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D75KS
COMMISSIONING MANUAL
November 2006
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:
DANGER
WARNING
CAUTION
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.
Table of Contents
DECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Management's Responsibilities . . . . . . . . . . . . . . . . . . . .
The Operators Responsibilities . . . . . . . . . . . . . . . . . . . .
Operator's Safety Check . . . . . . . . . . . . . . . . . . . . . . . . .
Planning the Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Maintenance Safety Practices . . . . . . . . . . . . . .
Fire Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Prepare Mast For Assembly To Machine . . . . . . . . . . . . . 20
Prepare The Machine Base Mast Pedestal . . . . . . . . . . . . 21
Mast Installation 21
Hydraulic Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Mast Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . 27
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iii
iii
v
vi
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1
1
3
4
5
6
MACHINE COMMISSIONING . . . . . . . . . . . . . . . . . 7
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
NEW MACHINE ARRIVAL . . . . . . . . . . . . . . . . . . . . . . . 7
COMPONENT WEIGHTS and LIFTING . . . . . . . . . . . . . 8
DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
PERFORM MACHINE PRESTART CHECKS . . . . . . . . . 10
STARTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . 11
TRAMMING THE MACHINE FROM THE TRANSPORT 12
Accessory Component Inventory . . . . . . . . . . . . . . . . . . . 14
MOUNTING THE RIGHT SIDE LADDER TO THE MACHINE
BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CAB EXTENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Drill Pipe Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
LOADING DRILL PIPE INTO THE MACHINE . . . . . . . . . 40
Load Drill Pipe Method 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Load Drill Pipe Method 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 43
PREDELIVERY CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . 46
Lubricate the Central Grease Points . . . . . . . . . . . . . . . . . 46
Service Lubricator Reservoir (DTH Applications) . . . . . . . 48
Inspect Engine fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Inspect Compressor Oil Level . . . . . . . . . . . . . . . . . . . . . . 49
Inspect the hydraulic oil level . . . . . . . . . . . . . . . . . . . . . . . 50
Inspect Pump Drive Gearbox Fluid Levels . . . . . . . . . . . . 50
Inspect Rotary Head Fluid Level . . . . . . . . . . . . . . . . . . . . 50
Inspect Final Drive Fluid Levels . . . . . . . . . . . . . . . . . . . . . 51
Inspect Winch Drum Fluid Level . . . . . . . . . . . . . . . . . . . . 51
Inspect Water Injection Pump Fluid Level . . . . . . . . . . . . . 51
FACTORY FILL FLUIDS . . . . . . . . . . . . . . . . . . . . . . . . . . 51
COOLANT SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . 56
FILL WATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Coolant Conditioner Elements . . . . . . . . . . . . . . . . . . . . . . 57
FUEL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 57
Cetane Requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Fuel Cloud Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Fuel Sulphur Content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Table of Contents 1
6-04
Introduction
SANDVIK MINING and CONSTRUCTION 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 and CONSTRUCTION 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.
Management's Responsibilities
It is the responsibility of management to:
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.
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6-04
condition exists. It is the responsibility of the drill operator to ensure that the drill is properly equipped, safe to operate
and that the site conditions make it possible for safe operation:
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.
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6-04
6-04
6-04
Operating Precautions
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.
.
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.
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6-04
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 pipe
from moving past the top plate
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.
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.
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6-04
Riding the rotary head up and down the mast is a crushing hazard.
Never ride the rotary head for any reason!!! It was not designed to be an elevator.
When there is a need for an operator or helper to work on the rig in the working area or danger zone and this work
involves activation of one or several machine functions, this work shall only be done under the following conditions:
a. There must be two safety trained people present, one should supervise the safety of the other doing the servicing.
Supervision should be done from the operators station to ensure immediate access to an emergency stop at all
times.
b. The area where the service work is to be done should be properly illuminated.
c.
A reliable mode of communication should be establish between the servicing person and the supervisor.
d. The rig must be completely shut down and all methods of starting disabled before servicing work begins.
Fire Prevention
Keep the machine clean of vegetation, coal dust and oily rags.
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 waterwell operations unless the well head is properly equipped with blowout preventers and safety equipment required by law or as recommended in the American Petroleum Institute's docSafe Operating Practices for Drillers
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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 160 F (71 C).
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 150 F (65 C), or in direct sunlight.
6-04
MANAGEMENTS RESPOSIBILITIES
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:
Be aware of daily weather conditions within a 100 mile (161 Km) radius of the mine property.
