISION 2-14

Operator Manual
dr580
FOR SERIAL NUMBER: 733741
The following three hazard signal words are used throughout this manual to emphasize important
instructions. For the purpose of this manual, these signal words are defined as follows:

Indicates a hazardous situation which, if not avoided,

! DANGER will result in death or serious injury.

Indicates a hazardous situation which, if not avoided,

! WARNING could result in death or serious injury.

Indicates a situation which, if not avoided, may result

! NOTICE in damage to machinery or components.

California Proposition 65
WARNING:
This Product Contains And, When Used, Produces Chemicals Known
To The State Of California To Cause Cancer, And Birth Defects Or
Other Reproductive Harm.
DR580 OPERATOR’S MANUAL

INTRODUCTION
1.1 The Purpose of These Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Identification Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Manual Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SAFETY AND ENVIRONMENTAL INSTRUCTIONS
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Safety Labels and Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 User Obligations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.4 Limits of This Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.5 General Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.6 Weather Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.7 Safeguarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.8 Fire and Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.9 Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.10 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
MACHINE DESCRIPTION
3.1 Nomenclature and Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.3 Main Components and Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.4 Display Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.5 Joystick Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
OPERATING THE MACHINE
4.1 Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.2 Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
4.3 Configuring the Display Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.4 Tramming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.5 Operating the Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
4.6 Drilling Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4.7 Delivery System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
4.8 Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
OPERATOR MAINTENANCE INSTRUCTIONS
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
5.2 Operator Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
5.3 Operator’s Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
ADDITIONAL INSTRUCTIONS
6.1 Transporting the Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
6.2 Machine Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
6.3 Safety First! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
6.4 Positioning the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
6.5 Initial Preparation of the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
6.6 Weekly Storage Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
6.7 Removal from Long Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
6.8 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

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6.9 Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
6.10 Wash Wand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
TROUBLESHOOTING
7.1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
7.2 Tram Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
7.3 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
7.4 Water Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
7.5 Air Drive Oil Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
7.6 Air Driven Grease Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
7.7 Air Delivery System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
7.8 Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
7.9 Drill Bit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
7.10 Depth Laser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
TECHNICAL SPECIFICATIONS
8.1 Torques and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
8.2 Machine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

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1. Introduction

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1. INTRODUCTION

1.1. The Purpose of These Instructions

The purpose of these instructions is to promote intended safe, proper and economical use of
Sandvik products and to help the user to identify, avoid and prevent hazardous situations and
related consequences.

These instructions must be followed along with any instructions given in local laws and regulations,
and orders given by local authorities and all protective measures specific for the site.

Read and understand the complete manual carefully and follow given instructions strictly. If there is
anything you do not understand, ask your employer or your local Sandvik representative to explain
it. All sections of this manual contain information which is vital for your safety. The maintenance
manual must be replaced immediately if lost, damaged, or unreadable. For replacement copies of
this manual please contact your Sandvik parts representative and order part number 023501-037
and include the serial number of the machine.

The instructions set forth in the maintenance and other manuals shall be used as part of the training
material during orientation/commissioning of the machine. By following these instructions,
maintenance cost and downtime will be minimized while the reliability and lifetime of the equipment
will be optimized.

1.2. Identification Plate

1.2.1. Product Type and Serial number

The model and serial number of this product are shown on the identification plate as shown below.

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1.2.2. Product Manufacturer

The product manufacturer and address are listed on the identification plate shown above.

1.2.3. Manuals
The model and serial number of the machine are shown on the spine of each manual’s binder.
Check that the model and serial number for your machine corresponds to this manual.

Support manuals available for this machine include:

• Operator’s Manual
• Maintenance Manual
• Service Manual
• Parts Manual

1.2.4. Validity of the Manuals

The information in this manual corresponds to the model and appearance of the product at the time
of delivery. Sandvik Mining U.S.A., LLC reserves the right to change the technical data and
components without prior notice. All information included in the manual is valid at the time of
publication.

1.3. Manual Contents

The operator’s manual contains the following information:

• General information about the purpose and content of the operator’s manual, instructions
for reading the manual.
• Information related to safety
• Operator maintenance check list
• Operator maintenance work instructions
• Operating Instructions
• Technical Specifications

1.4. Copyright
This publication is copyright of Sandvik Mining U.S.A., LLC and it must not be copied, reproduced,
or otherwise made available in full or in part to any third party without our prior written consent.

1.5. Definitions
- Emergency Stop - Function which is intended:
• To avert arising or to reduce existing hazards to persons, damage to machinery or to
work in progress.
• To be initiated by a single human action.
- Emission Value - Numerical value quantifying an emission generated by a product. (For
example: noise, vibration, hazardous substances and radiation).
- Environmental Risk - Combination of a probability of occurrence of environmental
damage and the severity of that environmental damage.
- Exposure Value - Quantifies the exposure of persons to emissions when the product is in
use. Exposure values can be estimated using the emission values.

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- Harm - Physical injury or damage to health. This is always in relation to people, not
equipment or property.
- Hazard - Potential source of harm.
- Hazard Zone - Any space within and/or around the product in which a person is exposed to
a hazard.
- Information for use - The information in this manual, the safety labels and signals on the
product and other related information used separately or in combination to convey
information to the user.
- Intended Use of a Product - Use of a product in accordance with the information provided
in the instructions for use.
- Product - Machinery, partly completed machinery, component or tool, including related
services.
- Prohibited Use - Any use which is not intended use. Especially the use, which is
specifically prohibited in information for use.
- Reasonably Foreseeable Misuse - Use of a machine in a way not intended by the
designer, but which may result from readily predictable human behaviour.
- Risk - Combination of a probability of occurrence of harm and the severity of that harm.
- Risk of Property Damage - Combination of a probability of occurrence of property
damage and the severity of that property damage.
- Safe Working Procedures - Developed for the users by their employer for work to be
performed. It details how specific risks in the workplace will be managed, taking into
account information for use supplied with the product as well as local acts, laws and
regulations.
- Safeguard - Guard (physical barrier, designed as part of the product, to provide protection)
or protective device.
- Protective Device - Safeguard other than a guard, which reduces the risk either alone or
in conjunction with a guard. (For example: interlocking devices, hold-to-run controls and
limiting devices).
- User - The owner, operator, authorized and trained people involved in the transportation,
installation, operation, maintenance and disposal of the product.

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2. Safety and Environmental Instructions

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2. SAFETY AND ENVIRONMENTAL INSTRUCTIONS

2.1. Introduction
SANDVIK MINING drilling equipment is carefully designed, tested and manufactured. When
operated and serviced by trained and qualified personnel, this machine will give safe and reliable
service. There are SANDVIK MINING offices world-wide to answer questions concerning the safe
operation and maintenance of this equipment.

To minimize the risk of accidents and injuries, all persons involved in the operation and servicing of
this machine MUST read and understand the following safety precautions and the manuals
developed for this machine.

While we believe that we have properly identified several potential hazards that could result in
property damage or injury or death to personnel, there are certain hazards which may be present
that we have not contemplated. It therefore is the responsibility of the drill owner, operator and crew
to be certain that the drill is properly equipped and safe to operate to assure accident free operation.

2.2. Safety Labels and Signals

2.2.1. Signal Words

The following hazard signal words are used throughout this products manuals and decals to
emphasize important instructions. These signal words are defined as follows:

! DANGER
The DANGER signal word indicates a hazardous situation which, if not avoided,
will result in death or serious injury.

! WARNING
The WARNING signal word indicates a hazardous situation which, if not avoided,
could result in death or serious injury.

! NOTICE
Indicates a situation which, if not avoided, may result in damage to machinery or
components.

2.2.2. General Hazard Symbol

This general hazard symbol identifies important safety messages in this manual. When
you see this symbol, be alert; your safety is involved. Carefully read and understand the
message that follows this symbol, and inform other users.

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2.2.3. Mandatory Action Symbols

Mandatory actions are indicated by white symbols on a blue background.

Hard Hat Required

Hearing Protection Required

Wear Safety Steel - Toe Shoes

Use Lock-Out / Tag-Out Devices

Safety Tether Required

Lifting Point

Towing Point

Eye Protection Required

Gloves Required

Refer to the Manual for Additional Information

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Respirator Required

Protective Clothing Required

2.2.4. Prohibitive Action Symbols

Prohibited actions are indicated by a red circle with a red diagonal line across the circle. The action
which is prohibited will always be in black.

No Smoking

No Climbing

Do Not Weld

Do Not Inject Ether Into Engine Air Cleaner

Do Not Drink the Water from this Source - Non-Potable

Do Not Touch - Hot Surface

Keep Open Flame Away

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Do Not Remove Guard

No Lift Point

Do Not Lift with Forklift

2.2.5. Hazard Symbols

Hazard symbols are indicated by a yellow triangle with black symbols and black frames.

Low Clearance Hazard

Lifting Hazard

Flying Material Hazard

Explosion Hazard

Skin Injection Hazard

Dust / Silica Hazard

Electrical Shock Hazard

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Fire Hazard

General Hazard

Falling Object Hazard

Trip Hazard

Crushing Hazard - Feet

Fan Blade Hazard

Entanglement Hazard

2.2.6. Safety Labels on this Machine

Safety labels communicate the following four things:

- The severity level of the risk - The signal word ‘DANGER’, ‘WARNING’, ‘NOTICE’ or
‘SAFETY INSTRUCTIONS’
- The nature of the hazard - Cutting parts, oil injection, crushing, explosion....
- The consequence of interaction with the hazard - A cut, burn, electrical shock...
- How to avoid the hazard - Allow to cool, relieve pressure...
You must ALWAYS follow the safety messages and symbols on the safety labels and the
instructions in the manuals to avoid death, injury or damage to property or the environment!

Keep the safety labels clean and visible at all times. Check the condition of the labels daily and
replace any missing, damaged or illegible labels that are cannot be read from a safe viewing
distance. The labels must be replaced, refer to the Parts manual, before operating the machine.

The following illustrations show the general placement of the Notice, Warning, Safety Instructions
and Danger labels found on this machine. These decals should make it clear to the operators and
maintenance people where the major risks for personal injury and machine damage are.

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CP13005

CP13008

CP13008

CP13005
CP13010

CP13014
CP13011

CP13006

CP13014
CP13045

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CP13016

CX000563

CX000562

CP13004

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CP13013

CX000674

CP13044

CP13043

CP13001039

CX008070

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2.3. User Obligations

! WARNING
WARNING! This product may only be operated and maintained by a person
who has received proper training and has demonstrated that he or she has
the competence and the skills needed for safe and proper operation or
maintenance.
The safe use of this product depends on, among other things, a combination of design and
construction measures taken by the manufacturer, skills of the operators and protective measures
taken by the users. This manual and its instructions are an essential and integral part of this product
and must remain in the cab and be available for users. It is important to forward the information
contained in this manual on to any subsequent users of this product.

Sandvik prohibits anyone with the access to this machine from consuming, possessing or
distributing:

• Intoxicants and narcotics

• Legal or illegal drugs
• Items related to either of these
• Firearms
• Unapproved explosives
This safety information includes the following: transport, assembly, installation, commissioning, use,
settings, operation, cleaning, troubleshooting, maintenance and disposal of machinery. If you need
more detailed instructions, do not hesitate to contact your local Sandvik representative.

Operators and maintenance personnel should include the following as part of their safety program:

- Use of personal protective equipment (PPE)

- Provision and use of additional safeguards
- Attend regular site safety and safe working procedures training.
Other issues the operators and maintenance personnel should be aware of:

- Mine site organization and supervision

- Workplace safety, including safe working procedures
- Permit-to-work systems
When a Sandvik product has been involved in a near-miss incident or accident, it MUST be reported
to a Sandvik representative without delay!

! WARNING
WARNING! The use of non Sandvik authorized replacement parts can cause
an uncontrolled risk to the machine’s users. The use of non-authorized parts
is prohibited. Always use genuine Sandvik parts.

The following safety guidelines apply to every person working with this equipment or in its vicinity.
Every person is responsible for their own safety and for the safety of their colleagues. In the case of

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a violation of safety guidelines or regulations, each person is responsible to warn the others and to
notify the responsible supervisor.

2.3.1. Managing Work Related Hazards

The users must always perform a local risk assessment before every new task. For example: A
work shift change or before performing maintenance. This assessment, also known as a Real Time
Hazard Analysis, ensures that the user stops and thinks about what she or he is going to do before
starting to work allowing them time to:

- Identify potential hazards that could impact themselves, their colleagues, the environment,
the machine and/or work method while they are performing the task.
- Assess the risks and implement the actions needed to eliminate or reduce the risk.
To ensure that only qualified users work with Sandvik equipment, the employer must:

- Validate training methods

- Verify competence and skills
- Monitor and evaluate user performance regularly
- See that all operators of this equipment are thoroughly trained (with special emphasis on
safety), competent, physically fit and if required, licensed.
- Assign specific crew members specific safety responsibilities and instruct them how to
report any unsafe conditions.
- Enforce the use of protective clothing, eye and hearing equipment.
- See that the operation and maintenance of this drill is in compliance with all Federal, State
and local codes, regulations and standards.
- Ensure that the work area is appropriately illuminated when drilling is performed at night.
- Maintain a complete first aid kit at the drill site. At least two members of the drilling crew or
personnel in the area where the drill is operated should be familiar with first aid and
Cardiac Pulmonary Resuscitation.
- Contact the utility companies for the exact location of underground transmission lines in the
drilling area.
The employer should plan for the job by asking:

- Will the drilling take place in wet formations?

- Are there utility lines or structures that must be moved or avoided?
- Are there unusual or extreme weather conditions expected?
- Will drilling be done in night hours?
- Will the machine be propelled on inclines?
- Will drilling be done into difficult formations?
- Has a drilling pattern been developed?
- What is the required depth of the drilling pattern?
- Will special drilling tools be required to complete the job?
- Will vertical or angle drilling be required?

2.3.2. Periodic Safety Inspections

It is important to thoroughly inspect this product before starting to ensure it is safe to operate. Look
for defects and damage before any operation so any problems can be reported and fixed.

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The operator shall be responsible to ensure:

- The machine is to be checked in accordance with the requirements of the machine

operating procedures before, during and after use and operation. The Operators Manual
which should always be located in the cab of the machine.
- Safety features, such as labels, safeguards and others should be checked frequently and
repaired immediately, if damaged.
- Check that there are no "lockouts" or "tagouts" attached to the controls.
- Check the machine log book to see that periodic maintenance and inspections have been
performed, and that all necessary repairs have been made.
- After starting the engine, check all indicators, emergency stop, trip devices and gauges for
serviceability.
- Check the fire extinguisher (s) for charge and accessibility.
- Clean the cab interior windows if necessary.
- Test all controls for proper operation.
- Check access ladders and decking for damage and slipping hazards such as mud, oil or
ice.
- At the end of the shift, the operator must properly secure the drill to prevent the machine
from being operated by unauthorized individuals.
- The operator must never permit personnel to ride on the machine except in the passenger
compartment.

! DANGER
The operator should treat all power lines as live.Operating near or
contacting a power line with any part of the machine can result in
electrocution. Do not raise the drilling mast or operate the machine in the
vicinity of electrical power lines without checking the minimum safe
operating perimeter set by local, state or federal regulations.
- The operator must see that all emergency stops, "operational aids" and "warning signals"
are functional before operating.
- The operator must be alert, physically fit, and free from the influences of drugs, alcohol and
medications that might impair eyesight, hearing or reactions.
- The operator should not attempt to start, operate or service the drill unless he has been
properly trained and read this manual.
- The operator should not operate this equipment if any of its controls display a "lockout" tag.
- If an unsafe condition exists, the operator must place a tag, identifying this condition, on the
starting controls and alert other potential users of the drill.
- The operator should not operate the drill without first checking that all PPE (personnel
protection devices) and machinery guards are in place.
- Raising or lowering the mast, and drilling with an unsupported or unleveled machine can
result in excessive structural stress to the machine frames or can cause the machine to
overturn. Do not raise or lower the mast or attempt to drill until the machine is fully
supported and leveled by the leveling jacks.
- Drilling with an unlocked mast can result in excessive pressure at the mast raising
cylinders causing the mast to fall. Do not attempt to drill until the mast locking pins are
fully engaged.

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- Before leaving the operator's station, all controls must be in the neutral position with all
locking and safety devices engaged. Do not allow the drill to operate unattended.
- Do not park or position the machine on grades that exceed the tilt ratings. Park or position
the machine on level ground or across (horizontal) grade.
- Park or position the machine to allow the wind to carry engine exhaust fumes away from
the operator. Exhaust fumes from diesel engines are lethal.
- Drill pipe that is free to slide through the opening in the top plate could be released from the
loader while traveling. Before lowering the mast, index the loader to a position such
that the top plate of the loader prevents all drill pipes from moving past the top plate.

2.3.3. Periodic Maintenance

Following the preventive maintenance schedule in the Maintenance manual is an essential
procedure to ensure and maintain safety and performance of the product. Follow the given
instructions for maintenance and inspection for this product.

! DANGER
The sudden release of a pressurized lid or hose can spray hot oil. Do not
open hydraulic tanks, air reservoirs or hydraulic connections while the
machine is running or the systems are under pressure.

• Before entering any enclosure, be sure that the door is secured open. Avoid entrapment;
be sure that no one is inside any enclosure before closing and latching the doors.
Enclosures can cause suffocation.
• Before starting any service or maintenance work, always perform a safety/risk analysis of
the task. Performing maintenance work without the proper tools and personal
protection equipment can cause serious injury or death.
• Climbing the mast is a crushing and falling hazard. Climbing the mast may cause
serious injury or death. Stay off the mast at all times.

! DANGER
Hydraulic oil under extreme pressure from a small opening can penetrate the
skin and inject oil into the body. Do not attempt to locate a hydraulic leak by
using your hand.

! DANGER
Pressure in hydraulic systems can be retained for long periods of time. If not
properly released before maintenance people attempt to work on the
hydraulic system, this pressure can let components move or cause hot oil to
spray and hose ends to shoot out at high speed. Release system pressure
before attempting to make adjustments or repairs.

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• Carelessness in getting on and off equipment can result in serious injuries. Always wait
until the machine has completely stopped. Do not jump on or off. Always use both
hands and feet and use the 3-point contact rule.
• Riding the top drive up and down the mast is a crushing hazard. Never ride the top drive
for any reason!!! It was not designed to be an elevator.

2.3.4. Personal Protective Equipment (PPE)

Operators, maintenance people and anyone in the vicinity of this product MUST wear approved
personal protective equipment, which includes but is not limited to:

- Safety helmet
- Goggles
- Hearing protection
- Steel toed boots
- Respirator
- Safety gloves
- Close fitting overalls
- Safety harness
- High visibility vest
Do not wear loose clothing or jewelry that can snag on controls or other components of this
machine. Confine long hair.

Special conditions may require the use of additional PPE as specified in safe working procedures.

2.4. Limits of This Machine

2.4.1. Intended use of this Rig

This machine is designed for construction and surface mine drilling. The maximum inclination
angles for this machine can be found in the ‘Tramming’ topic of this manual in section 3.

2.4.2. Recommended Operating Conditions

This machine was designed to operate at ambient temperatures of -40°C to +54°C (-40°F to
+130°F).

2.4.3. Manners and Conditions in which this Machine should not be used
Never operate this machine with:

• Inadequate training of operator.

• Unauthorized persons in working area.
• Inadequate lighting.
• Inadequate grading.
• Transporting people.
• Defective safety systems.
• Locked-out or tagged-out components

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2.4.4. Modifications

! DANGER
The installation and use of unauthorized components or modifications to the
original design of this machine may cause personal injury or death.
Do not modify or install aftermarket components to this machine without
approval from Sandvik Mining.

All modifications and corrections not authorized in the maintenance manual or which may affect the
maintenance, operation, safety, and availability of the product need to be approved in writing by the
manufacturer before implementation. Approval requires careful risk assessment taking into
consideration any new risks that the modifications may bring.

Changes and modifications without proper risk assessment, elimination or reduction of risk and
without appropriate safety measures may lead to death, serious personal injuries or damage to
property.

If modifications and corrections that affect the maintenance, operation, safety, and usability of the
product are made without the written permission of the manufacturer, the manufacturer is not
responsible for any incidents resulting in death, injury, or property damage brought about by such
modifications and corrections.

Should you consider a modification or correction necessary, please contact the Sandvik Alachua,
Florida USA facility. No modification is permitted unless you first obtain the written approval of the
manufacturer.

Prior to implementing or installing a modification to this product you must supply us with adequate
documentation such as:

- Product model/type
- Serial number of product
- Description of the modification or correction
- Related blueprints
- Related photos
- And other necessary materials related to the design change
If a modification or correction as described above has been implemented without the manufacturing
factory’s permission, its effect on warranty liability will be considered case-by-case. Thus, the
warranty application may be rejected altogether.

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2.5. General Hazards

2.5.1. Hazard Zones

Hazards zones when tramming the machine and when the machine is in operation are shown
below.

! WARNING
While tramming, it is forbidden for personnel to be in the tramming area.
Be sure the tramming area is clear of all personnel before tramming.

5 M (15 ft)

5M 5m
(15 ft) (15 ft)

5 M (15 ft)

TRAMMING SAFETY ZONE

! WARNING
While drilling, it is forbidden for personnel to be in the drilling area.
Be sure the drilling area is clear of all personnel before drilling.

DRILLING
SAFETY
ZONE

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2.5.2. Sound Pressure and Power Levels

The measurement of the sound power and the sound pressure levels at the operator’s cab have
been measured in accordance with European Drill Rig Standard EN791 and the EC Machinery
Directive 89/392/EEC and amendments thereof.

The average sound level emitted by machinery: 127 dB

Sound level In Cab: 86 dB

2.5.3. Vibration Value

The measurements of the vibration value at the operator’s cab have been measured in accordance
with European Drill Rig Standard EN791 and the EC Machinery Directive 2006/42/EC 3.6.3.1 and
amendments thereof. Vibration does not exceed 0.5 m/s².

2.5.4. Dust

Do not operate this machine if the dust suppression systems are not in proper working order.
Always use an approved respirator when making repairs or inspecting the dust suppression system
(s).

2.6. Weather Hazards

The following safety precautions were developed to minimize the risk of injury during inclement
weather when using Sandvik Mining drilling equipment.

All persons involved in the planning, operation and servicing of Sandvik Mining equipment MUST
read and understand the following safety precautions, the manuals developed for this machine and
the Safe Operating Practices outlined in the front of this manual.

While we believe that we have properly identified several potential hazards that could result in
property damage or personnel injury, there are certain hazards which may be present that we have
not contemplated.

Bad weather conditions as they relate to this topic include lightning, thunderstorms and severe
rainfall.

2.6.1. Management’s Responsibilities

High winds, rainfall and cloud cover are often precursors to actual cloud to ground strikes notifying
individuals to take action. Many reported lightning accidents occur with sun, clear skies and no rain
present at the beginning as the storm approaches because; people ignore these precursors.
Generally the lightning threat diminishes with time after the last sound of thunder, but may persist
for more than 30 minutes.

It is the responsibility of management to:

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• Be aware of daily weather conditions within a 161 Km (100 mile) radius of the mine
property.
• Determine a plan of action relating to expected bad or unexpected weather conditions.
• Notify equipment operators of impending storms. Communication to equipment operators
may be given via two way radio and/or in person.
• Consider that drill operators need ample time to:
• Retrieve drill pipe from blast holes and well bottom.
• Lower masts to a horizontal position or position feed rails into feed supports.
• Give the drill engine an adequate cool down period prior to shutting machine
down.
• Leave machine cabin or operator platform and transport to central meeting
location.
• Give equipment operators an all clear signal after the storm has cleared the area.

NOTE: Supervisors! Recognize that equipment operators should be given adequate time to prepare
the machine to move to specific locations for safe keeping. Crawler mounted drill machines
have a maximum travel speed not exceeding 3.5 kph (2.2 mph).

2.6.2. Rainfall and Flooding

When notified of an impending storm, machine operators should:

• Move the drill machine to higher ground conditions. Never leave a drill machine at the
lowest floor position of a mine or quarry or in a low lying ditch that could trap water runoff.
• Move the drill machine to stable ground and away from unstable crests or the face. Never
leave a drill machine on the front face of the drill pattern while rain and severe weather
pose a threat of loose ground falls or washouts.
• When operating machines in a construction application, equipment operators shall move
the drill machine to higher stable ground. Never leave a drill machine in any construction
zone roadway, river bed or drainage ditch.
• Move the drill machine to stable ground away from high walls and any threat where rock or
water erosion may allow unstable ground to fall or slide.

2.6.3. Thunderstorms and Lightning

A publication written in MSHA Holmes Safety Association Bulletin April 2001 gives a simple flash
bang formula to calculate lightning proximity.

The FLASH BANG method is determined by counting the seconds between the visible lightning and
the sound of thunder. This delay in seconds when divided by 5 will give an approximate value in
miles as to how close the active lightning is to your work site.

Example: when you see lightning and it takes (10) ten seconds to hear the thunder divide by (5) five.
The approximate distance of lightning proximity is 3.2 km (2 miles).

If the flash bang measurement is 30 seconds or less seek shelter immediately and remain indoors,
away from electrical devices, water and metal components.

Supervisors must notify equipment operators in a timely manner. This is to allow the drill operator
adequate time to perform the required operation principals needed and secure the machine in a
safe manner.

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• Equipment operators shall retrieve drill pipe from blast holes, secure drilling tools and lower
mast to a horizontal position into the mast rest supports. Understand that the mast in a
vertical position with drill pipe in the ground is capable of attracting high voltage lightning.

NOTE: If the operator and machine are inside or near a blast area follow procedures written in USA
Federal Metal and Nonmetal Mine safety Standards 30 CFR 56/57/58 manual.

• Equipment operators shall move the machine to secure ground as noted in the rainfall and
flooding description.
• Equipment operators shall give adequate engine cool down period prior to shutting
machine down. Adequate engine cool down periods range between 3 to 5 minutes. Follow
engine manufacture specifications as a standard.
• Equipment operators shall secure the machine, close doors and windows, leave the
machine cabin and dismount the machine in a proper 3 point contact with the boarding
ladder.
• Equipment operators shall drive or be transported to a central meeting location away from
bad weather and storm conditions.
There are exceptions to the rules when bad weather develops and time does not permit adequate
machine preparation - shutdown principals.

2.6.4. Exceptions
If you do get caught in an electrical storm and have little or no time to prepare, remember that, no
place is absolutely safe from the lightning threat, however, some places are safer than others.

When operators are inside an enclosed stable structure such as a machine cabin or the truck cab it
is recommended that:

• All windows are closed

• All doors closed
• Do not touch metal parts
• Do not use two way radio communications

NOTE: Wait inside the enclosed cab as long as it takes for the storm or lightning to subside. Do not
attempt to dismount the machine when lightning is in your immediate work area.

If lightning is present within a 32 km (20 mile) radius of your location, be aware of your surroundings
when outdoors. Seek adequate shelter immediately.

If lightning is present within the 32 km (20 mile) radius, and a decision is made to dismount the
machine, use a standard 3 point contact down the boarding ladder to dismount the machine.

Move away from the machine quickly and into an enclosed vehicle or adequate shelter. Maintain a
distance greater than 92 m (100 yards) to prevent electrical draw in the event lightning did strike the
mining equipment.

Static interference on AM radio channels is another indicator as to lightning proximity.

Lightning detectors are available aftermarket as a measuring instrument to determine lightning

proximity. Blasting crews are aware of lightning hazards and may have a lightning detector on site.

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If you are caught in the open with lightning nearby and shelter is not available the safest position to
be in is to be crouched down on the balls of your feet. Keep your feet as close to one another as
possible.

Do not allow your hands (or other body parts) to touch the ground. Use your hands to cover your
ears and brace for a loud thunderous bang.

Lightning struck victims carry no electrical charge and should be given first aid treatment
immediately!

2.6.5. Machine Maintenance

If lightning does strike a drill machine parked in any position (mast up or down) expect major
component failures. A total machine inspection is in order.

Electrical charge should dissipate immediately after impact.

Prior to climbing on board a machine known to have been struck by lightning use the back side of
either hand (knuckle side) to lightly touch the boarding ladder.

2.6.6. Reference Material

MSHA Holmes Safety Association Bulletin April 2001

Federal Metal and Non-metallic Mine Safety and Health Standards 30 CRF 56/57/58 Ninth Edition
(1999).

National weather service (www.noaa.gov)

2.7. Safeguarding

2.7.1. Guards

Guards have been design to protect the users of

this equipment from injury. It is important that the
guards are never altered or removed during the
operation of this machine. The guards should be
inspected at every operator shift change and the
work shift should not be started until the guard is
functioning properly. Guards are located in the
following locations on this equipment: ENGINE
EXHAUST
- Cooler coils COVER

- Engine alternator/air conditioner fan belts

- Engine to pump gearbox driveline
- Radiator fan blades
- Tram/Set-up System
- Engine exhaust
TURBO HEAT SHIELD

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ALTERNATOR/
AIR CONDITIONER
BELT COVER

RADIATOR
FAN BLADE
COVER

DRIVELINE
COVER

RADIATOR
AND COOLER
OVERS

TRAM SET-UP
SYSTEM
COVER

2.8. Fire and Safety Equipment

2.8.1. Emergency Stops (E-Stop)

The emergency stops were designed to shut down the machine in an emergency situation only.
Before resetting an emergency stop, determine how to avoid the situation which caused the
emergency stop to be used.

• E-Stop #1 is located on the control panel in the operator’s cab. Push this button to stop the
engine and all machine operations. Twist the button to reset.
• E-Stop #2 is located on the mast. Pull this cord to stop the engine and all machine
operations. Push the reset button before restarting the rig.
• E-Stop #3 is located on the right side for the drill rig, next to the mast rest. Push this button
to stop the engine and all machine operations. Pull the button out to reset.
• E-Stop #4 is located on RCP Panel on the left side of the machine. Push this button to stop
the engine and all machine operations. Pull the button out to reset.
• E-Stop #5 is located on the left side of the machine, near the battery box. Push this button
to stop the engine and all machine operations. Pull the button out to reset.
• E-Stop #6 is located on the left side of the machine, near the drill fluid panel. Push this
button to stop the engine and all machine operations. Pull the button out to reset.
• E-Stop #7 is located on a panel next to the pump drive gearbox. Push this button to stop
the engine and all machine operations. Pull the button out to reset.
• E-Stop #8 is located on a right side of the cab. Push this button to stop the engine and all
machine operations. Pull the button out to reset.

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3
EMERGENCY
TOPS
4

6
5

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2.8.2. Emergency Exits

The cab has only one door and the rear cab glass can
be kicked out in an emergency. The rear glass can be ULL TRIANGLE
kick out by first pulling the yellow triangle tag to remove
the moulding and then kicking the pane out.

2.8.3. Safe Access Points

This machine is equipped with five (4) access ladders.

When carrying tools or equipment onto the machine,
place these items on the deck before attempting to
board. Always use a 3-point support when boarding and
dismounting.

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3 2

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2.8.4. Isolation and Energy Dissipation

Anytime the operator dismounts the machine and if the machine is not going to be run for several
hours or maintenance is scheduled, turn the battery and starter isolation switches to the ‘OFF’
position and then lock-out the isolation box.
Hydraulic circuits maintain pressure after the machine is shutdown. If maintenance to a hydraulic
component or hose is to be done, relieve the pressure in the hydraulic system.

Prior to opening a valve hose fitting or removal of a valve assembly note the following:

• Gloves and PPE are worn.

• Push and pull the manual spool controls
several times to release oil pressure
trapped between the specific spool valve
and the hydraulic control. MANUAL
CONTROLS
• By using the controls and moving them
through the spool stroke, residual
pressure can escape to the return system.
When the hydraulic system is stopped, the
return system pressure equals zero.
• The technician must release the hydraulic
hose fittings slowly at first to minimize

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potential high pressure hydraulic oil or PSO pressure squirting out through the hose fitting.
Oil will drain out the loosened hose fitting.
• With the hose fitting slightly loose, manually rock the hose from side to side.
• Slowly open the hydraulic hose fitting and alternate the hose fitting to release residual
hydraulic oil pressure while maintaining the barrier between the hydraulic fitting and
technician.

! WARNING
Breaking a supporting cylinder hydraulic line may allow the supported load
to fall causing personnel injury or death.
When working with cylinders and any apparent loads they may hold,
MECHANICALLY SUPPORT AND SECURE the load prior to performing any
repair work.
NEVER attempt to work on hydraulic cylinders without adequate safety
training. Refer to bulletin SB243A for more information.

Hydraulic pressures may be trapped in the hydraulic system by design. For example the residual
pressure may be holding a load. A cylinder with attached components such as the top drive and drill
pipe weight, require some means of residual pressure to hold the oil in check thus holding the load.
Removing the pressure may lead to a falling load and a potential safety condition.

Contact your Sandvik representative for a copy of service bulletin SB243A for more information on
releasing stored hydraulic circuit pressures.

2.8.5. Fire Prevention

! DANGER
Fire Hazard:
Smoking and open flame are prohibited in the vicinity of this machine.
Keep the machine clean of vegetation, coal dust and oily rags.

Access to fire fighting equipment must be available at all times, particularly during maintenance and
repair work.

All fire fighting equipment has to be inspected and serviced regularly and according to local
regulations. Damaged fire fighting equipment or partially used fire fighting equipment, have to be
exchanged immediately.

All personnel must be trained regularly in fire fighting methods in cooperation with local authorities
and rescue organizations. Personnel must also be familiar with various types of fires and the
appropriate fire fighting methods. Be aware that some fires must not be extinguished with water.

Flammable products on this machine include:

- Gases emitted from batteries

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- Diesel fuel and its vapors

- Hydraulic oil
- Engine oil
- Compressor oil
- Engine starting fluid
Further preventive measures include:

• Clean-up any oil and fuel spills particularly around hot surfaces and heat producing
components.
• Check the Fire Suppression System (FSS), if fitted, for damaged hoses or cylinders.
• Check all electrical lines and connections including battery terminals for a tight fit, wear,
abrasion, and corrosion.
• Do not use the drilling machine in oil, gas or water well operations unless the well head is
properly equipped with blow-out preventers and safety equipment required by law or as
recommended in the American Petroleum Institute's document API 54.
• Check all machine ignition points (engine block, exhaust manifolds, mufflers, turbo-
chargers, etc...) to make sure they are not in contact with any hoses.
• Keep the batteries secured in their compartment and covered.
• Never inject ether or other starting aids into the engine and compressor intake filter (s).
Ether or other aids drawn into the compressor can cause an explosion.
• Do not store flammable fluids on or in the immediate vicinity of the machine.
• Engine oil, hydraulic fluid and compressor oil are flammable. Do not operate a machine
with leaking or worn hoses or lines.
• Do not clean washable filter elements with flammable solvents, diesel fuel, kerosene, or
gasoline.
• Do not attempt to perform welding repairs until all flammable materials including oil and fuel
spills oily rags, and rock and coal dust, have been isolated or removed from the machine.
• Disconnect the battery cables before welding on the machine.
• Keep tools away from exposed live electrical parts such as terminals, to avoid arching.
• If charging the batteries, always turn the charger off before making or breaking connections
to the battery.
• The compound (ethyl ether) used in the engine starting aid system is extremely flammable.
Changing the cylinders and servicing this system should be done in a well ventilated area.
Do not store or install the cylinders in temperatures above 71° C (160° F).
• The anti-freeze compound (methanol) used in the air line anti-ice systems is flammable.
Refill the system with compound only in well ventilated areas, away from heat, open flames
and sparks. Do not store or expose this system or the compound to temperatures above
65° C (150° F), or in direct sunlight.

2.8.6. Fire Suppression

IN CASE OF FIRE!

When a fire starts, the way you react is very important. As soon as you become aware of a fire, do
the following four things:

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1. Turn the machine off.

2. Get away from the machine. Take a hand
portable extinguisher along if you can. A
fire extinguisher is located on the outside
back of the cab.
3. Stand by with the hand portable
extinguisher.
RESULTS

- If you leave the machine running, it may add fuel to the fire or restart the fire with sparks.
- React quickly so the fire is caught before it grows too large.
- By leaving the immediate fire area, you protect yourself from windblown flames, explosions
or other dangers created by the fire.
- Heat remaining from the fire could cause reignition after the fire suppression system has
discharged. Because of this, it is important that someone stand by, at a safe distance, with
a hand portable extinguisher. This standby should be maintained until all possibility of
reignition is past.
- When a fire suppression system discharges, there is considerable noise accompanied by
clouds of dry chemical. While breathing foreign particles is not pleasant, the agent FORAY
is non-toxic and exposure during a fire will not harm you.

2.9. Maintenance Information

Before carrying out any maintenance on this product read and understand the information given in
the Maintenance Manual. Make sure that you have the skills and authority needed before starting
any maintenance work. The Maintenance manual supports maintenance personnel in respect of
preventive maintenance for this product. Section 5 provides instructions for periodic Mechanical
Inspections to the maintenance and operating personnel for components and equipment installed.

Ensure all necessary electrical, hydraulic and air isolations (see ‘Isolation and Energy Dissipation’)
have been carried out prior to starting any maintenance work. Also ensure that necessary original
spare parts or materials are available, or can be ordered and supplied in time to meet the work
schedule. Note all completed maintenance activities in a maintenance log or maintenance program.

The operator of this machine is also required to perform a series of maintenance tasks before
beginning his shift. Section 4 of the Operator’s manual contains a check list and description of how
the maintenance should be carried out. These tasks require a low level of technical skill.

Maintenance tasks requiring a high level of technical skill include:

• Hydraulic maintenance
• Electrical maintenance
• Crawler maintenance
• Engine maintenance
• Compressor maintenance

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2.10. Environment
Sandvik actively considers environmental concerns when designing and manufacturing its products.
Our equipment is designed to burden the environment as little as possible; examples; the vibration,
noise, exhaust, and lubrication/additive emissions of the machine have been minimized. The
manufacturing process for our equipment has been designed so that recycled materials are used as
much as possible, and the process quality and emissions are considered carefully in selection of the
subcontractors. There is an ongoing aim of continually lowering the emissions from the machining of
metal, and from painting and assembling this equipment.

These instructions that follow are not binding, but they offer suggestions for appropriate waste
disposal procedures. Local authorities always have more detailed instructions and
recommendations on the disposal of different materials.

If a known pollutant is accidentally released into the environment, the local authorities must be
notified immediately.

2.10.1. Destruction
The end user of the equipment is responsible for its decommissioning. If the end user does not have
the ability or the resources to disassemble the equipment, the work must be performed by someone
who does possess the necessary knowledge and skills.

2.10.2. Recycling
The equipment body, all the steel constructions, and the copper and aluminum in the electrical
wiring are recyclable. The metals can be melted and used as raw material for new products, except
for parts that have been in contact with substances that are regarded as hazardous waste. The
contaminated parts can usually be simply cleaned or rinsed, after which they can be recycled.
Most plastic parts are recyclable, similarly to the metals. Each plastic part carries information on the
material used and a manufacturing date, which can be used for determining whether the part can be
recycled.

2.10.3. Disposal
Follow all local laws and regulations when disposing of used machine components.

- Rubber parts are not regarded as hazardous, and they can be disposed of according to
normal procedures. Tubes (hydraulics etc.) must be cleaned before they are disposed of.
- Liquids such as fuel and oils should never be drained without suitable catch bins and
containers.
- Windshields and other cabin windows are not accepted for conventional glass recycling,
but they can be disposed of via normal waste disposal methods.
- Electrical components that are classified as hazardous waste (accumulators, batteries,
circuit boards) and other hazardous waste must be delivered to a licensed waste treatment
location or be disposed of according to local regulations.
- Air conditioning units, which contain CFC and HCFC compounds, must always be
delivered for treatment to a licensed waste disposal facility.

2.10.4. Incident Reporting

If an accident or near-miss occurs with this product, contact your regional Sandvik office. When you
contact the office be sure to include the following information:

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- Were personnel injured?
- The conditions and potential hazards at the machine location.
- The serial number of the machine.
- Detailed photographs or videos of the incident scene.
- The incident report from the mine operator.

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3. Machine Description

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3. MACHINE DESCRIPTION

3.1. Nomenclature and Terminology

- Air Swivel - The mechanical joint that allows flexibility between the fixed air pipe from the
compressor and the rotating drill head.
- Annulus - The clearance in the drill hole between the drill pipe and the walls of the hole.
- API - American Petroleum Institute.
- Auxiliary Pump Drive - The gearbox second in line from the engine. It transfers drive to
pumps for feed and rotation and cooling fan.
- Balling Air - Is compressed air, which has passed down the inside of the drill string to lift drill
cuttings from the bottom of the hole to the surface.
- Bench Drilling - Blast hole drilling for bench blasting, which is the simplest form of blasting.
Characteristic for a bench is that it has a free surface at the front towards which the rock is blasted.
Bench drilling can be carried out both over and underground and drilling can be directed upwards,
downwards or horizontally.
- Bit - The part of a drill string which cuts the rock or soil.
•Carbide - A bit having inserts of tungsten carbide.
•Coring - A bit that grinds the outside ring of the hole, leaving an inner core intact for
sampling.
•Roller - A drill bit consisting of a pin shank, pin shoulder, bit leg including shirttail,
three separate cones with cutter teeth, nozzles, and a stamped description.
- Bit Break-Out - See Bit Wrench
- Bit Wrench - A plate used to hold a drill bit while it is being joined to or removed from other drill
string components.
- Blast Hole - A drill hole 4 inches (10 cm) or more in diameter, used for a charge of explosives.
- Box - The female end of a drill pipe.
- Box Thread - The female side of API, IF, BECO or RH thread.
- Carbide Bit - A steel bit which contains inserts of tungsten carbide.
- Carousel - The rotating components of a loader.
- Centralizer - A device to assist in alignment of drill steel in the mast. Primarily used for angle
drilling applications and single pass machines.
- Choke - An adjustable restrictor for a DTH (down-the-hole hammer) that sets the division of air
flows between the hammer mechanism and the bailing air.
- Collaring - Starting a drill hole. When the hole is deep and solid enough to hold the bit from
moving about, it is said to be collared.
- Deck Bushing - See Table Bushing
- Deck Wrench - See Holding Wrench
- Diamond Drill - A light rotary drill, most often used for exploratory work.