Notify equipment operators of impending storms. Communication to equipment operators may be given via two way
radio and/or in person.
Give equipment operators an all clear signal after the storm has cleared the area.
Note To 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 2.2 mph (3.5 kph).
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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.
Equipment operators shall retrieve drill pipe from blastholes, 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 30CFR 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.
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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.
Exceptions
If you do get caught in an electircal 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 a enclosed stable structure such as a machine cabin or the truck cab it is recommended that:
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 20 mile (32 km) radius of your location be aware of your surroundings when outdoors.
Seek adequate shelter immediately.
If lightning is present within the 20 mile (32 km) 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 a enclosed vehicle or adequate shelter. Maintain a distance greater than
100 yards (92 m) 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.
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!
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.
Safe Operating Practices for Drillers
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xiv
D75KS
NEW MACHINE COMMISSION MANUAL
The purpose of this manual is to provide assembly details, required tools and lifting apparatus as needed to field assemble a new D75KS machine on a customer location.
D75KS Dimensions
6 9
52 9
D75KS TWO PIECE SHIPMENT
MAST 52 9 LONG X 7 10 WIDE X 6 9 HIGH 38,000 LBS
BASE 35 6 LONG X 14 WIDE X 13 6 HIGH 103,000 LBS
13 6
35 6
14
The D75KS uses a standard length mast designed for multi pass drilling applications. The
mast for this machine is shipped as one piece on a standard flat bed trailer.
The D75KS mast assembly may support work decks, dust collector hose and drill pipe.
The D75KS machine base is shipped on a I-Beam type trailer with a detachable goosekneck,
maximum height of 18 and length of 24 to meet the local US transportation requirements.
Accessories for the D75KS machine assembly will be placed in box containers strapped to
the machine deck unless specified within the sales order entry. A cab extension is removed
for transit. Wood panels are bolted over both cab pieces to seal the cab from the elements.
Due to wood panels bolted to the cab sections the cab entry is limited to the left side door for
transit purpose only.
The cab extension will be secured to the right side deck for transit.
Page 2
Remove machine accessories and box containers from machine deck and mast structures.
Organize machine accessories near the intended mounting position to minimize lifting.
Work Site Preparation
Establish a proper work area to assemble a new drill machine.
Outside on flat solid ground without overhead power transmission lines, (with access to
one 50 ton crane)
Inside or outside on flat solid ground without overhead power transmission lines, (with 2
each 20 ton cranes)
Appropriate 5 ton crane and lifting slings for positioning cab extension, decks and mast
work deck
MINIMUM DISTANCE
60 FOOT (18 METERS)
MINIMUM DISTANCE
80 FOOT (24 METERS)
ASSEMBLY LOT SIZE
D75KS MACHINE BASE
Page 4
With adequate lifting slings in place lift mast with crane less than 3 feet (1 meter) checking
that the mast is stable and balanced both front/rear and left/right. Lower mast and adjust
straps accordingly to get the mast balance correct.
When lifting the mast to set it on the machine the crown of the mast may be slightly higher
than the mast table during the lift to enable mast raise cylinder rod installation.
Assembly Tools
Sandvik offers a mechanic tool kit
006190-002
The tool kit is a tool chest and an assortment of up to 944 handtools that may be used by
field technicians to assemble and provide service work on heavy equipment.
Specialty tools such as torque multiplier, air compressor an air tools are not part of this kit.
This service truck (maintenance truck) is well equipped with a portable welder, oxygen and
acetylene cutting torches, portable compressor and a auto crane. The Ford truck shown in
this picture as an example of a typical field service truck used in the heavy equipment service
business.
The mechanic or technician in charge of this truck has service tools to perform mechanical
labor on heavy equipment.
Page 6
MACHINE COMMISSIONING
GENERAL
Due to the size of Sandvik Mining and Construction blasthole equipment several components
have been removed to enable the rig to be safely and legally transported. The purpose of this
manual is to provide suggested tools, equipment and procedures for safely commissioning a
new machine. This manual was written to cover a series of models so assembly times may
differ slightly.
SAFETY
Use a proper assembly site. Maintain safe and level ground conditions, clear of debris.
Use adequate lifting tools, allocate one assembler and crane operator to communicate the
load handling during lifting and setting procedures.
Do not assemble machine near overhead power lines.
Use caution when ambient conditions are extreme. Use appropriate personnel protective
equipment as required by mine specific regulations and safety programs.