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- Drill Bit - One of a number of different types of detachable cutting tools used to cut a circular
hole in rock, wood, metal, etc.
- Drill Collar - Thick walled drill pipe used immediately above a rotary bit to provide extra weight
on top of the drill bit.
- Drill Pipe - The sections of a rotary drilling string used to advance the drill bit or DTH into the
ground.
- Drill Steel - Hollow steel connecting a percussion drill with the bit. May be referred to as drill
rods.
- Drill String - All rotating components connected together between the top drive and drill bit.
- Down-The-Hole-Hammer (DTH) - Pneumatic powered percussion rock drill. A chuck driver,
drill bit, retaining rings and a foot valve for this type of rock tool make a very efficient drilling method.
- Feed Cylinder - Hydraulic cylinder (s) used to feed and retract the drill string by means of a
chain or cable attached to the top drive.
- Flushing Medium - Water, mud, air or foam used to flush drilled-out material out of the hole.
- GUI - Graphic User Interface display screen in the operator’s cab.
- Holding Wrench - A wrench tool mechanism fixed to the drill platform and used to hold drill
pipe and subs to prevent them from falling down the hole and turning when making and breaking
pipe joints.
- Lift Plug - A drill string tool that attaches to the winch cable and is used to lift hammers,
stabilizers, subs and drill pipe. Lifting plugs are manufactured with box or pin type connections.
- Loader - A rotating carousel rack designed to hold drill pipes. This device can be installed
inside or outside the mast.
- Main Pump Drive - The pump drive gearbox first in line from the engine. It normally drives the
propel pumps plus sometimes the feed and rotation pumps.
- Mud - Additives to ‘water injection’ water for making a drilling fluid to improve performance in
hole cutting, hole cleaning, hole stability and productivity.
- Multi Pass Drilling - Drilling to such depths that it requires the use of more than one piece of
drill pipe.
- Percussion - A pneumatic or hydraulic powered pulsation used to break rock.
- Pin - The male end of a drill pipe.
- Pin Thread - The male side of API, IF, BECO and RH tapered thread.
- Pipe Support - A mechanism used to support drill pipe in the mast during pipe changing
operations when angle drilling.
- Power Tong - A hydraulically operated wrench fixed at the bottom of a drill mast, used to break
tight drill string joints by clamping and turning.
- Power Wrench - See Power Tong
- Propel Gearbox - See Main Pump Drive
- Propelling - The act of moving a crawler mounted drill in either direction. Also may be referred
to as tramming.

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- Pulldown - The force used to press the drill string and bit against the bottom of the hole. It is
controlled by the hydraulic pressure in the feed cylinders (up to the relief valve setting), and is
related to the overall weight of the drill rig. The pressure at the bit will be the sum of the pulldown
force plus the force exerted by the weight of the drill string. The term is also used to specify the
pulldown force, which is available from a particular drill.
- Pulldown Cylinders - See Feed Cylinder
- Receiver Tank - A tank vessel in the compressor system used to hold compressed air and
separate the compressed air and oil. Also referred to as a Separator Tank.
- Round Trip - The process of pulling the drill string from a borehole, performing an operation on
the string (such as changing bit, emptying core barrel, etc.) and then returning the drill string into the
borehole.
- Single Pass Drilling - Drilling which is completed using only one piece of drill pipe.
- Stabilizer - A device to assist centering the bit in the hole to prevent hole deviation and
providing equal weight distribution to each rotary cone. It is normally placed immediately behind the
bit. Several stabilizers may be used in a long drill string.
- Stacker Valves - A slang term for a hydraulic control valve that contains several spool valves.
One inlet section, several working sections and an outlet section. The inlet section will have a relief
valve for circuit protection.
- Stroke - 1. Total top drive travel in the mast. 2. The extension length of a hydraulic cylinder rod.
- Subs
•Bit Subs - A section of drill string used to connect a bit, which have an API thread,
to the drill pipes, which may have API, IF, RH, BECO threads.
•Bypass Top Sub - A section of drill string that bypasses compressed air from a
DTH. Used when bad ground conditions warrant extra flushing.
•Saver Subs - Connectors between drill pipes, drill bits and the top drive that save
the threads of these components from the effects of constant use.
•Shock / Cushion Subs - Tools that absorb shock and vibration with a resilient
rubber element, preventing metal to metal contact in the drill string.
•Top Sub - A saver sub that connects to the top drive bull shaft.
- Swivel Head - A device that allows compressed air to be delivered to a drill bit on a diamond
drill, reverse circulation, and Kelly drive system.
- Table Bushing - A replaceable bushing located in the mast table. This bushing centralizes the
drill pipes as they passing through it. A fixed bushing for vertical drilling and a bearing type for angle
drilling.
- Thread Protectors - Threaded covers designed to prevent damage and contamination of the
threads on drill string components.
- Tooling - Tools used to ‘make’ and ‘break’ drill string joints, e.g. auto tong, holding wrench.
- Top Drive - The hydraulically driven gearbox that turns the drill string.
- Top Hammer - A rock drill which works on a feed slide. As the top hammer cannot enter into
the hole, the distance between it and the drill bit increases, as the hole becomes deeper.

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- Torque - Rotary - The turning force a hydraulic motor and planetary reduction gears mounted
on a top drive develop. The torque is specified in Nm (inch-pounds).
- Travelling Carrier - A support for the feed and hoist chains. Sprockets slide up and down by
the feed (pulldown) cylinder (s) motion.
- UHV Up-Hole Velocity - The upward speed of the bailing air in the annulus of the drill hole.
Refer to the Air Water Velocity Charts.
- Water Injection - The system by which the addition of a small quantity of water to the bailing
air is used to suppress drilling dust.
- Work Deck - A deck at the base of the mast which gives access to components in the drilling
area.

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3.2. Technical Data

135°

10109 mm
398”

3810 mm
150”

9817 mm
386 1/2”
3277 mm
129”
2997 mm
118”

40° 30°

90°

9458 mm
372 3/8”

10°

54°
VERTICAL
HOLE RANGE
9458 mm
372 3/8”

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3.3. Main Components and Systems

3.3.1. Mast and Feed System

The feed system uses a hydraulic pump to power a hydraulic cylinder in the mast. The rod end of
the cylinder is attached to a feed chain which raises and lowers the top head. Feed chain tension is
adjusted with adjusting nuts in the mast.

1. Boom
2. Boom Lift Cylinder
3. Boom Swing Cylinder
4. Mast Dump Cylinder
6
5. Mast Swing Cylinder
6. Mast Assembly
7. Carousel Assembly
8. Cable Chain
9. Mast Valve Junction Box (see
detail)
10. Triple Jaw Breakout (TJBO) 20
Manifold
11. Feed Extension Cylinder
12. GPS System (optional not 8 13
shown)
13. Digital Guidance System
(optional)
14. Cable Weight 13

15. Top Drive

16. Cushion Sub 10 7

17. Grease Fitting Bank

11
18. TJBO System
19. Diverter Assembly
20. Winch
1
21. E-Stop
4

See next page for other point locations. 3

9
2 9

18
19

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14
12

SEE ROTATION
SYSTEM DETAIL

13

17

21 5
18

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Rotation System

The rotation system takes hydraulic power and

turns it into mechanical energy to turn the drill
string. The hydraulic system is a closed loop circuit
with a pump and motor. The hydraulic motor turns a 15
planetary gear drive (Top Drive) for speed and
16
torque which turns the top drive bull shaft and the
drill pipe.

Mast Valve Junction Box

1. Lower Breakout Clamp 1

2. Carousel Rotation
3. Clamp 2
4. Arm
5. Diverter
3
6. Centralizer
7. Upper Breakout Clamp
4
8. Breakout
9. Winch
5

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3.3.2. Frame

Item Description Item Description

1 Undercarriage 12 Battery/Starter Isolator
2 Operator Tram Platform 13 Water Injection Pump
3 Remote Control Panel (RCP) 14 Hydraulic High Pressure Filters
4 Set-up Valves and Gauge Panel 15 Hydraulic Tank Isolation Valves
5 Water Tank 16 Compressor/Fan Electrical Panel
6 Hydraulic Tank 17 Receiver Tank
7 Compressor Air Filter 18 Fluid Sampling Panel
8 Compressor Air Intake 19 Drill Fluid Panel
9 Engine Air Intake 20 Emergency Stop
10 Engine Air Filter 21 Radiator Water Level Gauge
11 Fire Suppression System 22 Pump Selector Switch

3 4 5 6 7 8 9 10

21

22

1 2 11 12 13 14 15 16 17 18 19 20

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Item Description Item Description

1 Service Step 9 Engine Coolant Filter
2 Battery Box 10 Wash Wand and Hose Reel
3 Fuel Tank Assembly 11 Hammer Oil Tank
4 Mast Rest
5 Engine Filter Mounting Plate (detail below)
6 Fuel Filter/Water Separator
7 Manual Fuel Primer
8 Engine Oil Filter

11 10

7 8
2

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3.3.3. Frame Rear

Item Description Item Description

1 Engine Radiator 6 Compressor Oil Cooler
2 Hydraulic Oil Cooler 7 Remote Camera
3 Lights
4 Backup Alarm
5 Diesel Fuel Cooler

2
7

4
3

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3.3.4. Remote Control Panel

The RCP is made up of three panels. The left panel contains electrical switches and houses the
VMM modules and inputs/outputs. The right panel holds the main hydraulic valve bank with manual
controls for machine set-up as well as tram and compressor gauges. The lower panel contains tram
and drilling controls.

Item Description Item Description

PLC Panel (left)

1 Engine Speed - Dec / Inc 5

Ignition - Stop / On / Start

2 Engine Shutdown Timer 6 Both - Left Track / Right

(Optional)
Track

3 Horn 7
Emergency Stop
Oscillation - Up / Down
4 8
Lock / Float
Set-up Valve Bank and Gauges (right)
9 Oscillation 19 Compressor Discharge Pressure
10 Cab Swing 20 Compressor Discharge Temperature
11 Cab Tilt 21 Left Tram Pressure
12 Boom Lift 22 Right Tram Pressure
13 Boom Swing 23 Cab Control Lockout Switch
14 Mast Swing 24 Feed
15 Mast Dump 25 Left Tram
16 Feed Extension 26 Rotation
17 Air 27 Right Tram
18 Water 28 Water Level Gauge

PCP PANELS 9
10 19
11
12
2 (OPTIONAL)
13 20
1
14
4
3 15
16 22
6
5 17
18 21
28
7 8 27
26
24 25
23

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3.3.5. Inside of Frame

Item Description Item Description

1 Diesel Engine 11 Compressor Oil Filter
2 Rod Grease Solenoid 12 Washer Hose Reel
3 Air Pressure Regulator 13 Grease Pump
4 Inlet Bypass Solenoid 14 Return Filter
5 Compressor Air Inlet 15 Feed/Left Tram Pump
6 Compressor Inlet Cylinder 16 Rotation/Right Tram Pump
7 Compressor Oil Pressure Switch 17 Fan Pump
8 Compressor 18 Pump Drive Gearbox
9 Compressor Oil Stop Valve 19 Coupling Drive Cover
10 Compressor Differential Switch 20 Diesel Fuel Tank

3 7
2 4 5

12
6

11

13

8 9 10

1 20

17

19

14
15 16 18

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3.3.6. Operator’s Cab14

Item Description Item Description
1 Operator’s Cab Access Step 8 Cab Electrical Junction Box
2 Working Lights 9 Windshield Washer Tank
3 Boarding Light 10 Cab Boom Lift Cylinder
4 Driller Window Step 11 Cab Boom
5 Tramming Lights 12 E-Stop
6 Cab Boom Accumulator (cover) 13 Safety Handle
7 Cab Pressurizer/Air Filter 14 Grab Handle

5
3

13

14

4 14

2
1 7

13
6

11
9
10

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Cab Interior

Item Description Item Description

1 Joystick, Left 7 DTI Control Module
2 Joystick, Right 8 GPS Control Module
3 Engine Control Panel 9 Safety Decals
4 DTI Angle Blaster Display Screen 10 Buddy Seat
5 Touch Screen 11 Operator’s Chair
6 AM/FM Radio/CD Player 12 Video Camera Display

12 7
6

5
9

10
11
3
2

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Engine Control Panel

Item Description Item Description

1 Boarding Light Switch 14 Emergency Stop Switch
2 Battery Voltage Gauge 15 Engine Throttle
3 Fuel Gauge 16 Tram Window Wiper
4 Engine Tachometer 17 Drilling Window Wiper
5 Engine Run 18 Top Window Wiper
6 Engine Stop 19 Chair Heater
7 Engine Diagnostic 20 Floor Heater
8 Engine Wait to Start 21 Tram Lights
9 Coolant Temp Gauge 22 Drill Lights
10 Oil Pressure Gauge 23 Ignition Switch
11 Not Used 24 Engine Start Switch
12 12V Auxiliary Plug 25 Horn
13 Computer Switch 26 DTI Angle Blaster Display Screen

26

5 6 7 8
2 3 4 9 10

1
15
13 14
12

16 17 18 19 20 21 22 23 24 25

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Wireless Control Panel

After the engine has been started, the optional wireless controls can be activated by positioning the
CAB / WIRELESS MODE switch (24) to the wireless position. Active the remote with the START
button.

24

LEFT CRAWLER
RIGHT CRAWLER
OSCILLATION / TRAM
OSCILLATION / TRAM

WINCH CABLE
UP / DOWN

HORN

START
OSCILLATION
LOCK

EMERGENCY
STOP

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3.3.7. Tram/Propel System

The tram system takes hydraulic power and turns it into mechanical energy to power the crawler
final drive gearboxes. The final drive gearboxes have output sprockets which drive the crawler
chains and shoes.

OSCILLATION TOP ROLLERS

CYLINDER
TRACK
FRAME
PIVOT

FINAL DRIVE FRONT IDLER

LOWER ROLLERS TRACK FRAME

The tracked undercarriage has been designed as one complete unit. The undercarriage consists of
track frames (1), track chains and pads (2), drive components composed of a hydraulic motor (3),
final drive (reduction unit) (4), and a sprocket (5). Traction is transmitted to the track through the
sprocket (3) which is attached by bolts (6) to the final drive (4) that is driven by a hydraulic motor (1).

3
2

1
5

6
1 4

The final drive used for this undercarriage has a multi-stage planetary reduction gear, equipped with
multi-disc brakes that also act as parking brake. The brake is activated by a spring and released by
hydraulic pressure. The multi-disc brake must necessarily be released before activating the
hydraulic system of the final drive.

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Serial Number

All the undercarriages or side frames have a

drawing code and serial number located as
indicated on the identification plate.

These numbers must always be quoted when

asking for information or requesting parts.

IDENTIFICATION
PLATE
TRACK
FRAME
3.3.8. Fire Control System

Hand-held Extinguishers Locations

A hand-held fire extinguisher is mounted on the
outside of the cab on the left back side.

In Case of Fire:

1. Shut down the drill and set the brakes

immediately.
2. Evacuate the vehicle.
3. Stand by with a hand portable fire
extinguisher.
After the Fire is Out:

Machinery should not be restarted until it has been serviced and cleaned. IMMEDIATELY recharge
the fire suppression system. You needed it once; you may need it again.

DANGER
Heat remaining from the fire could cause re-ignition after the system has dis-
charged. Because of this, it is important that someone stand by, at a safe dis-
tance, with a hand portable extinguisher. This stand-by should be
maintained until all possibility of re-ignition is past.

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3.4. Display Screens

A color display screen is used for graphical illustration of various functions activated by an operator
using joysticks. Four screens have been programmed to control all functions of the drill. A menu bar
for the four control screens is always visible at the top of the display. They are accessed by using
the touch screen. Just touch the appropriate tab at the top and that screen will be displayed.

3.4.1. Control System Screen Display

The Control System Screen, as illustrated below, is the default screen that appears when the
system is turned on. The sections of the screen discussed below are as follows:

• Control Screen Selector

• Joy Stick Buttons
• Status Indicator
• Status Bar
• Menu buttons

CONTROL SCREEN STATUS

SELECTOR MENU INDICATOR
STATUS BAR

LEFT AND RIGHT

JOYSTICK BUTTONS

MENU
BUTTONS

The Air Flush button on the System screen is a cold weather applications option used to prevent ice
formation in the water pump discharge line. The 20 seconds default setting is adjusted in Config
settings.

Control Screen Selector Display

The Control Screen Selector bar has symbols that are highlighted when touch selected, but visible
in the each of the control functions. When selected by touching, the symbols display information
used to the access various operations of the drill.

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Status Indicator Display

At the top right hand corner of every

operating screen, there is a status Outer Ring - Canbus gateway
indicator. Green means the status is fine GREEN - Functioning
while orange means there is an issue with ORANGE - Not Functioning
the corresponding system. Please refer to
figure the different systems that are Inner Ring - Safety Bar at door
monitored GREEN - Engaged (down)
ORANGE - Disengaged (up)
Status Bar Display

There is also a status bar with symbols that are always visible in the each control functions. These
symbols represent and display information about the various systems of the drill.

1 2 3 4 5 6 7 8 9 10

Item Description
1 Rotation speed
2 Feed rate (feet per minute)
3 Weight on bit (pounds)
4 Carousel - rods in string
5 Pulldown pressure (psi)
6 Holdback pressure (psi)
7 Rotation pressure (psi)‘
8 Air pressure (psi)
9 Hole depth - Top displays of current rod in feet, can be reset by
touching icon. Bottom displays pre-set depth in feet.
10 Total footage - Can be reset in pre-set menu or by touching icon.

NOTE: Some symbols may not be shown if that feature is not installed or enabled on your unit.

Joystick Button Display

At the bottom portion of the operating screen are sets of six circles representing the various joystick
selector buttons. The circles indicate the buttons selected and are lit up when selections are
engaged.

SCREEN
DISPLAY

JOYSTICK

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Menu Button Display

On the right side of the display, various configuration and display menus can be
accessed by touching the screen.

Operate will display the ERIS system that operates the touchscreen signal sending
module interface for controlling the drill

Config will display various configuration options for the drill

Diagnostic will display various diagnostic options (only available if logged in with
Config or Administrative password)

Engine will display various engine parameters and any fault codes

Exit will shutdown ERIS program (only available if logged in with Config or
Administrative password)

Error will display various errors that have occurred while operating the equipment

3.4.2. Shutdowns and Warnings Display Screens

There is a comprehensive instrumentation and protection group on this unit to protect both the
operator and the machine. This package includes visual aids, shutdown protection devices, and
visual alarms. The shutdowns will shut the engine down in the event that they are activated.
Warning indicators warn the operator whenever the system is not operating within its parameters.

Whenever a shutdown or warning has been activated, it will be necessary to acknowledge it by

touching the Panel View on the Acknowledge symbol. The problem must be diagnosed and repaired
before continued use. In the event of a shutdown, allow the receiver tank to bleed down before
restarting the unit.

NOTICE
NOTICE
Startup should never be attempted until the pressure in the receiver tank has
fully bled down. If start up is attempted with high receiver pressure, damage
could result.

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Items on the screen below with red numbers will shut down the entire system if activated.

1 2 3 4 5

6 7 8 9 10

11 12 13 14 15

16 17 18 19 20

21 22 23 24 25

26 27 28 29 30

31 32 33 34

1. Engine Oil Pressure Low

Shutdown - Activated when the engine oil pressure drops below the acceptable level based. To
repair this error, please contact a Sandvik service representative.
2. Compressor Oil Pressure Low
Shutdown - Activated when the compressor oil pressure drops below 6.2 bar (90 psi).
3. Compressor High Interstage Temp
Shutdown - Activated when the compressor interstage temperature rises above 138°C (280°F).
4. Compressor High Discharge Temp
Shutdown - Activated when the compressor discharge temp rises above 149°C (300°F).
5. Low Water Level
Warning - Activated when the water level in the water tank is approximately below 0.305 m (1 ft.).
6. Hydraulic Oil Low Level
Warning - Activated when the hydraulic oil level drops below 0.79 m (30 in.).
7. Hydraulic Oil High Temp
Warning - Activated when the hydraulic oil temperature rises above 82°C (180°F).
8. Low Rock Oil Level
Warning - Activated when the rock oil level drops below the bottom sight glass on the tank.
9. Cab E-Stop
Shutdown - Activated when the cab E-Stop button is pushed
10. Tram Step E-Stop
Shutdown - Activated when the tram step E-Stop button is pushed.

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11. Engine Air Filter

Warning - Activated when the engine air filter requires replacement.
12. Cable Safety Mast E-Stop
Shutdown - Activated when the mast E-Stop cable is pulled.
13. Intentional left blank
14. Chassis Grease Pressure Switch
Warning with Alarm - Activated when the correct grease pump pressure has not been reached
before the pre-set time cycle is complete.
15. Pulldown Out of Range
Warning - Activated when the pulldown pressure is out of range 0-345 bar range (0 – 5000 psi).
16. Holdback Out of Range
Warning - Activated when the holdback pressure is out of range 0-345 bar range (0 – 5000 psi).
17. Rotation Out of Range
Warning - Activated when the rotation pressure is out of range 0-345 bar range (0 – 5000 psi).
18. Drill Air Out of Range
Warning - Activated when the drill air pressure is out of range 0-70 bar range (0 – 1000 psi).
19. E-Stop Mast Rest
Shutdown - Activated when the mast rest E-Stop button is pushed.
20. Safety Relay
Shutdown - Activated when any shutdown is triggered; eliminates electrical power to any moving
parts on the unit – lights, gauges, sensors remain active.
21. Compressor Air Filter
Warning - Activated when the compressor air filter requires replacement.
22. Right Auxiliary E-Stop
Shutdown - Activated when the right side auxiliary E-Stop button is pushed.
23. Left Auxiliary E-Stop
Shutdown - Activated when the left side auxiliary E-Stop button is pushed.
24. Compressor Oil Temperature High
Alarm - Activated when the compressor oil temperature reaches 143°C (290°F).
25. Engine Coolant Temperature High
Alarm - Activated when the engine coolant temperature reaches 106°C (223°F).
26. Compressor Differential Pressure High
Alarm - Activated when the pressure differential between receiver and oil pressure
is greater than 6.9 BAR (100 psi) for more than 2 seconds.
27. Compressor Oil Pressure Out of Range
Alarm - Activated when the compressor oil pressure transducers does not send a valid
signal.

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28. Receiver Air Pressure Out of Range
Alarm - Activated when the receiver pressure transducer does not send a valid signal.
29. Compressor Oil Temperature Out of Range
Alarm - Activated when the compressor oil temperature does not reach 10°C (50°F) after 5
minutes.
30. Hydraulic Oil Pressure Out of Range
Alarm - Option not included.
31. Compressor Oil Pressure Low [Secondary]
Shutdown - Activated when the compressor oil pressure drops below 6.2 bar (90 psi) for more
than 2 seconds after it reached 6.2 bar (90 psi) once.
32. Engine Intake Manifold Temperature High
Alarm - Activated when the engine intake manifold temperature reaches 75°C (167°F).
33. Hydraulic Oil Temperature High
Alarm - Activated when the compressor oil temperature reaches 82.2°C (180°F).
34. Fire Suppression
Shutdown - Activated when the fire suppression actuator is pushed.

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3.4.3. Configuration Menu Display Screen

Use the touch screen and press the Config symbol on the main display to access the configuration
menu. To access the configuration system, use the password 129124.

This menu is used to access and change the various settings available for the options on your drill.
Touch Config to bring up key pad. If you log in with the Config password, the following parameters
can be set:

• Tram settings • Accra-Feed Configuration settings

• Makeup/Breakout settings • Lube/Grease/Water settings
• Weight on Bit settings • Pre-set – Setting Hole Depth
• Hour meter settings • Miscellaneous settings
• Diagnosis

Refer to Section 4 (Operations) for Setup procedures.

3.4.4. Tramming and Oscillation

From the Tram screen, oscillation and high speed tramming are
controlled.
Oscillation is controlled by the left joystick. The unit is oscillated up
or down (from front to back) by moving the joystick forwards or
backwards while in this screen.
At the bottom of the screen, there is a graphical representation of
the buttons of the left joystick (except for the yellow selector button).
Oscillation can be locked by pressing the corresponding button on
the joystick as represented on the screen.

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Tramming is controlled with the right joystick. The axis and buttons of the right joystick are
graphically represented on the screen.

NOTICE
NOTICE
Tramming is disengaged by default. To engage tramming, press the “Tram
Enable” button on the left joystick. When tramming is enabled, the button
will show red as seen below.

To perform a function for tramming, the right joystick is moved and/or buttons are pressed for the
corresponding function required as represented on the screen. A red indicator arrow will move pro-
portionally on the screen, showing you the current position of the joystick.
When buttons are depressed, they will first turn red, showing that the button is depressed. When the
function is fully engaged, a green indicator will show up on the screen to confirm that the function is
activated and engaged.

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3.4.5. Set-up Screens

The default screen when switching to the Set-up screen is Layer 1. There are a total of three layers
in the Set-up screen.

Set-up Screen – Layer 1

Layer 1 displays the functions for tramming the left and right tracks individually (set-up mode
tramming). Oscillation and tramming are controlled by the joystick axis. At the bottom of the screen,
the joysticks buttons are represented showing you the available functions of each button.

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Set-up Screen – Layer 2

Set-up screen Layer 2 can be selected from the main set-up screen (Layer 1) by pressing and
holding the Layer 2 button on the left and right joysticks. These layers can be brought up
independently left or right.
The controls in Layer 2 are:
• Left joystick controls cab positioning.
• Right joystick controls the position of the mast boom: up, down, left, and right.

NOTE: This screen will default back to Layer 1 if layer button is release

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Set-up Screen - Layer 3

Set-up screen Layer 3 can be selected from the main set-up screen (Layer 1) by pressing and
holding the Layer 3 button on the left and right joysticks. These layers can be brought up
independently left or right.

The controls in layer are:

• Left joystick controls mast dump and swing.

• Right joystick feed extension up or down.

NOTE: This screen will default back to Layer 1 if layer button is released.

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3.4.6. Drill Screens
Drill Screen – Layer 1

The default screen when switching to the Drill screen is Layer 1.

• Left joystick controls functions for the carousel arm and clamps.
• Right joystick controls functions for the feed and rotation.

Stage 1 and 2 top drive position indicators are also displayed, along with a Carousel Arm Out indica-
tor. During the pipe storage process, Stage 1 light is on indicating that a pipe (drill rod) is in position
to be returned to the carousel. During the next stage of the pipe storage process, the Stage 2 light is
on indicating the top drive is elevated to a position above and out of the way of the pipe, so the pipe
can be returned to the carousel.

The Carousel Arm Out light is on when the arm out of the drill area and in the carousel.

The buttons also control various functions for drilling, such as turning on drill air and water.

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Drill Screen – Layer 2

Pressing and holding the Layer 2 button on each joystick will display Layer 2 of the Drill screen as
shown in the figure below.

• Left joystick controls the winch.

• Right joystick controls the Breakout clamp, and Centralizers.

NOTE: This screen will default back to Layer 1 if layer button is released.

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Drill Screen – Layer 3

Pressing and holding the Layer 3 button on each joystick will display Layer 3 of the Drill screen as
shown in the figure below.
• Left joystick controls carousel rotation, and pipe breakout functions.
• Right joystick controls the breakout wrench, and diverter functions.

NOTE: This screen will default back to Layer 1 if layer button is released.

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Drill Screen – Manual Drilling Layer 1

Manual drilling is accessed from the main drill screen.

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3.4.7. Accra-Feed Screen – Layer 1
The Accra-Feed screen can be accessed from the Drill menu.

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3.5. Joystick Functions

The following diagrams and tables provide explanations of the joystick functions for Tramming and
Oscillation, Set-up Screen and Drill Screen sections of the touch screen operation. As selections
are made on the joysticks, the choice is reflected on the touch screen.

RIGHT
JOYSTICK

LEFT
JOYSTICK

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3.5.1. Tramming and Oscillation Functions

TRAMMING AND OSCILLATION

The following table illustrates
OSCILLATE TRAM
functions that are available when TRAM
TRAM function is selected on the 3 4 3 4 SPEED (+)

Touch Screen. Tramming is

disengaged by default. LEFT RIGHT
2 5 2 JOYSTICK 5
JOYSTICK

1 6 1 6
TRAM OSCILLATION TRAM TRAM
ENABLE FLOATING SPEED LOW SPEED (-)

LEFT JOYSTICK
Unit Function Button Selection Joystick Action
Oscillation Down 6 Left Forward
Oscillation Up 6 Left Back
Tram Enable 1 Left None
Oscillation Floating 6 Left None

RIGHT JOYSTICK
Unit Function Button Selection Joystick Action
Tram Forward 1 Left Forward
Tram Reverse 1 Left Back
Tram Right 1 Left Right
Tram Left 1 Left Left
Tram Speed Low 1 Right None
Tram Speed Increase‘ 4 Right None
Tram Speed Decrease 6 Right None

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3.5.2. Set-up

SETUP - LAYER 1
Set-up Layer 1. The following
LEFT TRAM - OSCILLATE RIGHT TRAM - OSCILLATE
table illustrates functions that are
available when the SETUP 3 4 3 4
function is selected on the Touch
Screen. Layer 1 is the default LAYER LAYER LAYER LAYER
3 LEFT RIGHT
screen. 2
JOYSTICK
5 2 2
2 JOYSTICK 5 3

1 6 1 6
TRAM OSCILLATION
ENABLE FLOATING

LAYER 1

LEFT JOYSTICK LEFT TRAM - OSCILLATE

Unit Function Button Selection Joystick Action
Left Tram Forward 1 Left Forward
Left Tram Reverse 1 Left Back
Cab Oscillation Down 6 Left Left
Cab Oscillation Up 6 Left Right
Tram Enable 1 Left Button Only
Oscillation Floating 6 Left Button Only

RIGHT JOYSTICK RIGHT TRAM - OSCILLATE

Unit Function Button Selection Joystick Action
Cab Oscillation Down 6 Left Forward
Cab Oscillation Up 6 Left Back
Right Tram Reverse 1 Left Left
Right Tram Forward 1 Left Right

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SETUP - LAYER 2
Set-up Layer 2. The following
table illustrates functions that are CAB UP - CAB LR BOOM UP - BOOM LR
available when the SETUP
3 4
function is selected on the Touch 3 4
Screen. Layer 2 is selected be
pressing and holding the Layer 2 LAYER LEFT RIGHT
2 5 LAYER LAYER 2 JOYSTICK 5
LAYER
3 JOYSTICK 2 2
buttons on the left and right 3

joysticks or the buttons can be

independently selected. 1 6 1 6
TRAM OSCILLATION
ENABLE FLOATING

LAYER 2

LEFT JOYSTICK CAB UP - CAB LR

Unit Function Button Selection Joystick Action
Cab Down 5 Left Forward
Cab Up 5 Left Back
Cab Left 5 Left Left
Cab Right 5 Left Right
Oscillation Floating 6 Left Button Only

RIGHT JOYSTICK BOOM UP - BOOM LR

Unit Function Button Selection Joystick Action
Boom Down 2 Right Forward
Boom Up 2 Right Back
Boom Left 2 Right Left
Boom Right 2 Right Right

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SETUP - LAYER 3
Set-up Layer 3. The following
table illustrates functions that are DUMP - SWING FEED EXT
available when the SETUP
3 4 3
function is selected on the Touch 4
Screen. Layer 3 is selected be
pressing and holding the Layer 3 LAYER LEFT LAYER LAYER RIGHT LAYER
3 2 5 2 2 JOYSTICK 5
JOYSTICK 2 3
buttons on the left and right
joysticks or the buttons can be
independently selected 1 6 1 6
TRAM OSCILLATION
ENABLE FLOATING

LAYER 3

LEFT JOYSTICK DUMP - SWING

Unit Function Button Selection Joystick Action
Mast Dump Down 3 Left Forward
Mast Dump Up 3 Left Back
Mast Swing Left 3 Left Left
Mast Swing Right 3 Left Right
`
RIGHT JOYSTICK FEED EXT
Unit Function Button Selection Joystick Action
Feed Extension Down 5 Right Forward
Feed Extension Up 5 Right Back

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3.5.3. Drilling

Drilling Layer 1. The following DRILL - LAYER 1

table illustrates functions that are
ARM- CLAMP FEED - ROTATION
available when the DRILL COLLAR WATER MANUAL HIGH
function is selected on the Touch AIR DRILLING TORQUE
3 4 3 4
Screen. Layer 1 is the default
screen.
LAYER LEFT LAYER LAYER RIGHT LAYER
3 2 5 2 2 2 JOYSTICK 5
JOYSTICK 3

1 6 1 6
DRILL ACCRA THREAD
AIR FEED GREASE

LAYER 1

LEFT JOYSTICK ARM - CLAMP

Unit Function Button Selection Joystick Action
Arm In None Forward
Arm Out None Back
Clamp Open None Left
Clamp Close None Right
Drill Air 1 Left None
Collar Air 3 Left None
Water 4 Left None

RIGHT JOYSTICK FEED - ROTATION

Unit Function Button Selection Joystick Action
Feed Forward None Forward
Feed Reverse None Back
Rotation Forward None Left
Rotation Reverse None Right
Accra Feed 1 Right None
Manual Drilling 3 Right None
High Torque 4 Right None
Thread Grease 6 Right None

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Drill - Layer 2. The following DRILL - LAYER 2

table illustrates functions that are LOWER BREAKOUT- WINCH UPPER BREAKOUT - CENTRALIZER
available when the DRILL COLLAR WATER MANUAL HIGH
AIR TORQUE
function is selected on the Touch DRILLING
3 4 3 4
Screen. Layer 2 is selected be
pressing and holding the Layer 2
LAYER LEFT LAYER LAYER RIGHT LAYER
buttons on the left and right 3 2 5 2 2 2 JOYSTICK 5
JOYSTICK 3
joysticks or the buttons can be
independently selected.
1 6 1 6
DRILL ACCRA THREAD
AIR FEED GREASE

LEFT JOYSTICK LOWER BREAKOUT- WINCH

Unit Function Button Selection Joystick Action
Clamp Drill String 5 Left Forward
Release Drill String 5 Left Back
Winch In 5 Left Left
Winch Out 5 Left Right
Drill Air 1 Left None
Collar Air 3 Left None
Water 4 Left None

RIGHT JOYSTICK UPPER BREAKOUT - CENTRALIZER

Unit Function Button Selection Joystick Action
Breakout Clamp Engage 2 Right Forward
Breakout Clamp Reset 2 Right Back
Centralizer In 2 Right Left
Centralizer Out 2 Right Right
Accra Feed 1 Right None
Manual Drilling 3 Right None
High Torque 4 Right None
Thread Grease 6 Right None

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Drill - Layer 3. The following DRILL - LAYER 3
table illustrates functions that are MAKEUP/BREAKOUT - CAROUSEL DIVERTER - BREAKOUT WRENCH
available when the DRILL HIGH
COLLAR WATER MANUAL
function is selected on the Touch AIR DRILLING TORQUE
3 4 3 4
Screen. Layer 3 is selected be
pressing and holding the Layer 3
buttons on the left and right LAYER LEFT LAYER LAYER RIGHT LAYER
3 2 5 2 2 2 JOYSTICK 5
JOYSTICK 3
joysticks or the buttons can be
independently selected
1 6 1 6
DRILL ACCRA THREAD
AIR FEED GREASE

LAYER 3.

LEFT JOYSTICK MAKEUP/BREAKOUT - CAROUSEL

Unit Function Button Selection Joystick Action
Makeup Pipe 2 Left Forward
Breakout Pipe 2 Left Back
Carousel Rotate Out 2 Left Left
Carousel Rotate In 2 Left Right
Drill Air 1 Left None
Collar Air 3 Left None
Water 4 Left None

RIGHT JOYSTICK DIVERTER - BREAKOUT WRENCH

Unit Function Button Selection Joystick Action
Diverter Down 5 Right Forward
Diverter Up 5 Right Back
Wrench In 5 Right Left
Wrench Out 5 Right Right
Accra Feed 1 Right None
Manual Drilling 3 Right None
High Torque 4 Right None
Thread Grease 6 Right None

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Drill - Manual Drilling The DRILL - MANUAL

following table illustrates PULLDOWN - HOLDBACK FEED - ROTATION
functions that are available when COLLAR HIGH
WATER MANUAL
the MANUAL DRILLING function AIR DRILLING TORQUE
3 4 3 4
is selected on the Touch Screen.
Layer 1 is the default selection.
LAYER LEFT LAYER LAYER RIGHT LAYER
3 2 5 2 2 2 JOYSTICK 5
JOYSTICK 3

1 6 1 6
DRILL ACCRA DRILL
AIR FEED LOCK

MANUAL DRILLING.

LEFT JOYSTICK PULLDOWN - HOLDBACK

Unit Function Button Selection Joystick Action
Pulldown (+) None Forward
Pulldown (-) None Back
Holdback (+) None Right
Holdback (-) None Left
Drill Air 1 Left None
Collar Air 3 Left None
Water 4 Left None

RIGHT JOYSTICK FEED - ROTATION

Unit Function Button Selection Joystick Action
Feed Forward 3 Right Forward
Feed Reverse 3 Right Back
Rotation Forward 3 Right Left
Rotation Reverse 3 Right Right
Accra Feed 1 Right None
Manual Drilling 3 Right None
High Torque 4 Right None
Thread Grease 6 Right None

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4. Operating Instructions

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4. OPERATING THE MACHINE

4.1. Starting Procedure

Become familiar with the Sandvik drill controls on the operator station and seat prior to starting the
machine (refer to Section 3). While sitting in the operator’s seat check the seat for operator comfort.
The armrests can be adjusted for height, length and width.

The drill must be inspected thoroughly at the beginning of a shift or a project. All items on the
Operators Maintenance Instructions (Section 5) must be OK before starting the engine and
subsequently drilling. It may be necessary to inspect all these items when the drill has to be stopped
and started several times during a shift.

NOTICE
NOTICE
It is not recommended to shut off the engine immediately after starting
unless there is an emergency. The compressor needs time to stabilize after
starting and may become damaged if not allowed to do so.

4.1.1. Starting the Engine Inside the Cab

The following is a step by step procedure for the proper start up the machine inside the cab. The
engine can also be started from the outside panel.

1. Perform the Operator Maintenance

Checklist tasks presented in Section 5.
2. Disengage all the emergency stop
buttons. CAB
3. Turn the Ignition Switch at the Remote ISOLATOR
Control Panel to the OFF position and
ensure the Cab Isolation Switch is
plugged in.
4. Turn the battery and starter isolation
switches to the ON position.

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5. Enter the cab and lower the Safety

Handle.
BATTERY
6. Place all controls on the Cab Control ISOLATOR
Panel in the OFF position.
7. Push the COMPUTER ON/OFF button
(13) on the Cab Control Panel (See
below). Allow the computer time to
boot up or the engine will not start. The
touch screen will display the System
STARTER
Screen. The drill must be in System ISOLATOR
Screen to start the engine.
8. Position the THROTTLE lever (15) in
the idle position, all the way to the
right.
9. Sound HORN (25) to warn people in the machine area prior to startup.
10. Turn the IGNITION key (23) to the ON position. When the engine starting lights 6, 7and 8
turn off and engine light 5 remains on the engine is ready to start.
11. Turn IGNITION key (23) to the START position and release it when the engine starts.

5 6 7 8
4

15

13

23 25

12. Once the engine warms up, the throttle can be moved to the left to increase ENGINE RPM
(4). Set the throttle as needed for operating the machine.

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13. If the engine cranks, but fails to start check that all four E-Stops are pulled out.

NOTICE
NOTICE
If the engine fails to start within 10-15 seconds, turn the ignition key to the
OFF position. Wait for about one minute and turn the key to the START
position again. After about 45 seconds, the compressor low oil pressure
light should go out.

If there is an issue starting the machine due to a low battery condition, the
unit should be started from outside the cab. This will protect the computer
system from any problems that might arise from booting up in a low battery
condition.

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4.1.2. Starting the Engine Outside the Cab

The following is a step by step procedure for the

proper start up of the drill outside the cab:
RCP PANELS
1. Perform the Operator Maintenance
Checklist tasks presented in Section 5.
1
2. Disengage all the emergency stop
buttons. 3
3. Turn off the Touchscreen and all controls
on the Cab Control Panel. 5
4. Make sure the Cab Control Panel throttle
lever is in the idle position all the way to
the right 7
5. Raise the cab door Safety Handle.
23
6. Turn the battery and starter isolation
switches to the ON position.
7. Unpin the Operator Tram Platform and
step up to Remote Control Panel.
8. Sound HORN (3) to warn people in the
machine area prior to startup.
9. Unplug the Cab Isolator Switch (23).
10. Turn IGNITION key (5) to the START
position and hold until the engine starts.
Release the key after the engine starts.
11. Once the engine warms up, the throttle (1)
can be turned to the left or right to set the
rpm.
12. If the engine cranks but fails to start, check
that all E-Stops are pulled out and the cab
isolator switch is unplugged.

NOTICE
NOTICE
If the engine fails to start within 10-15 seconds, turn the ignition key to the
OFF position. Wait for about one minute and turn the key to START again.
After about 45 seconds, the compressor low oil pressure light should go out.

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4.2. Shutdown Procedure

NOTICE
NOTICE
Do not shut off the engine using the battery isolation switch. The computer
may become damaged if not shut down properly.

Shut down the machine as follows:

1. Position the engine THROTTLE (15) to the

low idle position - right. Allow the engine
several minutes to cool down
13
2. Turn IGNITION switch (23) to the OFF
position. If equipped with an optional 15
Engine Shutdown Timer the engine will
continue to run.
23
NOTE: If equipped with an engine timer and the
engine shuts off immediately, ensure the
engine timer switch at the RCP is in the 23
OFF position.

3. Push COMPUTER button (13) to OFF and

wait for two minutes for the computers to
shutdown.
4. Once the IGNITION switch is off and the
computer ON/OFF button has been
pushed, ensure that the Touchscreen is off
before proceeding to step 4. If the
Touchscreen is still on, repeat step 2. The
DTI Angle Blaster display screen above
the control panel may remain on.
5. Proceed to the right rear of the machine to
the battery disconnect box. Turn the main
disconnect box handle from the ON position to the OFF position using the rod key handle
and pull the key out. Now put the lock cover over the slot for the key. This will ensure that
the power has been isolated.

6. The drill has now been shut down DTI ANGLE BLASTER DISPLAY SCREEN
properly.

TOUCHSCREEN

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4.3. Configuring the Display Screens

The DR500 series will operate “default” mode settings with no adjustments to the operational
functions (Tram, Makeup/Breakout, Weight on Bit, etc.). If the operator needs to adjust any of these
functions the machine must be configured from the Touchscreen “Config” menus explained tin the
following topics.

4.3.1. TRAM SETTINGS DISPLAY SCREEN

If you log in with the Configuration password and press “Tram”, the following options become
available. In this menu, you can set the following using the pop-up keypad:

• Default tram speed (default maximum tram speed for single joystick tramming) - entered as
a value between 0-100%. Default is 75%.
• Set up tram speed maximum (two joystick set up for maximum tram speed) - entered as a
value between 0-100%. Default is 65%.
• Left track Forward Bias (used to adjust and offset left track forward speed) - entered as a
value between 0-100%. Default is 100% (full speed).
• Left track Reverse Bias (used to adjust and offset left track reverse speed) - entered as a
value between 0-100%. Default is 100% (full speed).
• Right track Forward Bias (used to adjust and offset right track forward speed) - entered as
a value between 0-100%. Default is 100% (full speed).
• Right track Reverse Bias (used to adjust and offset right track reverse speed) - entered as
a value between 0-100%. Default is 100% (full speed).