NEW MACHINE ARRIVAL
Machines arrive on a I beam type transport trailer appropriate for the base machine.
Perform a walk around inspection of the base machine visually checking for damage and
loose accessories.
Sandvik Mining and Construction
Page 7
Lifting apparatus must be serviceable and have sufficient capacity for the load
Follow recommended guidelines and crane load charts. Do not exceed manufacture
rated capacity.
The chart below is approximate component weights for the purpose of selecting the proper
lifting slings. Component weights vary according to part number. Drill tool weights vary
according to dimensions and length specific to the part number.
As a general rule select a heavier rated lifting sling than the intended load weight.
Sandvik Mining and Construction
Page 8
D75KS MAST
38,000 LB (17236 KG)
ACCESSORY CRATE
800 LB (363 KG)
ACCESSORY CRATE
2200 LB (998 KG)
7 TABLE BUSHING
212 LB (96 KG)
7 X 24 BIT SUB
210 LB (95 KG)
DIMENSIONS
D75KS machines are shipped as two loads for domestic and export deliveries. The mast, cab
extension and work decks are disassembled from the machine base. The mast supports
some of the items for transit. Mounting hardware and drill accessories will be inside a crated
container positioned on the right side deck as shown here.
A service truck with air compressor and standard hand tools will be required to assemble
work decks, ladders, dust control accessories and drill tools to the new machine.
A hand held grease gun and grease cartridges should be available to service the lube points
prior to new machine start up.
For DTH applications the customer must have a minimum of 5 gal (20 liters) of a selected
rock drill oil to fill the lubricator reservoir. This oil is required to lubricate the down the hole
hammer and drill bit shank.
PERFORM MACHINE PRESTART CHECKS
Add fluid as needed to the respective compartment prior to starting the machine.
Page 10
1. Check that the engine idle switch is in the LOW idle mode for start up.
2. Check that the emergency stop buttons are released.
3. Turn the key switch to the start position.
4. Apply the bypass switch.
5. Engage the start push button to start the engine.
ENGINE IDLE
SWITCH
KEY SWITCH
The engine idle speed switch enable selection of the engine rpm. Toggle switch down is low
idle speed set for 1200 rpm. Toggle switch up is high idle speed set for 1800 rpm.
Engine idle speeds affect hydraulic pump flow. For the purpose of tramming the machine
from a transport or in a confined space such as a work shop the engine idle speed may be at
low idle mode for short distance. The engine idle speed must be at high idle mode for the
purpose of tramming the machine long distances.
TRAMMING THE MACHINE FROM THE TRANSPORT
Perform a risk assessment of the off loading procedure with the transport driver and available
ground support personnel.
A tram interlock system option may hinder tram conditions unless the operator applies the
foot switch first. Machines equipped with tram interlock use a foot pedal on the floor inside
the cab.
Page 12
1. The machine will be off loaded to the rear. This position enables best overall view through
cab windows. Ground level personnel may assist in guiding the operator.
2. Equipment with a foot switch apply the foot switch first, disregard this step if the machine
does not have a foot switch.
3. Apply push lock buttons on tram levers to move the controls.
NOTE!
The machine may be operated at low engine idle speed (1200 RPM) during unloading conditions.
NOTE!
Operator control configuration: left control operates left track, right control operates right
track. The controls shall be pulled slowly toward the operator to initiate reverse track motion.
As the controls are moved to full position tram speed will increase.
4. Use caution as machine comes off timbers onto level ground as not to drag front jack on
the transport trailer.
5. Set the machine to high idle speed (1800 rpm) to tram the machine to the designated
assembly area.
6. Assembly area must be smooth surface, free of debris and hazardous working conditions.
Stay away from electric power lines or power transmission facilities.
7. Center tram controls to stop machine travel.
8. Equipment with a foot switch release the foot switch when tram is complete, disregard
this step if the machine does not have a foot switch.
9. Lower engine idle to (1200 rpm) for proper engine cool down period.
10. Turn key switch to the off position to activate machine shutdown. If immediate shutdown
is required engage any of three emergency stop switches.
Sandvik Mining and Construction
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NOTE!
It is recommended by the engine manufacturer to allow an adequate cool down period of 3 to
5 minutes for engine turbo speed and engine oil pressure to stabilize.
Accessory Component Inventory
Remove decks, ladders, front jack pad, chain supports, optional dust collector hose and
accessory crate from machine deck, mast rest and or mast.