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4.3.2. MAKEUP/BREAKOUT SETTINGS DISPLAY SCREEN
If you log in with the Configuration password and press “Makeup/Breakout”, the following options
become available. In this menu, you can set the following using the pop-up keypad:

• Makeup rotation – default is 80%

• Makeup feed – default is 30%
• Breakout rotation – default is 80%
• Breakout feed – default is 33%

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4.3.3. WEIGHT ON BIT SETTINGS DISPLAY SCREEN

If you log in with the Configuration password and press “Weight on Bit”, the following options
become available. In this menu, you can set the following using the pop-up keypad:

• Weight of top drive – default is 500 kg (1100 lbs)

• Weight of hammer and starter rod – default is 330 kg (730 lbs)
• Weight of one rod – default is 177 kg (390 lbs)
• Number of rods in string
• Travel Distance – this is the max travel distance of the top drive
• Calibrate Laser (see below). To calibrate the laser, move the top drive all the way to the top
of the mast and press “”Mark Top”. Then move the top drive all the way to the bottom of the
mast and press “Mark Bottom”.

Weight on Bit

Calibrate Laser

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4.3.4. HOUR METER SETTINGS DISPLAY SCREEN
If you log in with the Configuration password and press “Hour Meters”, the following options become
available. In this menu, you can set the following using the pop-up keypad:

• Tram Hours – Hours unit has been used in tram mode

• Set up Hours – Hours unit has been used in set up mode
• Drill Hours – Hours unit has been used in drill mode
This screen should only be used to adjust hours to proper values if they have become mismatched
or a major component such as the engine has been replaced.

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4.3.5. ACCRAFEED CONFIGURATION SETTINGS

If you log in with the Configuration password and press “Accrafeed”, the following options become
available. In this menu, you can set the following using the pop-up keypad:

• Feed Forward -% of feed rate – default is 50%

• Feed Reverse -% of feed rate - default is 50%
These values are adjusted to maximize the drilling efficiency of the DR500 series drill when it is
using the Accrafeed function

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4.3.6. LUBE/GREASE/WATER SETTINGS DISPLAY SCREEN
If you log in with the Configuration password and press “Lube/Grease/Water”, the following options
become available. In this menu, you can set the following using the pop-up keypad:

• Hammer Lubrication Off Time (default: 20 seconds)

• Hammer Lubrication On Time (default: 20 seconds)
• Water Line Air Flush Time (default: 20 seconds.
These values are adjusted to maximize the drilling efficiency of the DR500 series drill when it is
using the Accrafeed function.

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4.3.7. PRE-SET CONFIGURATION - SETTING HOLE DEPTH DISPLAY SCREEN

If you log in with the Configuration password and press “Pre-set”, the following options become
available. In this menu, you can set the following using the pop-up keypad:

• Touch the “Hole Depth” symbol to access the swing and dump pre-sets. The hole depth
symbol will now be displayed. To set the “Hole Depth”, touch the symbol and a keypad will
pop-up. Enter the desired depth in feet for each hole and touch the accept symbol to set
the depth.

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4.3.8. MISCELLANEOUS SETTINGS DISPLAY SCREEN
If you log in with the Configuration password and press “Misc”, the following options become
available. In this menu, you can set the following using the pop-up keypad:
• Select “Language Option” for your preferred language for the screen display.
• Select “Unit Options” for your preferred units of measure (bar or psi; feet or meters).

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4.3.9. DIAGNOSTIC DISPLAY SCREEN

If you log in with the Configuration password and press “Diagnostic”, the following options become
available. In this menu, you can set the following using the pop-up keypad:
On this screen, each VMM is shown. If there is any kind of problem with a VMM, it will be shown
outlined in red.

• The “Engine Communication” button will also be shown outlined in red if the engine
becomes disconnected (i.e. if an emergency stop is activated).
• The “Input Device” button shows the status of the joysticks. If the button outlined in red, as
seen below, this indicates there is a problem with the joysticks. Also, an orange image of a
joystick will appear at the top right of the screen when there is a joystick issue.

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4.4. Tramming
Tramming can be done from the cab or from the tram station at the left side of the drill. The
tramming controls are spring-loaded and will automatically return to the neutral position when
released. These controls are proportional and are variable from 0 to full speed of 5 km/hr (3.1 mph).
The tram speed can also be controlled by changing engine speed. The load sensing components of
the hydraulic system maintain the torque on the tracks at a constant level.

The brakes are spring applied/hydraulic released. They are always on and disengage when the
tram lever is pushed away from neutral position allowing hydraulic pressure to release the brakes.

Before tramming the drill:

• Lower the mast if tramming for a long distance or transporting the machine.
• Remove all drill pipe if tramming for long distances.
• Fully retract the drill pipe loader.
• Determine if tramming will be in high or low speed.
• Raise the mast to clear ground obstacles using the feed extension cylinder or boom lift
cylinder or both.

WARNING
While tramming, it is forbidden for personnel to be in the tramming area. Be
sure the tramming area is clear of all personnel before tramming.

5 M (15 ft)

5 M (15 ft) 5 M (15 ft)

5 M (15 ft)

TRAMMING SAFETY ZONE

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There are three ways to tram the drill:

• In Cab TRAM mode - single joystick

• In Cab SETUP mode - dual joysticks
• Outside Tram Station - - dual joysticks
TRAM MODE

4.4.1. Tramming in Cab TRAM Mode

The tram speed is set at low by default. It can be
set to high by pressing the “Tram Low Speed”
button. Tram speed can be increased or decreased
by pressing the tram speed increase or tram
decrease buttons.

1. By selecting the TRAM mode and the

Tram Enable button on the Touchscreen,
the right side joystick will move the
machine in the direction the joystick is
moved.
2. To tram forward or reverse, move the right TRAM ENABLE
joystick forward or backward. To turn
either right or left, move the joystick forward and then to right or left. Tram direction will be
indicated on the screen with the red indicator arrow along the appropriate axis.
3. Tramming function is disengaged by default. To tram, press and hold the ‘Tram Enable’
button on the left joystick. To disengage tramming, release the button. Center the joysticks
to set the crawler brakes.
4. Oscillation is in the unlocked position by default. To change oscillation, press the
“Oscillation Lock” button on the left joystick. This will set oscillation to “locked” indicated by
the function engaged symbol. Move the left joystick to right or left as well as forward or
backward to change oscillation. To unlock oscillation, press the Oscillation Lock button a
second time.

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4.4.2. Tramming in Cab SETUP Mode
SETUP
Tramming controls are also available from the
SETUP mode. In SETUP mode, tramming speed is
much lower than the low speed in the Tram mode.
1. Select the SETUP screen on the upper
part of the Touchscreen. By selecting the
SETUP mode on the Touchscreen, the left
and right joysticks will operate the
individual trams as required for tramming
the left and right tracks separately.
2. Tramming this machine in SETUP mode is
typical of tramming any track driven
machine:
• Push both controls forward an equal
amount to tram straight forward.
• Pull both controls back an equal amount to tram straight in reverse.
• Position one control ahead of the other in the same direction to obtain a large radius turn.
• Counter-rotate (one track forward one reverse) the tracks to make a pivoting turn.

4.4.3. Tramming Outside Tram Station

Select oscillation control (Float/Fixed or Up/Down)

depending on the distance to be trammed and
condition of ground.

The left and right tracks are steered by the left tram
and right tram levers respectively.

TRAM TRAM
LEFT RIGHT

4.4.4. Tramming Stability

WARNING
DO NOT tram the drill on steep inclines, or crosswise to grades; this greatly
increases the risk of drill rollover. DO NOT tram the drill on soft or unstable
ground, or close to unsupported excavation.

When tramming on a slope, the possibility of tip-over exists. In order to reduce and eliminate this
possibility, the DR500 series drill stability limits have been documented. Refer to the Tramming
Stability figure below for stability requirements. A decal of the Tramming Stability figure is found in
the operator’s cab. Familiarize yourself with the limits and recommendations shown on the label
before operating the drill.

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 
20 20
36% 36%
 
3 18

 
11 11
19% 19%

 
20 20
36%  36%
 10
7

 
6 6
10% 10%

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4.5. Operating the Mast
Once the drill is trammed to the desired location, the mast can be set up to drill at a specific angle.
SETUP mode controls include the following:

• Cab Swing: Right or Left

Swing the cab out to the left of the machine for

52°
better visibility and maximum movement of the
boom and mast. To swing cab to left, activate Layer
2 of the left joystick and move the left joystick to the
left.

To move mast boom to right or left, activate Layer 2

of the right joystick and move the right joystick to
the right or the left.

• Cab movement: Up or Down

• Mast Boom movement: Up or Down
• Mast Boom swing: Right or Left
• Mast Swing: Right or Left
• Feed Extension: Up or Down
• Oscillation: Fixed, Float, or Up / Down
• Tram: Right Tram or Left Tram, or Both.

4.5.1. Vertical and Angle Drilling Set Up

1. With engine running, use the Touchscreen to select SETUP. The SETUP screen will
appear as below.

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2. Tramming controls are also available in SETUP mode. Tramming speed in this mode is
much lower than the speed available in TRAMMING mode.
3. Two joysticks accomplish all SETUP and tramming controls
Left joystick has the following controls:

• Layer 1: Left oscillation and left track steering

• Layer 2: Cab swing right/left and cab movement up/down
• Layer 3: Mast dump down/up and mast swing right/left
Right joystick has the following controls:
• Layer 1: Right oscillation and right track steering
• Layer 2: Boom right/left and boom up/down
• Layer 3: Feed extension up/down

Raising the Mast

To raise the mast vertically up, activate Layer 3 with the left joystick and move the left joystick
forward. The mast can be positioned from 10° above horizontal axis to 45° underneath the drill
along its axis.

135°

Always look over head for obstructions or high

voltage power lines when raising the mast. High
voltage power lines can cause severe injury or
death.

10°

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Swinging the Mast
To swing the mast, activate Layer 3 of the left
joystick and move the left joystick to left or right.
Once the mast has been positioned, bring the mast
into firm contact with the ground by lowering the
boom or extending the mast with the feed extension
cylinder. To lower the mast, move the right joystick
forward while layer 3 is activated.
70°

30° 30°

4.5.2. Horizontal Drilling

WARNING
There are inherit risks when drilling close to high wall areas and each owner/
operator must complete their own safety assessment to consider if this
action is acceptable to their own standards.

In preparation of horizontal drilling it is necessary to re-position the swing cylinder to mast mounting
pin. Horizontal drilling is not production drilling. Horizontal drilling requires careful attention to drilling
activities and moving components.

When horizontal drilling, you must adhere to all safety concerns listed below:

• Operator escape route (egress) - Operator’s cab position must never be placed against the
high wall where as the main egress of the operator’s cabin door is blocked. You must follow
your own mine site regulations for safe distance practices while drilling near a high wall.
• Rocks falling off wall face - You must observe the high wall for any loose rocks for
stabilization according to your own mine site regulations.
• Wall falling or sloughing off - You must observe the high wall instability according to your
own mine site regulations.

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• Unstable rock due to excess water - During horizontal drilling mode you must observe the
high wall at all times for any instability issues caused by excessive water drainage and
hammer impact actions.
Use the following procedure to re-pin the swing cylinder to allow the mast to be positioned for
horizontal drilling:

1. Position the top drive to the midpoint of the mast.

LOCKING
2. Rotate the mast in horizontal position as PIN
shown here until the locking pin holes are
aligned.
3. Insert the locking pin 8.9cm x 39.4cm (3.5
in. x15.5 in.) as shown here to secure the
mast, preventing mast from rotating.

4. Use a 19 mm (¾ in.) wrench to remove the

keeper bolt from the mast swing cylinder SWING CYLINDER
pin.

KEEPER PIN BOLT

SWING CYLINDER
5. “Wiggle” the swing cylinder pin with a pry
bar to loosen and remove the pin.

SWING CYLINDER
PIN

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6. Move the swing cylinder to the horizontal
drill position.

7. Install the swing cylinder pin and keeper LOCKING PIN

bolt.
8. Remove the locking pin and stow it.

SWING CYLINDER
PIN

LIMITS OF VERTICAL MAST TRAVEL IN THE HORIZONTAL CONFIGURATION

NOTICE
NOTICE
When drilling horizontally the mast must be rotated top drive up as shown
above to prevent cable chain assembly binding and damage.

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4.6. Drilling Operations

4.6.1. Drilling Procedures

This section describes how to perform the operations required for drilling. During drilling, a number
of functions and controls are available to the operator via the Touchscreen display. To access these
functions, switch to the drilling screen as described in Section 3. The drilling screen with default
Layer 1 will appear as presented below.
The left and the right joystick are used to access the makeup and breakout functions.
The left joystick has been programmed for the following functions and controls:
• Layer 1: Pipe Clamp Close /Open and Carousel Arm In /Out,
• Layer 2: Winch In or Out,
• Layer 3: Carousel Rotation In / Out and Pipe Makeup / Breakout,
Control Buttons: Collar Air On/Off, Drilling Air On/Off, Water Pump On/Off, and Reverse Breakout.
The right joystick has been programmed for the following functions and controls:
• Layer 1: Rotation Reverse /Forward and Feed Forward /Reverse,
• Layer 2: Centralizer Out /In and Slip Plate In /Out,
• Layer 3: Breakout Wrench Out /In and Diverter Down /Up,
Control Buttons: Manual Drilling OFF/ON, Accrafeed OFF/ON, Rotation Torque LOW/HIGH, and
Thread Greaser OFF/ON

Drill Screen - Layer 1

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Drill Screen - Layer 2

Drill Screen - Layer 3

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To access the Manual Drilling screen seen below, press the Manual Drilling button.
This will give you access to the following on the joystick axis:
• Holdback Pressure: Increase or Decrease
• Pulldown Pressure: Increase or Decrease
• Rotation: Reverse or Forward
• Feed: Forward or Reverse
The feed rate and rotation in percentage will be displayed on the status bar at the top of the screen.
Once the desired feed rate and rotation speed are achieved, press the drill lock button to maintain
them.

Drill Screen - Manual Drilling

Drill Screen - Drill Lock On

Once the Drill Lock button is

pressed, the new drilling screen
will appear as illustrated here. Fine
adjustments of feed rate and
rotation speed can also be made
from this screen.

DRILL LOCK

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4.6.2. Hammer Installation Procedures
There are many different types of hammers available but they all have a piston that hammers on the
bit. The differences are the piston size, air porting, and assembly requirements. The installation is
the same and is done as follows:

1. Lean the right joystick slightly to the left (or right) to slowly rotate the top drive while tapping
button 1 on the left joystick to open and close the drill air. Top drive speed will increase with
the distance the joystick is being moved. Pressing button 1 (Drill Air) on the left joystick will
open the air line. Drill air is switched off by default.

ROTATION ROTATION
FORWARD REVERSE
3 4 3 4
2 5 2 5
1 6 1 6
LEFT RIGHT
JOYSTICK JOYSTICK
DRILL
AIR

2. Examine the exhaust air from the top drive for lubrication oil/grease. If no oil/grease is
detected, adjust the injection system until oil/grease appears. See the section below for
grease injection procedures.
3. Stop rotation of the top drive by releasing the joystick. The joystick will return to neutral
position. Pull the right joystick backward and raise (Reverse Feed) the top drive to about
five feet from the drilling table.
4. Select button 2 on the right joystick to engage Layer 2and then push the joystick forward to
close (Breakout Clamp Engage) the lower breakout clamp (slip plate).

BREAKOUT
LAYER 2 CLAMP ENGAGE

3 4 3 4
2 5 2 5
1 6 1 6
LEFT RIGHT
JOYSTICK JOYSTICK

FEED
REVERSE

5. Place the hammer on the slip plate and press button 6 (Thread Grease) on the right
joystick to lubricate the top sub thread and the thread in the top drive. If using a bit basket,
the bit hammer is lowered into it.
6. Select button 2 on the left joystick to engage Layer 3and then push the joystick forward to
makeup (Makeup Pipe) the top joint (between the top drive and the hammer). When joint
makeup is complete, pull the right joystick backward to raise ((Feed Reverse) the hammer
off the slip plate. If using a bit basket, push the right joystick fully to the left (Rotation
Forward) to use full forward rotation pressure to makeup the joint.

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MAKEUP
LAYER 3
PIPE
ROTATION
3 FORWARD
4 3 4
2 5 2 5
1 6 1 6
LEFT RIGHT
JOYSTICK JOYSTICK

FEED
REVERSE

7. Rotation speed and feed defaults can be changed, if needed, in the configuration screen.
8. Select button 2 on the right joystick to engage Layer 2 and pull the joystick backward
(Breakout Clamp Reset) to open the slip plate (Lower Breakout Clamp). Release the button
and push the right joystick forward to move the hammer down until the bit is aligned with
the centralizer jaws.

FEED
LAYER 2 FORWARD

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

LEFT RIGHT
JOYSTICK JOYSTICK

RELEASE
DRILL STRING

9. Select button 2 on the right joystick to engage Layer 2 and then lean the joystick left to
move the bit with centralizer. Release the button then lean the right joystick the left to rotate
the top drive forward to makeup the top driver with the hammer case.

FEED
LAYER 2
FORWARD

3 4 3 4
2 5 2 5
1 6 1 6
LEFT
ROTATE
RIGHT
JOYSTICK FORWARD
JOYSTICK

10. Select button 2 on the right joystick to engage Layer 2 and then lean the joystick right to
open (Centralizer Out) the centralizer jaws. Release button 2 and then push the right
joystick forward to lower (Feed Forward) the hammer through the jaws.

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FEED
LAYER 2
FORWARD
CENTRALIZER
OUT
3 4 3 4
2 5 2 5
1 6 1 6
LEFT RIGHT
JOYSTICK JOYSTICK

11. Select button 2 on the right joystick to engage Layer 2and then lean the joystick to the left
to close the centralizer jaws (Centralizer In) around the hammer to centralize it in
preparation for collaring the hole.

FEED
LAYER 2
FORWARD

3 4 3 4
2 5 2 5
1 6 1 6
LEFT RIGHT
JOYSTICK CENTRALIZER JOYSTICK
IN

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4.6.3. Drill Pipe Installation - Adding Pipe

To increase the length of the drill string, add pipe sections by the procedure outlined below.

1. In Drill mode Layer 1 (default mode), push the right joystick forward to feed (Feed Forward)
the drill string forward (downward in the position shown below) and lean the right joystick to
the left to rotate (Rotate Forward) the pipe forward (clockwise) until the top drive stops
advancing. Turn off all drill functions on the left joystick (drill air, collar air, water) and right
joystick (Accrafeed, manual drilling, high torque and thread grease).
2. Pull the right joystick backward, to reverse feed the drill string until the top of the pin end of
the pipe is located slightly above the Lower Breakout Clamp.

FEED FORWARD
COLLAR WATER
AIR HIGH
MANUAL
TORQUE
DRILLING

3 4 3 4
2 5 2 5
1 6 1 6
LEFT RIGHT
JOYSTICK JOYSTICK

DRILL AIR ACCRA THREAD

FEED GREASE
FEED REVERSE
TRIPLE JAW BREAKOUT (TJBO)

UPPER
BREAKOUT
CLAMP

LOWER
BREAKOUT
CLAMP

CENTRALIZER

TJBO

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3. Select button 5 on the left joystick to engage Layer 2and then
push the joystick the forward to close (Clamp Drill String) the
Lower Breakout Clamp on the pipe.
4. Select button 2 on the left joystick to engage Layer 3, pull the
joystick backward to reverse (Breakout Pipe) rotate (counter-
clockwise) and raise the top drive until it is disconnected from the
pipe.

CLAMP
LAYER 3 DRILL LAYER 2
STRING

3 4 3 4
2 5 2 5
1 6 1 6
LEFT RIGHT
JOYSTICK JOYSTICK

BREAKOUT 4
PIPE

5. Pull the right joystick backward to raise the top drive to the top of
the mast.
6. Lean the left joystick to the right to close the clamp on the pipe
(Clamp Closed). 5

3 4 3 4
2 5 2 5
1 6 1 6
LEFT CLAMP RIGHT
JOYSTICK CLOSED JOYSTICK
6

FEED
REVERSE

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7. Push the left joystick forward to move (Arm In) the carousel arm
in, moving the pipe into the mast.

ARM IN

SWING
3 4 3 4 ARM IN
2 5 2 5
1 6 1 6
LEFT RIGHT
JOYSTICK JOYSTICK

8. Select button 2 on the left joystick to engage Layer 3and then

push the joystick forward to forward rotate (Makeup Pipe) and
lower the top drive until the top joint is made up.
9. Once the joint is made, release button 2 and lean the left joystick
to the left to slightly open the clamp (Clamp Open).

MAKEUP
PIPE
LAYER 3

CLAMP
OPEN 3 4 3 4
2 5 2 5
1 6 1 6
LEFT RIGHT
JOYSTICK JOYSTICK

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10. Push the right joystick forward to lower top drive and pipe until it is
close to pin end of the pipe in the clamping device.
11. Select button 2 on the left joystick to engage Layer 3and then
push the joystick forward to forward rotate and lower the top drive
and pipe until the bottom joint is made up.