Place the component near the intended assembly position.
MOUNTING THE RIGHT SIDE LADDER TO THE MACHINE BASE
The right side boarding ladder is shipped separately.
Mounting hardware consists of 12 ea 3/8 inch bolts for the boarding ladder.
Suggested tools
1. Secure the emergency stop panel to the side frame with two mounting screws.
2. Position the auto crane and appropriate lifting sling for lifting the right side ladder in place.
Page 14
EMERGENCY
STOP PANEL
RIGHT SIDE
BOARDING LADDER
3. Secure the boarding ladder onto the entry deck with 12 bolts.
4. Clean the hand and foot rails to remove road dirt and oils that may have accumulated during transit.
After the boarding ladder has been installed be sure to utilize a three point stance (two hands
on the rails and one foot on the step at all times) when mounting the machine.
CAB EXTENSIONS
The cab extension allows for larger cab interior and easy access to the cab from right side
deck.
Suggested tools
Silicon sealant
1. Position the crane and appropriate lifting sling for lifting the cab extension in place.
2. Remove sound abatement panels from cab sections to access the cab mounting bolts
and nuts.
3. Remove the bolts that secured the plywood panels to the cab extension and machine
cab.Use caution when removing plywood, do not damage roof seals for air conditioner
unit.
4. Clean cab mating surfaces and apply bead of silicone to both surfaces.
5. Attach appropriate lifting strap to cab roof panel and lift cab extension into place.
6. Roll cab floormat away at the two outside corners to access shock mount bolts.
7. Set cab extension on 2 each shock mounts and secure the cab with the 1 X 5.5 inch UNC
bolts, washers and self locking nuts. Final bolt torque shall be 1000 ft lb (827 Nm).
8. Secure cab extension panel to the cab with 24 each 3/8 bolts, washers and self locking
nuts.
Sandvik Mining and Construction
Page 16
15. Install the cab pressurization precleaner and filter assembly to the air conditioner unit.
16. Secure the pressurization filter electric connectors and test cab fan switch positions.
17. Clean the cab roof window.
18. Apply the main light switch in the cab to check the night light operation, inspect the electrical plugs. Rotate the night lights to suit the operating condition.
The cab is ready for occupancy.
DECKS
Deck features available for the D75KS machines may vary from those depicted in this manual.
Suggested tools
1. Position the auto crane and appropriate lifting sling for lifting the right side cab deck with
handrail.
RIGHT DECK
2. Secure right side cab deck and handrail with 12 each 1/2 bolts.
3. Position the auto crane and appropriate lifting sling for lifting the rear cab deck with handrail.
REAR DECK
4. Attach the right side hand rail to the cab panel with 9 each 1/2 bolts. Connect both rear
handrails with 2 each 3/8 inch bolts and self locking nuts.
5. Remove decals and clean windows to remove transit road dirt.
Sandvik Mining and Construction
Page 18
6. Secure boarding ladder to left front deck with 4 each 1/2 inch bolts. This ladder allows
maintenance access to the air receiver tank and air filter assemblies.
LEFT LADDER
Avoid slip and fall hazards by keeping deck surfaces clear of debris as service work is being
performed.
After the boarding ladder has been install be sure to utilize a three point stance (Two hands
on the rails and one foot on the step at all times) when mounting the machine.
When service tools are required on the machine decks, place the tools on deck prior to climbing the ladder or ask for assistance with handing tools up to the deck level.
MAST
The D75KS mast assembly consists of the structure with pulldown and hoist chains, rotary
head, drill pipe loader, power breakout tool, holding wrench, dust hood, winch with wire rope,
all hydraulic and air hose connections, angle drill pipe guide, electrical switches and junction
box.
The mast may be loaded with work decks and drill accessories for transit purpose.
Prepare Mast For Assembly To Machine
1. Perform a walk around inspection of the mast assembly and related components visually
checking for damage and loose accessories.
2. Note any damage to the truck company.
3. Remove decks and accessories from mast, set decks aside in a logical order according to
frame mounting for final assembly.
4. The mast must be lifted from the transport and placed on solid ground.
5. Remove straps supporting wood cribbing.
6. Remove mast support bearing caps and mast cylinder pins, clean and prepare for installation. Note that the bearing caps are stamped and must be replaced as left and right with
the matching mast bearing block.
7. Remove tape and tie straps from hoses and electrical components.
8. Inspect and prepare electrical limit switches and proximity switches wire connectors as
they apply for mast options.