MAKEUP FEED
PIPE FORWARD
LAYER 3

3 4 3 4
2 5 2 5
1 6 1 6
LEFT RIGHT
JOYSTICK JOYSTICK

12. Lean the left joystick to the left to open the clamp and then pull the
joystick back to move carousel arm out (Arm out) away from the
mast.
13. Push the left joystick forward to rotate the carousel arm in as
addition pipes are required.

CAROUSEL
ARM IN

CLAMP 3 4 3 4
OPEN 2 2
5 5
1 6 1 6
LEFT RIGHT
JOYSTICK JOYSTICK

CAROUSEL
ARM OUT

NOTE: Make sure that the thread connection is tight before drilling (110 bar or 1600 psi max).
Do not allow the rotary action of drilling to tighten the threaded connections. This may
result in thread damage and will require a greater breakout force.

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4.6.4. Drill Pipe Removal

1. Move the right joystick (forward or backward) to position the top

and bottom pipe joint between the Triple Jaw Breakout (TJBO)
Upper Breakout Clamp and the Lower Breakout Clamp jaws.

FORWARD

3 4 3 4
2 5 2 5
1 6 1 6
LEFT RIGHT
JOYSTICK JOYSTICK

FEED

2. Select button 5 on the left joystick to engage Layer 2and then

push the joystick forward to grip the lower pipe (Clamp Drill String)
with the Lower Breakout Clamp.

CLAMP
DRILL
STRING
LAYER 2

3 4 3 4
2 5 2 5
1 6 1 6
LEFT RIGHT
JOYSTICK JOYSTICK

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3. Select button 2 on the right joystick to engage Layer 2and then
push the joystick forward to break (Breakout Clamp Engage) the
pipe joint.
4. After the joint is broken, select button 2 on the right joystick to
engage Layer 2and then pull the joystick backward to partially
release (Breakout Clamp Reset) the jaws from the pipe.

CLAMP ENGAGE
LAYER 2

3 4 3 4
2 5 2 5
1 6 1 6
LEFT RIGHT
JOYSTICK JOYSTICK

BREAKOUT

5. Select button 2 on the left joystick to engage Layer 2and then pull
the joystick backward to finish breaking out (Breakout Pipe) the
two drill pipes clearing the threads.

3 4 3 4
2 5 2 5
1 6 1 6
LEFT RIGHT
JOYSTICK JOYSTICK

BREAKOUT
PIPE

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6. Select button 2 on the right joystick to engage Layer 2and then

push the joystick forward to clamp the drill pipe again.
7. Release button 2 and lean the right joystick to the right to reverse
the rotation on the pipe to breakout the joint between the saver
sub and the drill pipe.

BREAKOUT
CLAMP ENGAGE
LAYER 2

7
ROTATION
3 4 3 4 REVERSE
2 5 2 5
1 6 1 6
LEFT RIGHT
JOYSTICK JOYSTICK

8. Lean the left joystick to the left to open the carousel (Clamp Open)
function.
9. Push the left joystick forward to rotate carousel (Arm In) to bring
the carousel arm into the feed pipe.
10. Lean the left joystick to the right to close the carousel clamp
(Clamp Close) completely and then lean it to the left briefly
partially release the clamp (Clamp Open).
10
CAROUSEL
ARM IN

CLAMP CLAMP
3 4 CLOSE 3 4
OPEN 2 2
5 5
1 6 1 6
LEFT RIGHT
JOYSTICK JOYSTICK

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11. Pull the right joystick backward to feed the pipe backward until the
Stage 1 indicator comes on.
12. Select button 2 on the right joystick to engage Layer 2and then
pull the joystick backward (Breakout Clamp Reset) to allow the
drill pipe to move freely. 11

LAYER 2

3 4 3 4
2 5 2 5
1 6 1 6
LEFT RIGHT
JOYSTICK JOYSTICK

BREAKOUT FEED
CLAMP RESET REVERSE

13. Select button 2 on the left joystick to engage Layer 3and then pull
the joystick backward to rotate the pipe (Breakout Pipe) until the
Stage 2 light becomes active.
14. Lean the left joystick to the right to close the carousel clamps
(Clamp Close) completely on the drill pipe. 13

LAYER 2

CLAMP 14
3 4 3 4
CLOSE
2 5 2 5
1 6 1 6
LEFT RIGHT
JOYSTICK JOYSTICK

BREAKOUT
PIPE

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15. Pull the left joystick backward for the carousel to return (Arm Out)
the drill pipe to the carousel. To remove additional drill pipe from
the drill string, repeat the process starting at step 1.

3 4 3 4
2 5 2 5
1 6 1 6
LEFT RIGHT
JOYSTICK JOYSTICK

CAROUSEL
ARM OUT

4.7. Delivery System

Drilling operations are performed from the control panel in the cab using
the electric/hydraulic controls. They can also be performed from the mast by operating the hydraulic
valves directly.
The DR500 series drills can be fitted with water injection or a dust collector or both. All DR500
series drills are equipped with oil or grease injection systems.

4.7.1. Water Injection Procedure

The water injection procedure is as follows:

1. Make sure that the water tank is full. The water tank has a sight tube on one side to
indicate the water level in the tank.
2. Start drilling.
3. Turn on the water by pressing water pump button on the left joystick. This activates the
hydraulic valve that directs the flow of oil to the water pump drive motor.
4. Use the proportional hydraulic valve to control the pump speed. This controls water flow.
The water flow should be just enough to suppress the dust.
5. The water pressure should always exceed the air pressure. Adjust the operating pressure
of the pump to approximately 100 psi (7 bar) above the drilling air pressure.

4.7.2. Grease Injection Procedure

The grease injection system is designed so that the grease pump and injector will operate only
when the drill air is ON. The system is programmed to energize the air solenoid valve for 20 sec-
onds in order to admit air to the grease pump. Grease is pumped to the injector and the injector dis-
charges grease to the drill air stream. Grease injection cycle is 30 seconds (10 second ON and 20
second OFF).
The grease injection procedure is as follows:

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1. Start drilling.
2. Set drilling air ON.
3. Set the regulator at 5.5 bar (80 psi), if not already set.
4. Check if grease is coming out of the top drive shaft with the drilling air. Adjust injector
nozzle if more grease is needed.

NOTE: The injection rate for hammer is 0.7 L (0.7 qt.) of grease per hour for a 150 mm (6 in.)
hammer.

4.7.3. Oil Injection Procedure

The air supply line to the oil injection pump is designed so that the pump will operate only when the
rotation is on.
The oil injection procedure is as follows:

1. Close ball valve on air supply line. Remove top of tank and fill with rock drill oil. Reinstall
top and turn on air.
2. Set the air supply regulator at the tank to 60 psi.
3. Adjust the oil flow with the metering valve located on the discharge line of the pump. Open
it 1/4 turn to start.
4. Check if the oil is coming out of the shank at the water swivel with rotation on. If not, open
the valve further until there is noticeable oil in the drilling air.

NOTE: The injection rate for hammer sizes are as follows:

• For a 4" hammer, it is 1 L (1 qt.) per hour.

• For a 6" hammer, it is 2.5 L (2-1/2 qt.) per hour.

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4.8. Drilling
Now all the systems are in operation and are ready for drilling. Select the drilling screen using the
Touchscreen interface to active the drilling tab. Use the following procedures while drilling.

4.8.1. Manual Drilling

Manual Drilling Screen - Drill Lock Off

Manual Drilling Screen - Drill Lock On

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1. Increase engine throttle.
2. Lower the hammer until the bit touches the rock using the Forward Feed function of the
right joystick.
3. Close the centralizer jaws loosely around the hammer using the Centralizer IN function of
the right joystick.

NOTE: This assures that the hammer will not deviate from the target angles and is one of the
most important steps in maintaining hole accuracy.

4. Set the air pressure to High on the control panel.

5. Turn manual drilling on.
6. Turn collar air on.
7. Prior to commencing of the initial drilling sequence, decrease both the pulldown and
holdback to the lowest settings.
8. Rotate the top drive slowly using the Rotation Forward function of the right joystick.
9. Lower the hammer slowly until it contacts the rock using Feed Forward function of the right
joystick.
10. As the bit starts breaking the rock, increase the down feed slowly. It may be necessary to
increase the pulldown pressure to accomplish this. Continue drilling to a depth of at least 1
meter (3 feet) depending on ground conditions.

NOTE: This step must be performed carefully and slowly or the drilling angle may change.

11. After the hole is collared, turn drill air on (collar air will turn off automatically).
12. Increase feed to full feed forward and set rotation speed as required. The desired values of
feed rate and rotation speed can be locked by pressing the Drill Lock button. The Manual
Drilling screen with Drill Lock button lit will appear as shown below. Final adjustments can
be made to rotation speed by moving the right joystick left or right, and changes to
pulldown pressure by moving the left joystick forward or backwards.
13. Continue drilling until the top drive mounting plate contacts the mast stops. Turn water off
prior to the end of travel to insure that all the water is removed from the air lines.
14. At the end of travel, turn off the Manual Drill Lock and the feed will automatically lift to a
pre-set value allowing the hole to blow out. Raise and lower the drill string to clear the hole
as required.
15. Refer to drill pipe installation procedures provided in this section to add another drill rod.
16. Turn on drilling air and water and feed the hammer down to resume drilling.
17. When the required hole depth is reached, follow rod removal procedures provided in this
section.

4.8.2. Drilling with Accrafeed Feature (Optional)

Accrafeed is a patented system for automatic control of feed, rotation, and torque during drilling.
This allows for drilling a straighter hole with minimal drill bit wear. The basic principle of operation of
the Accrafeed system is as follows:

Accrafeed allows feed rate to decrease with the increase of drilling resistance encountered by the
drill bit in harder rocks. Conversely, it increases feed rate when drilling resistance becomes lower in
softer rocks. Increase of feed rate is limited to a maximum level. As a result, the drill bit will not
advance faster in voids.

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Higher drilling resistance in harder rocks causes rotation pressure to go up. Once rotation pressure
reaches a set level, the feed reverses automatically and the top drive moves up. Forward feed
resumes again when a set time has elapsed. This cycle of feed forward and feed reverse continues
until any one of the following conditions is met:
• Harder rocks have been broken loose.
• Drilling is stopped.
The procedures for the employment of Accrafeed features are as follows:
1. Select the drilling screen with the touchscreen interface.
2. Set all drilling parameters as needed for producing accurate hole efficiently. See the
Configuration Menu section.
3. Set Accrafeed ON by pressing Accrafeed button on the right joystick. Accrafeed screen
appears as shown in figure below.
4. Change pull down, if needed, using the left joystick. Holdback will not work, as this is
automatic depending on rotation pressure.
5. Change rotation speed using the right joystick.
6. Continue drilling until the top drive mounting plate contacts the mast stops.
7. Turn OFF Accrafeed.
8. Follow the steps described in previous sections to move up the hammer, break joints and
to add or remove pipes into the drill string.

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NOTE: The feed/rotation lock function must be engaged before the anti-jam system can be used.

WARNING
While drilling, it is forbidden for personnel to be in the drilling area.
Be sure the drilling area is clear of all personnel before drilling.

DRILLING
SAFETY
ZONE

4.8.3. Winch Operation CABLE

WEIGHT
The Winch is used to load and unload pipe into the
carousel. The winch cable passes through a pulley
assembly at the top of the mast and is attached to a
cable weight near the Carousel. The cable weight
maintains tension on the cable during pipe loading
WINCH
activities. MOTOR
CAROUSEL
The winch is controlled by a lever located at the
bottom of the Mast Valve Junction Box. MAST
Additionally, the winch may also be operated from
the cab by selecting the Drill mode on the
Touchscreen and Layer 2 on the joystick and then
leaning the left joystick left or right to raise or lower
the cable.

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5. Operator’s Maintenance Instructions

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5. OPERATOR MAINTENANCE INSTRUCTIONS

5.1. General
At the start of each shift it is important that the operator conduct an equipment inspection and
perform basic maintenance to ensure his safety and the long life of the machine. A grease gun is the
only tool required. Note that several of these checks are done while the machine is running; plan the
checks accordingly to prevent repeat start-ups.

5.2. Operator Maintenance Checklist

OPERATOR’S POINT SERVICED BY

AIR INLET and EXHAUST SYSTEMS
Empty Air Filter Vacuator Valves
Check Air Filter Restrictor Indicator (if equipped)

COOLER SYSTEMS and COOLANT

Check Radiator and Oil Coolers for Restrictions
Check Radiator and Oil Coolers Fluid Levels

COMPRESSOR SYSTEM
Check Compressor Oil Level at Receiver Tank
Check Receiver Tank Element Indicator
Drain Water from Receiver Tank
Drain Air Control Line Water Trap
Drain Moisture Eliminator Tank

ENGINE
Check Crankcase Oil Level
Inspect Alternator and Compressor Belts Tension and Condition

FUEL SYSTEM
Check Fuel Level and Fill as Required
Drain Water from Primary Fuel Filter

MAST SYSTEMS
Lubricate Cushion Sub
Lubricate Air Swivel
Inspect Lower Mast Feed Chain Idler for Debris
Check Top Drive Oil Level and Inspect for Leaks
Check Feed Chain Sag
Inspect Slider Adjustment Top Drive Mounting Plate and Mast Mounting Plate
Inspect Winch Wire Cable
Inspect Winch Safety Latch Hook Operation

CAROUSEL
Check Drill Pipes Alignment with Top Drive

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OPERATOR’S POINT SERVICED BY

HYDRAULIC SYSTEM
Check Hydraulic Fluid Tank Level
Drain Water from Hydraulic Fluid Tank

PUMP DRIVE GEARBOXES

Check Pump Drive Gearbox Oil Level

UNDERCARRIAGE
Check Tracks for Debris
Check Track Tension

LUBRICATION SYSTEMS
Lubricate all Cab, Frame, Mast, Mast Boom and Pivot Points
Check Auto Lube and Thread Grease Levels
Drain Water from Auto Lube System Water Separator
Fill Hammer Lube Tank

MISCELLANEOUS
Check for Air, Water, Coolant and Oil Leaks before and after start-up
Check Hoses, Hose Whips and Air Pipe Clamps
Check Fire Extinguishers and Accessories
Check Water Tank Level
Check Battery Connections.
Check for Loose Bolts and Fittings
Fill the Cab Window Wash Tank

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5.3. Operator’s Procedures

5.3.1. Check Engine Crankcase Oil Level

1. Measure engine oil level. Maintain oil level to ‘FULL’ mark on the ‘ENGINE STOPPED’ side
of the dipstick.
2. Add oil if necessary through fill point.

NOTICE
NOTICE
DO NOT OVERFILL CRANKCASE
Overfilling the engine crankcase can damage the engine.
Refer to the ‘Refill and Capacity’ table in Section 6 of this manual for the
proper refill capacity of this component.

OIL PORT

ENGINE DIPSTICK

5.3.2. Check Engine Belts

Check the air conditioning and alternator belts.

Inspect the belts for cracks or damage. The tension
can be checked by depressing the belt between
pulleys. If the belt depresses more than the width if
a thumb and then tighten the belt.

BELTS

TENSIONERS

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5.3.3. Drain Fuel Water Separator Bowl

DANGER
FIRE HAZARD
Smoking while performing maintenance on the fuel system can ignite fumes
and cause serious injury or death.
Extinguish all smoking materials before working with components of the
fuel system.

1. Locate the water separator bowl at the

base of the primary fuel filters.
2. Open the drain valves to allow the
accumulated water to drain.
3. Close the drains.

FUEL FILTER
WATER
SEPARATOR
5.3.4. Drain Air Filter Vacuator Valves
Squeeze the vacuator valves to allow dirt to fall. Check the filter restriction indicators.

INDICATORS

CAB AIR
FILTER
VACUATOR
VACUATOR
VALVE IF
VALVES
EQUIPPED

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5.3.5. Check Coolant Level

WARNING

BURN HAZARD

Hot surfaces and steam can cause severe burns to skin. At operating
temperature, engine coolant is hot and under pressure.

Open the cooler filler cap slowly and ONLY IF the cap is cool to the touch.

CAP
Check the coolant level using the sight glass
provided. If the engine overheats, the coolant is
contaminated or foaming is observed in the
radiator, follow the “Change Engine Coolant”
procedure in the “2000 Hour or 1 Year”
maintenance check.

SIGHT GLASS

5.3.6. Check Compressor Oil Level

WARNING
PRESSURE HAZARDS: Pressurized compressor components and hoses can
cause serious injury or death if serviced while still pressurized.
Do not remove caps, plugs or other components while the compressor
system is running or still pressurized. Stop the engine and allow time for the
system to relieve all internal pressure before servicing. Check the air
pressure gauge in the cab to ensure pressure is zero.

1. Observe the oil level in the Receiver Tank

sight glasses. The oil level should be
maintained so that it is visible in the center
sight glass.
OIL
2. Add oil if necessary, through the fill point. FILL
Do not overfill; the oil level must not rise PORT
above the upper sight glass.

OIL LEVEL

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NOTICE
NOTICE
DO NOT MIX COMPRESSOR OIL TYPES
Incompatible oils may cause compressor damage or reduced oil change
intervals.
When adding oil to the system, always add the same type and weight of oil
that is currently in the system.
5.3.7. Check Receiver Tank Element Indicator

When the engine is running, locate the indicator on

the top side of the receiver tank. Ensure the
indicator is not showing its red band. If the red band
is fully visible, change the separator element.

ELEMENT
RESTRICTION
INDICATOR

5.3.8. Drain Condensation from the Receiver

Tank and Moisture Eliminator Tank
RECEIVER MOISTURE
Remove the drain plugs and open the valve. Drain DRAIN PORT ELIMINATOR
off water until oil appears DRAIN PORT

NOTE: Water can cause compressor failure. If the

oil appears cloudy, water is entering the
system. Determine the point of entry and
rectify the problem and then drain, flush
and refill the system.

5.3.9. Check Hydraulic Oil Tank Level

1. Fully retract all hydraulic cylinders and VENT MUFFLER
shutdown the engine.
2. The Hydraulic Oil Tank level must be
maintained to center of the middle sight
glass. Add oil if necessary and do not fill above the center sight glass.
3. Add hydraulic oil via the Drill Fluid Panel located next to the Receiver Tank.

NOTICE
NOTICE
DO NOT OVERFILL OR MIX HYDRAULIC OILS
Double check that all hydraulic cylinders are retracted or the tank may be
overfilled and rupture. Do not mix brands of hydraulic oils. Incompatible
fluids may cause pump damage and reduce oil change intervals

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DRILL
FLUID
PANEL

SIGHT GLASS
LEVEL INDICATORS

5.3.10. Drain Water from Hydraulic Tank

HYDRAULIC TANK
Remove the valve plug and open the valve. Drain DRAIN VALVE
the water until oil appears.

NOTE: Water can cause pump failure. If the

oil appears cloudy, water is entering
the system. Determine the point of
entry and rectify the problem and then
drain, flush and refill the system.

5.3.11. Check Pump Drive Gearbox Oil Level

1. Shut the machine down.
2. Remove the dipstick and wipe the end clean.
FILL CAP
3. Place the dipstick back into the tube until
the cap is secured in the tube.
4. Remove the dipstick and note the level of
oil on the stick. The proper level should be
between the two notches on the stick.
5. If necessary, add oil through the fill plug on
the top of the gear case. Use only oil of the
type specified in Section 6 of this manual.
6. Recheck the oil level after adding oil. DO
NOT OVERFILL GEARBOX. DIPSTICK

WARNING
DO NOT OVERFILL GEARBOX.
Overfilling the gearbox can cause heat buildup and damage bearings and
seals. Refer to the Refill and Capacity table in Section 6 for the proper refill
capacity of this component.

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5.3.12. Check Slider Adjustment Top Drive Mounting Plate and Mast Mounting Plate
Check the sliders gaps distance to the top drive mounting plate, mast connection plate and carrier
block parallel to the guide bars. This is done by rotating mast to vertical position and moving the top
drive mounting plate and mast connection plate to bottom of mast, The gap settings as shown
below, can be inspected at all four corners of plate assembly.

EQUAL GAPS AT
WEAR GUIDE LEFT, RIGHT, TOP
AND BOTTOM

EQUAL GAPS AT
LEFT, RIGHT, TOP
AND BOTTOM

GUIDES

SLIDERS

5.3.13. Lubricate the Cushion Sub

With the spindle retracted (up), lubricate the

cushion sub with five to ten pumps of the grease
TOP DRIVE
gun.

NOTE: If at any time, the sliding spindle will

not retract or extend from the housing
there could be too much grease in the
housing cavity. See maintenance
manual for repairs. CUSHION SUB
GREASE
FITTING

5.3.14. Visually Inspect Winch Wire Rope

Visually inspect the winch wire rope for kinking, twisting and general wear, lubricate if necessary.
Replace as necessary and discard in accordance with 3.5 of ISO 4309:1990.

5.3.15. Inspect Wire Rope Safety Latch Hook Operation

Operate the safety latch on the hook to ensure it operates as designed and closes completely.

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5.3.16. Check the Carrier Block for Debris

CARRIER
BLOCK

5.3.17. Check the Mast Connection Pin Retaining Bolts

PIN
BOLTS

5.3.18. Check Tracks for Debris

Visually inspect the undercarriage for rocks, debris and built-up dirt. Clean all the rollers, idlers and
sprockets as necessary.

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5.3.19. Manual Lubricate All Cab, Frame, Mast, Mast Boom and Pivot Points
Use a grease gun and pump grease to the lubrication fittings at the grease points presented below.
Ensure that adequate lubricant is being delivered.

LEFT SIDE CAB BOOM MAST

MAST BOOM

5.3.20. Automatic Machine Lubricate All Cab, Frame, Mast, Mast Boom and Pivot Points
The Automatic Machine Lubrication system uses an air operated pump and is controlled by the
unit’s PLC. The system uses injectors for grease delivery to lubrication points on the unit. These
injectors are mounted together in banks of 2 to 6 depending upon location and the number of
grease points in the area where the bank is mounted. Each injector is individually set to deliver the
correct amount of grease to the point it is servicing, which depends on pin size and usage.
Grease flows from the pump to the mast boom and the frame to the mast and cab boom until the
pre-set pressure is reached. The automatic pressure switch shuts of the system at that point.

Manually lubricate the compressor air inlet butterfly valve.

FRAME CAB BOOM

COMPRESSOR AIR INLET

MAST BOOM MAST

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5.3.21. Check the Feed Chain Sag
MEASURE FROM
Move Top Drive to the bottom of the mast and MAST CENTER LINE
place the mast in a horizontal position. Inspect the
gap from the center line of the mast to the chain.
Adjust the chain if the gap is less than 25 mm (1
inch) or greater than 50 mm (2 inch).

5.3.22. Check Lubricator System Grease Level

Check the grease levels and replenish as required.

CENTRAL
UBRICATION
REASE TANK
PIPE
THREAD
LUBE

5.3.23. Check Grease Injector Air Lubricator Oil Level

AIR FILTER AIR LUBRICATOR
If no Airline Lubricator, fill coupler with No. 10 SAE
oil then reconnect to fitting. The Air Lubricator is
located on the right side of the drill opposite the
engine Filter Mounting Plate.

5.3.24. Drain Grease Injector Air Filter

Drain the water from the petcock on the bottom of
the air filter.

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5.3.25. Fill Hammer Lube Tank Daily

HAMMER LUBE TANK

5.3.26. Check Water Injection Pump Crankcase Oil Level (Cat Pump)
Check the oil level through the sightglass provided (Cat pumps)

WATER PUMP
SIGHT GLASS

5.3.27. Fill The Alcohol Injection Bowl

Unthread the bowl and fill as needed.

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5.3.28. Drain the Air Control Line Water Trap assembly with the engine running.

5.3.29. Drain Condensation from the Receiver Tank and Moisture Eliminator

RECEIVER TANK MOISTURE

Remove the drain plugs and open the valve. Drain DRAIN ELIMINATOR
off water until oil appears. DRAIN

NOTE: Water can cause compressor failure. If the

oil appears cloudy, water is entering the
system. Determine the point of entry and
rectify the problem and then drain, flush
and refill the system.

VENT MUFFLER

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6. Additional Instructions

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6. ADDITIONAL INSTRUCTIONS

6.1. Transporting the Machine

The following procedures are to be used as a guide. The equipment you have and the regulations
for lifting and transporting this type of equipment will vary.

Clean the machine to remove any rocks or dirt that might dislodge during transporting.

Index the loader a half turn to prevent drill pipe from sliding out.

Position the boom in the horizontal position. Swing the cab in.

Assemble the operator’s standing platform on the left side crawler frame. Unpin and lower the
manual controls guard.

Refer to Section 3 of this manual to become

familiar with the tram manual controls on the left
side of the machine.

Load the machine on the trailer and then shut the

machine down and disconnect the battery. Use
suitable chains and hold-downs to chain the front
and rear of the machine down. Remove the
operator’s standing platform from the crawler frame
and stow it.

6.2. Machine Storage

If this machine is to be removed from service for an extended period of time, the following
procedures should be used when removing the machine from service and placing the machine back
into service to ensure proper operation of the machine at all times.

Turn the battery and starter isolator switches to the “OFF”

position and remove the key. Lock out the battery isolation box
and tag out the system

6.2.1. Short Term Storage

6.2.2. General
Short term storage for the machine is 30 days or less.

Perform the following steps to prepare the machine proper for

short term storage:

6.2.3. Preparation for Short Term Storage

• Clean the entire machine.
• Touch up painted surfaces as necessary, after proper
preparation and priming.
• Lubricate all grease points on the machine.

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NOTE: The following step is unnecessary if the machine is stored in a building and the air will be dry for
the duration of storage.

• With all hydraulic cylinders fully retracted, coat the exposed portions of the cylinder piston
rods with multipurpose grease.
• Contact the engine manufacturer for engine storage procedures.
• Clean and lubricate the feed chain.

6.2.4. Removal from Short Term Storage

• Lubricate all points equipped with grease fittings.
• Remove preservative grease, if applicable, from the cylinder piston rods and other surfaces
where applied.
• Check the oil level in each gear housing. Add oil as necessary as specified in Section 6 of
the Operator’s Manual.
• Check the oil level in the hydraulic reservoir. Add oil of the proper type, as specified in
Section 6 of the Operator’s Manual.
• Install the battery if it was removed, fully charged.
• Contact the engine manufacturer for procedures on removing the engine from storage.
• Make a thorough visual inspection of the entire machine before operating it for the first time
following storage. Check, especially, for damaged or deteriorated hydraulic hoses.

6.2.5. Long Term Storage

6.2.6. General
Long term storage for the machine proper is for periods longer than 30 days.

6.2.7. Preparation for Long Term Storage

The purpose of managed storage:

• Maintain battery condition and charging system.

• Circulate fluids to minimize contamination.
• Circulate fluids in pumps, motor shaft and cylinder rod seals.
• Actuate operator controls to prevent lock-up.
• Actuate components to prevent lock-up.
During the storage period;

• Plan to start the equipment once per week for a minimum of 30 minutes, for as long as the
machine will be stored.
• Select trained personnel responsible for managing this task.
• Document engine hours accordingly for each start up.

6.3. Safety First!

• Always Perform Job Risk Assessment
• Always Wear Proper PPE

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6.4. Positioning the Machine
• Park the machine on level terrain so fluid levels can be monitored accurately.
• Drill pipe stowed in the loader should be indexed under the top plate to prevent pipe from
unlocking or falling out of the loader during start up or tramming.
• Remove drill bits from drill string and stow the bits in lubricant to minimize rust and bearing
failures.
• To prevent potential trip and fall hazards, stow drill tools in a safe place NOT ON DECK
surfaces. Drill tools include:
> Bit wrenches
> Lifting bell
• Lower the boom and stow it in the rest.
• In arctic conditions, park on hard, solid ground or place a barrier between the track pads
and the frozen ground to minimize tracks freezing to the ground.

6.4.1. At a Mine Site

• Park the machine to allow safe efficient access and maintain an adequate distance from
bad ground conditions, rock face and high walls.
• Park on high ground, away from potential flooding conditions.
• Park away from high dust concentrations and potential blast zones.

6.4.2. At a Dealers Facility

Park the machine to allow safe efficient access away from confined spaces, bad ground conditions
and power lines.

6.5. Initial Preparation of the Machine

• If available, pressure-wash the machine to remove dirt and oil.
• Store the machine manuals and 50 hour service kit in a clean dry area.
• Reference to the machine’s specific operator’s guide.
• Check battery electrolyte, specific gravity, cable cleanliness and tightness.
• Secure all electrical junction box doors.
• When applicable cover dust collector exhaust port.
• Cover the top drive top sub or bullshaft.
• Apply a liberal amount of grease to all grease points.
• When necessary, remove the boom and mast from the base and apply anti-seize
compound or equivalent to exposed bearing points. Examples:
> Mast bearing caps
> Mast and boom pivot pins
> Mast cylinder pins
> Winch safety hook latch
• The cab door and windows should remain closed and locked as needed.
• Operator controls should be placed in the neutral position.
• Position the air conditioner switches to off.
• Turn off CB and CD player/radios.
• Battery disconnect switches should be opened to minimize battery drain.

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• Rain and snow accumulation can settle into roof mounted A/C unit. Cover the cabin roof
top to minimize water entry through roof mounted air conditioner.
• Drain water tanks to prevent freeze during inclement weather.
• The water injection pump should be winterized with antifreeze solution.
• In severe summer heat, protect rubber seals on the engine and compressor air inlet pipes
and air hoses (cover hump hose adapters and air hoses to protect from UV rays).
• Rain and snow can rust unused chains. Lubricate the feed chains with quality chain lube
such as Texaco Canopus 46 or equivalent.

6.6. Weekly Storage Maintenance

6.6.1. Prior to Start-Up

• Drain condensation from the compressor receiver tank. Circulating compressor oil
contaminated with water will do irreversible damage to compressor bearings.
• Drain condensation from the hydraulic reservoir. Circulating hydraulic oil contaminated with
water will do irreversible damage to pump bearings.
• Check the following fluid levels:
> Engine coolant
> Engine oil
> Pump drive gearbox oil
> Hydraulic tank oil
> Compressor oil
> Air line lubricant for auto grease system

6.6.2. After Start-Up

Allow the engine, compressor and hydraulic fluid temperatures to reach 37.8° C (100° F) then
operate various functions to cycle fluids throughout components thus exercising oil seals.
In the cab, cycle both heating and air conditioning systems in all seasons.
In arctic conditions:
• Check battery electrolyte, specific gravity, cable cleanliness and tightness.
• When applicable engage heater element circuit breakers to warm machine fluids prior to
machine start.

6.7. Removal from Long Term Storage

• Clean the entire machine thoroughly, then inspect the machine thoroughly, paying
particular attention to hydraulic hoses, tubes, and fittings.
• Lubricate all points equipped with grease fittings.
• Check the oil levels in the gear housings including the winch and crawler final drive. Add oil
as required of the types specified in Section 6 of the Operator’s Manual.
• Drain the hydraulic tank down to the proper level.
• Remove the preservative grease from the cylinder rod pistons and other machined
surfaces, if applicable.

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6.8. Towing

6.8.1. Towing Guideline and Procedures

These towing instructions are for moving a machine for a short distance at low speed. Move the
machine at a speed of 1.6 km/hr (1.0 mph) or less to a c ne continuous hour while the final drive is
disengaged. Always haul or tram the machine if long distance travel is required.

WARNING
Block the machine to prevent movement before final drives are re-engaged.
The machine may roll freely if it is not blocked. With final drives disengaged,
the machine cannot be stopped or steered.

WARNING
Personal injury or death could result when towing a machine incorrectly.
Do not allow anyone to be on or near a machine that is being towed or
connected to a towing machine. Injury or death may result when towing a
machine incorrectly.

WARNING
Both final drives must be disengaged before towing the machine. Do not
operate drive motors with final drives disengaged. Damage could result.

This drill is equipped with hydraulic track drive motors with automatic spring set brakes. If the
machine cannot be started, or hydraulic components are defective preventing the system to be
pressurized, the machine can be towed by removing the disengagement mechanism from the final
drive as discussed below in this section.

Do not use a chain for towing a machine. A chain link can break and cause personal injury. Use a
tow bar or cable with ends that have loops or rings. Put an observer at a safe distance in a position
to watch the towing procedure. The observer can stop the procedure if the tow bar or cable starts to
break. Stop pulling whenever the towing machine moves without moving the drill unit.

WARNING
A tow bar is recommended for moving this equipment. The strength of the
tow bar or tow cable should be at least 150% of the gross weight of the
towing machine.

Shields must be provided on both the drill unit and towing machine to protect the towing machine
operator if the tow bar or cable breaks. Attach the tow bar or cable to the towing eye on the front of
the machine if you are towing the machine forward. Attach the tow bar or cable to the drawbar pin
on the rear of the machine if you are towing the machine backward.

Keep the tow bar angle to a minimum. Do not exceed a 30° angle from the straight ahead position.

Before you tow the machine, make sure that the tow bar or cable is in good condition. Make sure
that the tow bar or cable has enough strength for the towing procedure involved. This requirement is
for towing a machine that is stuck in the mud and for towing on a grade.

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Quick machine movement could overload the tow bar and could cause the tow bar to break.
Gradual, steady machine movement will be more safe and effective.

The towing machine should be as large as the machine being towed. Make sure that the towing
machine has enough brake capacity, enough weight, and enough power. The towing machine must
be able to control both machines for the grade, surface condition and distance that is involved.
Minimal towing machine capacity is required on smooth, level surfaces, maximum towing machine
capacity is required on inclines or on rough, uneven surfaces in poor condition.

You must provide sufficient control and sufficient braking when you are towing a machine downhill.
This may require a larger towing machine or additional machines connected to the rear of the drill
unit to prevent the drill unit from rolling downhill out of control.

Some towing situation requirements may not be addressed in this document; consult your Sandvik
dealer if questions arise.

6.8.2. Parking Brake Disengagement

Undercarriages with final drives parking brake engaged cannot be moved if the hydraulic system is
not operational. For this reason, a disengagement mechanism is installed so the undercarriage can
be towed if the motor is inoperable.

WARNING
The engine must be stopped with the machine on level ground before
releasing the parking brakes. Releasing the parking brake may cause the
machine to move unexpectedly.
Block the machine to prevent movement before final drives are disengaged.
The machine may roll freely if it is not blocked. With final drives disengaged,
the machine cannot be stopped or steered.

The disengagement plug is located on the final drive assembly cover, opposite the motor. The sun
gear release device is under the disengagement plug, on the inside of the final drive and is held in
place by a disengagement plug (cap and bolts on some models). Make sure that you put the sun
gear release device back to its original position before attempting to return the machine to normal
operation (see below).

UNSCREW REMOVE THE SUN

PLUG GEAR FROM THE
REDUCTION GEARS

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WARNING
Risk of scalding and burns due to the high temperature of the final driver oil.
Final drive may be boiling hot after long periods of operation. Even after the
machine has been turned off, the hydraulic oil can still be hot enough to
burn.
Always wear protective gloves and allow the hydraulic oil to cool before
draining.
Removing the disengagement plug from the final drive without first relieving
the internal pressure will cause hydraulic oil to squirt out.

6.8.3. Procedure for Sun Gear Removal

1. Position the machine on a level surface. Turn the engine off and lock out the power.
2. Block the machine to prevent movement.
3. Relieve the hydraulic tank and line pressure before any disassembly. Operate the tram
levers back and forth with the engine stopped to relieve hydraulic system pressure.
4. Remove the disengagement plug. Allow the oil to drain into a suitable container for proper
disposal as per local regulations.
5. Screw a bolt in the hole in the center of the sun gear. Remove the sun gear by pulling on
the inserted bolt.
6. Leave the bolt in the sun gear until it is re-installed. Place the sun gear in the cab.
7. Re-install the disengagement plug to avoid contamination in the system while towing.
8. Repeat steps 4 through 7 on the other final drive.
9. The final drives are now ready for towing. Follow all the Towing Guidelines and
Precautions listed above.

DISENGAGEMENT PLUG
M72x1.5 TORQUE TO 250 N-m REMOVE
DISENGAGEMENT
PLUG

SUN GEAR
DISENGAGED INSTALL M6x1 BOLT
22 MM TO REMOVE
SUN GEAR SOCKET SUN GEAR FROM
ENGAGED FINAL DRIVE

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6.8.4. Procedure for Sun Gear Installation

WARNING
Block the machine to prevent movement before final drives are re-engaged.
The machine may roll freely if it is not blocked. With final drives disengaged,
the machine cannot be stopped or steered.
1. Remove the cover plate.
2. Re-install the sun gear by fitting the gear teeth into the teeth of the planetary gear.
3. Unscrew the bolt from the sun gear. Ensure that the sun gear remains seated completely to
the back.
4. Re-install the disengagement plug; torque to 185 ft-lbs (250 N-m).
5. Refill the final drive gear oil as discussed in the Maintenance Manual, Section 5.

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6.9. Air Conditioning
The rooftop mounted package unit incorporates both the evaporator and condenser sections in the
same case with heating and fresh air pressurization.

The circuit breakers are located in the return air chamber. They can be reset through return air filter
opening or top entry through evaporator cover.

6.9.1. Operating Instructions

The operating controls are designed to provide a means of controlling the cab environment in
varying outdoor ambient conditions. The control panel, as shown below, is located on the return air
plenum adjacent to the filter, inside the cab ceiling where it can be easily reached by the operator.

6.9.2. Fan Speed Switch

This switch provides three fan speeds for
varying cab airflows chosen by the operator
comfort. In the 'OFF' position no components
within the air conditioning unit will operate even
though there may be electrical power supplied FAN THERMOSTAT MODE
to the unit.

6.9.3. Mode Switch

This switch controls the unit function and
provides for either ventilation, cooling, heating
or demisting. For all modes except ventilation, electrical power, compressor power and hot water
need to be supplied to the system. The ventilation mode only requires electrical power to be
supplied. For any mode to function, a fan speed must be selected. The fresh air pressurizer unit
operates automatically in any mode whenever the unit is 'ON'. The condenser fans operate
automatically only in the 'COOLING' and 'DEMISTING' modes whenever the unit is 'ON' and the
thermostat calls for cooling.

6.9.4. Ventilation
This mode controls supply air fan operation only, at the fan speed selected. No cooling or heating
takes place except for the effect of recirculated air movement. Because the pressurizer fan is
operating as well, it is recommended that this mode be used if neither heating or cooling is required
so that the cab remains dust free.

6.9.5. Cooling
This mode energizes the compressor circuit controlled by the thermostat to cool the cab. Maximum
cooling is obtained when fan speed is set on 'HI' and the thermostat is turned fully counter-
clockwise. When the cab temperature is reduced to a comfortable level, the fan speed and
thermostat can be altered to maintain comfort.

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6.9.6. Heating
This mode energizes the heater hot water solenoid valve controlled by a thermostat to heat the cab.
Maximum heating is dependent on water temperature and is obtained when fan speed is set on 'HI'
and the thermostat is turned fully clockwise. As with cooling, both the controls can then be adjusted
to maintain comfort.

6.9.7. Demisting (Defrost)

In this mode both the compressor and heater solenoid valve circuits are energized with only the
compressor being controlled by the thermostat. The heater valve remains fully open at all times in
this mode. Maximum defrost ability is obtained when fan speed is set on 'LO' and the thermostat is
turned fully counter-clockwise. However the fan speed may have to be increased to fully defrost a
window if it is located too far from the supply air outlet.

6.9.8. Thermostat
The electronic thermostat controls the cab temperature between 18 and 28°C (64 and 82°F) by
sensing the system return air temperature. As a safety feature, a de-ice thermostat automatically
senses the coil temperature and overrides the system if the evaporator coil is icing up. Excessive
turning of this control should be avoided so that the system can operate properly.

6.9.9. Supply Air

This plenum incorporates multi-directional diffusers through which supply air is discharged into the
operator cabin. It is located adjacent to the return air plenum, ideally forward of the operator so that
cool (or warm) air can be directed over his way. The diffusers can also be directed away from the
operator, onto windows for defrosting or both if required.

6.10. Wash Wand (Optional)

When a machine has an optional wash wand installed, a toggle switch is mounted above the
receiver tank on the exterior of fan/compressor control panel to control the 3-way valve that directs
water flow to the wash wand. Some options may have a manually 3-way valve located near the
water pump to switch the flow. This switches diverts water flow from the water pump to the water
injection system or to the wash wand option. When the toggle is switched to the wash wand option,
it will also send a signal to the main control system that the switch has been activated.

The operate the wash wand:

SWITCH
1. Place the switch in the WASH WAND
mode.
2. If the computer is off the wash wand the
can not operate. Turn the computer on
and set to SYSTEM MODE.
3. Place the door safety bar in the upright
position.
4. Make sure the water tank has enough
water to assure the low water alarm is not
activated.

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7. Troubleshooting

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7. TROUBLESHOOTING
If the performance is lacking, action must be taken to correct any problems. The operator is
expected to be able to repair minor problems that are within his/her responsibilities. Any problem
beyond that must be repaired by certified maintenance people.

This section is intended for the use of the operator and a more detailed Troubleshooting Guide can
be found in the Operator’s Manual.
It is the operator's responsibility to report any apparent problems to the maintenance personnel.

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7.1. Engine
PROBLEM CAUSE REMEDY
ENGINE WILL NOT
START
Optional fire suppression reset button is
disengaged. Push the reset button in the
cab.

Emergency stop button on the Cabin

control Panel is depressed. Turn red button
to release

Emergency stop button on the machine’s

right side of the mast is depressed. Turn
blue button counterclockwise to release..

Emergency stop button on the machine’s

right side near the filter mounting plate is
depressed. Turn red button to release

Emergency stop button on the machine’s

left side remote RCP panel is depressed.
Turn red button to release

Emergency stop button on the machine’s

right rear is depressed. Turn red button to
release

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PROBLEM CAUSE REMEDY
ENGINE WILL NOT
START

Emergency stop button on the machine’s

right side fan shroud is depressed. Turn
red button to release

Emergency stop button on the right side of

the operator’s cab. Turn blue button
counterclockwise to release..

Emergency stop button on the machine’s

left side by the drill fluid panel is
depressed. Turn red button to release

Emergency stop button on the machine’s

right side of the mast is depressed. Turn
blue button to release.

Battery and starter isolation switches are in

the OFF position. Position the battery
disconnect handle to the ON position.

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PROBLEM CAUSE REMEDY

ENGINE WILL NOT Push to reset.
START

Main circuit breaker on engine junction box

has tripped.

Low fuel supply. Add diesel to tank

FUEL
TANK

Emergency stop handle at the Operator’s

Cab entrance is raised. Lower the handle
as shown.

The switches on the hydraulic tank

isolation valve handles are closed. The
valve handle are in the close as shown.

The cab isolation switch is pulled out.

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7.2. Tram Drive
PROBLEM CAUSE REMEDY
TRAMMING MOTORS
OPERATING, CRAWLER
DOES NOT MOVE
Tram mode button and Tram Enable are
not depressed. Push the two tramming
buttons

The engine is still in the ‘Warming’

status. Wait for the Engine Run Light
status to change

Check for sheared off bolts at the final

drive sprocket

Check for frozen tracks Thaw ice as required

Check for mud build up at the crawler
Clear mud from tracks
tracks.
Loosen the track and move it
Check for tracks off the front idler.
back onto the wheel.
TRAMMING MOTORS Check causes in “MOTORS
See above
NOT OPERATING, OPERATING” above
CRAWLER DOES NOT
Check for damaged parts in the tram Replace or repair effected
MOVE
drive and the final drive gearbox. components
Check to see if the tram motor is
Repair or replace motor
running.

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7.3. Hydraulic System

PROBLEM CAUSE REMEDY

PUMP DOES NOT Check for proper fluid level and Refill oil with correct fluid. In
DELIVER OIL appropriate oil viscosity in hydraulic extreme cold conditions, it
reservoir. may be necessary to heat the
Check for proper pump rotation as oil.
marked on coupling guard. Correct pump rotation.
Check for flow restriction by inspecting Repair leaks, remove
the suction line, strainer, and reservoir. restrictions,replacestrainers.
Check for air leaks at pump intake. Oil Repair pump leaks.
level must be above bottom of sight Fill oil to proper level.
glass.
Replace pump shaft.
Check for sheared off pump drive shaft. Remove sense line restriction.
Check pump load sense line for oil flow.
Test each function separately.
PUMP IS RUNNING HOT Check for any function stuck open Correct pump function
position.
CAVITATION OR PUMP Check for air leaks at the pump intake Pour oil on joints and around
NOISE or shaft packing. drive shaft then listen for
Check for proper oil viscosity. change in operation and repair
pump leaks. Replace oil
with correct viscosity oil.
INSUFFICIENT Check for proper oil level in the tank Fill oil tank
PRESSURE
SLOW ROTATION AT Check for low pump delivery; see Repair or replace hydraulic
THE TOP DRIVE "Pump Does Not Deliver Oil". motor
Check for malfunctioning of hydraulic
motor.
NO ROTATION AT THE Check for hydraulic motor Repair or replace hydraulic
TOP DRIVE malfunctioning. motor. Replace damaged gears
Check for damaged gears or bearing. and bearings

Check for pump flow, see "Pump Does

Not Deliver Oil".
SLOW OR NO FEED Check for low pump delivery; see Repair or replace hydraulic
"Pump Does Not Deliver Oil". motor Fill oil tank
Check for oil insufficient pressure. Pull down pressure must be
approximately 100 psi (6.9 bar)
Check pulldown relief valve for high higher than holdback
setting. pressure. Repair leaks
Check for high setting of holdback relief Adjust binding on top drive
valve. mounting plate
Check for internal leaks in feed cylinder.
Check for binding in top drive mounting
plate.

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PROBLEM CAUSE REMEDY
MAST DOES NOT Check for restrictions in set up control Correct hose restrictions
ROTATE valve by removing hoses. Adjust main pressure setting
Check for collapsed hydraulic hose to on hydraulic pump
actuator.
Check main pressure in hydraulic
pump.
ACTUATOR ALLOWS Check for bypassing of directional
MAST TO MOVE AFTER control valve.
BEING SET Inspect the valve spool.
Check for damaged counterbalance
valve cartridge.

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7.4. Water Injection Pump

PROBLEM CAUSE REMEDY

DISCHARGE PRESSURE Check for restrictions in suction line or
TOO LOW relief valve.
Check for incorrect valve adjustment or
damaged relief valve.
Check for low pump speed. Pump
should run at 12 l/min proportionally.
CAVITATION Cavitation occurs in the pump when the
PROBLEMS cylinders do not fill completely with
water during the suction stroke. This
condition creates a pressure pulsation,
which may damage the pump and
equipment if not repaired immediately.
Check for proper diameter of water
supply line. This line must be the same
or larger than pump suction plumbing.
Check for air leaking into the suction
system by tightening fittings and
inspecting hoses.
Check for weak or worn plunger
packing. Partially worn plunger packing
may draw air on the suction stroke but
these may not leak during the discharge
stroke, creating a similar condition as in
cavitation.
NO WATER DISCHARGE Check for suction line restrictions
Check for suction line valve closed
EXCESSIVE PUMP Check for loose suction line
NOISE connection.
Check for over speeding of pump.
Reduce the flow to the hydraulic motor
by adjusting the flow control valve.

7.5. Air Drive Oil Injection Pump

PROBLEM CAUSE REMEDY
AIR MOTOR DOES NOT Check for restrictions in the air line
OPERATE
AIR SEEPAGE FROM Check for leaking inlet valve
AIR EXHAUST WHILE
PUMP IS NOT WORKING
LOSS OF PRESSURE, Check for foreign particles on the
VOLUME, OR piston seat or on the ball of the foot
CONTINUOUS valve.
OPERATION OF PUMP Check for damaged piston or foot valve.
WHEN NOT IN NORMAL
USE Check for scorn pump tube wall and
replace if required.

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PROBLEM CAUSE REMEDY
EXCESSIVE AMOUNT OF Check air leakage at gland packing,
AIR IN LUBRICANT OR gland gasket, O-ring and U-cup packing
EXCESSIVE AMOUNT OF NOTE: Some lubricant in the exhaust air
LUBRICANT IN AIR is required.

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7.6. Air Driven Grease Injection

PROBLEM CAUSE REMEDY
AIR PRESSURE BUILDS Check for leaks in air line.
TOO SLOWLY Check for restrictions in the air filter or
inlet.
Check for improper operation of 3-way
valve on air inlet. Ensure that the valve
opens and closes fully.
Check for unloader plunger being stuck
in open position.
COMPRESSOR SHUTS Clean compressor fluid cooler and
DOWN WITH AIR check for poor ventilation.
DEMAND PRESENT Check fluid level, add fluid.
Check compressor fluid, change fluid.
Check temperature-regulating valve.
Check for a short or open circuit in
discharge temperature switch. Change
if discharge temperature switch is
malfunctioning.
COMPRESSOR DOES Check for leaks in air line or open
NOT BUILD-UP FULL valves.
DISCHARGE PRESSURE Check for restrictions in the air filter or
inlet. Check the filter indicator and
change element if required.
Adjust pressure regulator and replace if
necessary.
COMPRESSOR Readjust pressure-regulating valve.
UNLOADING WITH AN Check for cracks in unloader line.
EXCESSIVE PRESSURE
BUILD-UP Check inlet valve.
Check for worn seals or unloader
plunger.
EXCESSIVE Check return line; clean orifice and
COMPRESSOR FLUID strainer.
CONSUMPTION Check and replace separator element if
necessary.
Check all pipes, connections, and
components in lubrication system.
COMPRESSOR Clean fluid cooler core.
OVERHEATING Change thermostat element in thermal
valve.
Clean fluid cooler tubes.
Check and fill sump fluid.
Clean orifice and strainer in plugged
return line.

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7.7. Air Delivery System
PROBLEM CAUSE REMEDY
AIR PRESSURE BUILDS Check for leaks in air line.
TOO SLOWLY Check for restrictions in the air filter or
inlet.
Check for improper operation of 3-way
valve on air inlet. Ensure that the valve
opens and closes fully.
Check for unloader plunger being stuck
in open position.
COMPRESSOR SHUTS Clean compressor fluid cooler and
DOWN WITH AIR check for poor ventilation.
DEMAND PRESENT Check fluid level, add fluid.
Check compressor fluid, change fluid.
Check temperature-regulating valve.
Check for a short or open circuit in
discharge temperature switch. Change
if discharge temperature switch is
malfunctioning.
COMPRESSOR DOES Check for leaks in air line or open
NOT BUILD-UP FULL valves.
DISCHARGE PRESSURE Check for restrictions in the air filter or
inlet. Check the filter indicator and
change element if required.
Adjust pressure regulator and replace if
necessary.
COMPRESSOR Readjust pressure-regulating valve.
UNLOADING WITH AN Check for cracks in unloader line.
EXCESSIVE PRESSURE
BUILD-UP Check inlet valve.
Check for worn seals or unloader
plunger.
EXCESSIVE Check return line; clean orifice and
COMPRESSOR FLUID strainer.
CONSUMPTION Check and replace separator element if
necessary.
Check all pipes, connections, and
components in lubrication system.
COMPRESSOR Clean fluid cooler core.
OVERHEATING Change thermostat element in thermal
valve.
Clean fluid cooler tubes.
Check and fill sump fluid.
Clean orifice and strainer in plugged
return line.

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7.8. Hammer
PROBLEM CAUSE REMEDY
TOLL DOES NOT START Check for correct assembly of tool.
Check if piston is binding in the piston
case or against the valves. Remove all
burrs, gall marks, and scratches.
Check for damaged check valves
springs. Clean rust, burrs, and
scratches from valve dart.
Check for broken foot valve assembly.
TOOL STOPS Check for "collared" or "bridged" hole.
OPERATING Lift the drill assembly off the bottom of
the hole and then clean the hole with
water injection.
Check for damaged parts such as
piston case, pistons, driver sub, and
drill bit. Polish galled spots and replace
parts as required. Insure that the piston
slides freely inside the piston case.
Check for clogged air passages in the
drill bit.
Check for obstructions in the drill pipe,
air hoses, and top drive.
OPERATING PRESSURE Check if correct type of choke is
IS LOWER THAT installed.
SPECIFICATIONS Check for wear of choke. Install a
smaller choke to bypass less air. If wear
is excessive, replace any worn parts.
Check for restrictions in the air delivery
system.
LOW PENETRATION Check for dull drill bit.
RATE Check for broken or missing carbides in
bit. Before using a new bit, clean out the
drilling hole.
Check for excessive back pressure in
the drill hole. Remove any collaring
around the hole and then flush the hole
with the drill's water injection.
GALLING OF INTERNAL Check for proper lubrication and adjust
PARTS the oil injection rate.
Check for uneven lubrication. Repair
injection pump if required.
Check for foreign material inside of tool.
Check for warpage in the piston case

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7.9. Drill Bit
PROBLEM CAUSE REMEDY
ABRASIVE WEAR Check for worn carbides in bit. Use the
proper rotation speed and drill weight to
suit the drilling conditions.
LOSS OF CARBIDES IN Check the bit for loss of carbides. If any
BIT are missing and no damage is apparent,
it indicates that the piston was striking
the bit while the bit was not in full
contact with the rock formation. This
force tends to loosen the inserts. This
condition may occur when the bit
encounters broken or loose formation.
To avoid these conditions, control the
drill to minimize these heavy blows
when the bit is not in full contact.
BIT BREAKAGE AND Check for hairline cracks and breakage
CARBIDE FAILURES around the buttons in the bit. Gauge
buttons are most prone to such failures.
This condition may be due to excessive
weight on bit, improper rotation speed,
or a lack of sharpening the bit.
Inspect the bit face periodically and
sharpen the bits when required.
CARBIDE BREAKAGE Breakage may occur due to the
following:
A piece of carbide may have been left in
the socket when a new bit was installed.
The carbide may have been pinched
while being pushed into an undersized
carbide hole.
The bit may have been pushed through
a bent drill hole casing.
Excessive use between recommended
sharpening periods.
NOTE: Drilling in hard formation
requires more frequent sharpening.

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PROBLEM CAUSE REMEDY

UNEVEN WEAR Uneven wear conditions may be due to
CONDITION the following:
Check for uneven wear spots at the
gauge row buttons. The drill bit may
remove the rock chips too slowly.
Increase the air volume to avoid this
condition.
Check for a bent drill rod and replace as
required and then check the machine
set-up.
Check for bit erosion just above the
gauge buttons. This creates spiralling
into the rock and poor hole cleaning.
Adjusting the rotation speed and
frequent hole cleaning may help but the
bit should be replaced at this time.
Check for excessive button wear or
breakage indicating dry drilling
conditions. The buttons may overheat
due to extreme weight on the bit or due
to improper rotation speeds. Increase
the water injection and adjust the
drilling speed to avoid these problems.
Check for powdery cuttings, which
indicate that the bit requires
sharpening.
Check for squealing of bit during
drilling. The bit steel at gauge may be
rubbing. Grind any projections or
deformations on the bit steel. Cutting
relief slots in the bit skirt may also be
helpful.
Check for shank failure due to
insufficient drill weight, uneven drill
feed, or excessive operating pressure.
Operate the drill at the proper air
pressure and maintain a steady down
pull on the bit to prevent shock loading.

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7.10. Depth Laser
PROBLEM CAUSE REMEDY
LASER APPEARS NOT Power supply could be The unit requires 24VDC power supply.
WORKING. NO RED disrupted. Red wire must be connected to Positive,
LIGHT IS COMING OUT Power supply wiring and green wire must be connected to
OF APERTURE polarity is not in right order. Negative.
Laser unit burnt out. Short Replace the laser unit.
condition, nearby arc-
welding performed, reverse-
polarity power introduced,
water short-condition in
junction box …etc.
LASER APPEARS Laser appears working. Red All four connecting wires must be free of
WORKING. RED LIGHT light is pulsing in even insulation damage and in no contact
IS PULSING IN EVEN intervals, no output signal. between them.
INTERVALS, NO White wire is analog positive output; black
OUTPUT SIGNAL. wire is analog ground output.
Laser beam must be able to reach the
target surface throughout the entire travel.
If laser bounces of any surface at any time,
the readings would be incorrect or zero
output (error condition for analog output)
appears. Target surface cannot be
reflective or polished surface.
LASER APPEARS Laser beam is not reaching/ Laser beam must be able to reach the
WORKING, RED LIGHT reading the target correctly. target surface throughout the entire travel.
IS PULSING BUT IN UN- Loose or missing target. If laser bounces of any surface at any time,
EVEN INTERVALS the readings would be incorrect or zero
output (error condition for analog output)
appears. Target surface cannot be
reflective or polished surface.
Target must be “visible” to the laser beam
at all the time. Surface of the target might
need re-painting (satin/flat finish spray
paint in neutral colors are recommended
such as primer gray, primer yellow, primer
red). If used in location where direct sun
light is present, olive green (military) color
is recommended. Loose target plate
creates undesirable readings.
GENERAL NOTES Check for the condition of the protective lens. The glass must be free of
cracks, dirt, grease and other obstructions. Order and replace lens if
required.
To test and inspect the functionality of the TERRA DP-1 laser sensor, you
must have the ANALOG output wires disconnected at the sensor closest
mast junction box. First make sure that laser light is hitting the target and
flashing evenly. Use digital meter instrument to measure the 4-20 mA
signal direct from the disconnected wires. Some digital meters cannot
measure this way. If so, connect the wires back to the PLC input and
install the meter leads between the black signal wire and the PLC signal
input wire.

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8. Technical Specifications

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8. TECHNICAL SPECIFICATIONS

8.1. Torques and Specifications

8.1.1. Recommended Torque Values for Standard Hardware - UNC

This table applies to part numbers:

• 001554-___Capscrew, Hex head

• 005486-___Capscrew, Hex head
• 001559-___Capscrew, Socket Head
• 001570-___Screw, Flat head socket
• 001577-___NUT, Hex, regular
• 001575-___NUT, Hex, heavy
• 001562-___NUT, Hex, self-locking

Coarse Thread Torque Value - Grade 5 Torque Value - Grade 8

(Diameter in inches) N-m (Ft-lb) N-m (Ft-lb)
1/4 8 (6) 12 (9)
5/16 16-19 (12-14) 23-26 (17-19)
3/8 30-160 (22-24) 42-46 (31-34)
7/16 49-53 (36-39) 68-75 (50-55)
1/2 73-80 (54-59) 103-114 (76-84)
9/16 104-115 (77-85) 149-163 (110-120)
5/8 145-160 (107-118) 207-225 (153-166)
3/4 257-285 (190-210) 366-395 (270-292)
7/8 380-420 (280-310) 592-644 (437-475)
1 576-624 (425-460) 881-963 (650-710)
1-1/8 773-840 (570-620) 1260-1355 (930-1000)
1-1/4 1098-1180 (810-870) 1776-1912 (1310-1410)
1-3/8 1437-1545 (1060-1140) 2345-2508 (1730-1850)
1-1/2 1912-2047 (1410-1510) 3105-3335 (2290-2460)

NOTE: These torque values are to be used for general assembly procedures. Special torque
requirements may be specified on assembly and installation procedures.

NOTE: All fasteners are to be free of dirt and rust at time of assembly. Lubrication is not to be
applied to threads unless so specified.

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8.1.2. Recommended Torque Values for Standard Hardware - UNF

This table applies to part numbers:

• 001555-___Capscrew, Hex head

• 005498-___Capscrew, Hex head
• 001580-___Capscrew, Socket head
• 001571-___Screw, Flat head socket
• 001578-___Nut, Hex, regular
• 001576-___Nut, Hex, heavy
• 001563-___Nut, Hex, self-locking

Fine Thread Torque Value - Grade 5 Torque Value - Grade 8

(Diameter in inches) N-m (Ft-lb) N-m (Ft-lb)
1/4 9 (7) 13-15 (10-11)
5/16 19-22 (14-16) 27-30 (20-22)
3/8 34-38 (25-28) 47-53 (35-39)
7/16 53-58 (39-43) 74-83 (55-61)
1/2 85-93 (63-69) 117-127 (86-94)
9/16 118-129 (87-95) 167-182 (123-134)
5/8 171-187 (126-138) 216-253 (171-187)
3/4 289-316 (213-233) 407-445 (300-328)
7/8 423-458 (312-338) 651-705 (480-520)
1 616-683 (466-504) 969-1044 (715-770)
1-1/8 868-942 (640-695) 1410-1518 (1040-1120)
1-1/4 1600-1301 (900-960) 1979-2115 (1460-1580)
1-3/8 1640-1762 (1210-1300) 2671-2847 (1970-2100)
1-1/2 2149-2305 (1585-1700) 3484-3728 (2570-2750)

NOTE: These torque values are to be used for general assembly procedures. Special torque
requirements may be specified on assembly and installation procedures.

NOTE: All fasteners are to be free of dirt and rust at time of assembly. Lubrication is not to be
applied to threads unless so specified.

8.2. Machine Specifications

COMPONENT / SYSTEM METRIC U.S.
COMPRESSOR
Working Pressure, max 34.5 bar 500 psi
Fad, at 1800 rpm Max Working Pressure 637 L/s 1350 cfm
Fad, at 2100 rpm 743 L/s @ 34.5 bar 1575 cfm @ 500 psi

HOLE RANGE
Hammer Size, min 102 mm 4 inch
Hole Depth, Carousel 42.6 mm 140 ft
Hole Size, max 216 mm 8.5 inch
Hole Size, min 114 mm 4.5 inch

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COMPONENT / SYSTEM METRIC U.S.
ENGINE - Cummins Turbo Charged, QSK 23, Tier II
Power Rating at 1800 rpm 708 kW 950 HP
Mesabi Radiator, max cooling capacity 52°C 125°F

TRAMMING
High Gear Speed 5 km/hr 3 mph
Gradeabilty 35%
Brake SAHR
Track Oscillation (Independent) =/- 10%
Ground Clearance 530 mm 21 inch

DUST SUPPRESSION: WATER INJECTION SYSTEM

Triplex Pump 0-45 Lpm 0-12 gpm
Tank Capacity 1135 liters 300 gallons

FEED
Feed Rate, max 1.3 m/s 257 ft/min
Hoisting, max 47 kN 10 600 lbf
Pulldown, max 47 kN 10 600 lbf
Total Length 10185 mm 33 feet 5 inches
Travel Length 7315 mm 24 feet
Feed Extension 1371 mm 4.5 feet

BREAKOUT SYSTEM
Jaw Rotation 15°
Clamping Force 288 kN 67,800 lbf

TOP DRIVE
Rotation Torque 5730 Nm 4225 ft-lbs
Rotation Speed 0-80 rpm variable

ELECTRICAL SYSTEM
Voltage 24v
Batteries 4 x 12 volt, 190 Ah
Alternator Caterpillar 24v, 100 Ah
Lights Front -5 x 55W HID 2xx6
Rear - 2 x 65W
Side - 2 x 55W HIND

CAROUSEL
Capacity, Standard 6 rods
Rod Size, max 127 mm 5 inch
Rod Size, min 83 mm 3.25 inch
Rod Length 6.1 m 20 ft

HYDRAULIC SYSTEM
Hydraulic Oil Cooler, upper design temperature 52°C 126°F

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COMPONENT / SYSTEM METRIC U.S.

Axial Piston Pump 1 100 cc/rev 6.1 cu in/rev
Axial Piston Pump 2 100 cc/rev 6.1 cu in/rev
Axial Piston Pump 3 75 cc/rev 4.6 cu in/rev
Return and Pressure Filters (3 x 2 filters) 5 micrometer absolute

HAMMER LUBRICATION
Positive metering of either grease lubricant or Rock Type 000NLG1
Drill oil
Metering Capacity, max 1 500 cc/hr 91.5 cu.in./hr
Metering Capacity, min 60 cc/hr 5.3 cu.in./hr

TANK VOLUMES
Hydraulic Oil 303 liters 80 gallons
Compressor Oil 140 liters 37 gallons
Diesel Fuel 1400 liters 370 gallons
Hammer Lubrication 20 liters 5.3 gallons

AIR CONDITIONING UNIT

Estimated Refrigerant Charge (R134a) 2 kg 4.4 lbs

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