Page 20
Loosen the transit rope from the mast raise cylinders and lay the cylinders towards the
engine prior to placing the mast onto the machine base.
Mast Installation
It is the region and/or local dealer responsibility to locate and make available proper tools to
assemble the machine mast to the machine frame.
Suggested tools
NOTE!
Perform a risk assessment with assembly crew and crane operator prior to lifting mast structure. Establish who will be communicating during the lift and install process.
1. Secure mast with adequate lift slings through both left and right side mast chords.
2. Secure a guide rope on the mast to assist manuevering the mast as it is raised.
3. Lift mast with crane less than 3 feet (1 meter) from ground checking that the mast is stable and balanced both front/rear and left/right. Lower mast to ground and adjust straps
accordingly to get the balance correct.
4. When mast balance is correct: continue to raise mast so machine may be driven under
raised mast.
5. One operator shall be in cab driving machine as needed.
One person from ground level is the director to assist the operator as needed to align the
mast bearings to the machine pedestal shaft.
Mast bearing caps are identified as left or right side.
If a spacer is on the mast pivot shaft move the spacer towards the right side. The spacer is a
shim to gain additional clearance so the mast will not contact the cab.
Page 22
Mast bearing cap bolts use lock washers and lock plates that must be bent over to secure the
bolt upon final torque.
6. Secure each mast bearing cap with 4 each bolts.
7. Final torque for the bearing cap bolts shall be 650 ft lbs (880 Nm).
8. Bend lock plates over bolt head and bearing cap.
9. Connect grease line for auto grease systems or manually grease lube point as needed.
10. Connect mast raise cylinder rod ends to mast. The crane may have to lift the mast slightly
to allow the cylinder rod clevis end to fit into the pin recess.
The operator may have to cycle the mast raise cylinders to enable proper rod bore and
recess alignment.
DANGER
Hydraulic Connections
Machine must be stopped and LOTO Lock Out/Tag Out applied. Follow regional and governmental safety policies prior to working with the hydraulic system.
Relieve hydraulic pressure from the reservoir by opening the ball valve on the hydraulic reservoir air pressurization components.
Relieve hydraulic pressure from the valves and hose connections by moving the middle
stacker, upper stacker and feed directional control valve handles.
Use caution when opening the flange plugged feed system pipes as oil will be present.
Loosen flange bolts slightly and open flange plug slowly to allow oil to drain from pipe.
Use suitable containers for collecting residual hydraulic oil.
Page 24
Hydraulic hoses have to be connected at the mast pivot point. Check the hydraulic plug and
caps for numeric or alphabetical stamps. Connect #1 to #1 or A to A accordingly.
DANGER
Position the hoses without twist prior to final flange clamp tightening.
Hydraulic oil is lost from the rotation pump hoses due to this assembly procedure so it is
mandatory to follow new pump startup guidelines when the machine is started. Refer to
hydraulic book 5 new pump startup procedures.
Allow a minimum of 15 minutes of neutral pump run time prior to operating the rotation pump
and turning the rotary head or drill pipe. This pump run time is critical to purge air from the
hoses.
NOTE!
Cycle the feed system in both directions (down and up) to remove air from the feed cylinder
prior to installing drill pipe to the rotary head.
DANGER
Page 26
loader (cylinders)
winch (motor)
EXPLODED
VIEW
Medium pliers
1. Place the front jack pad on the ground under the front jack assembly.
2. Start the machine (engine at low idle speed 1200 RPM).
20%
ADJUST PRESSURE
CONTROL CW
3. Place the fast feed pump control on 20% to enable oil for the lower stacker valves.
4. Pull the front leveling jack control reverse to extend the front leveling jack cylinder down.
Page 28
5. Adjust pressure control CW accordingly to develop operating pressure for the leveling
jack circuit.
6. With a second person as a guide stop the front leveling jack control when the jack and
pad alignment enables the pin to be inserted.
7. Operators must center the fast feed pump control and front leveling jack control prior to
personnel installing the pin into the leveling jack pad.
8. Secure the jack pad pin in place.
9. Cycle all jacks to assure air is out of the system.
10. After the leveling jack cylinders are cycled and all jacks are raised so the green jack up
lights are alluminated, stop the machine engine by standard procedure.
MAST WORKDECK
Depending on transport methods the mast work deck is typically strapped to the mast as
shown. Remove the mast workdeck from the transport position prior to installing the mast to
the machine frame.
There are a variety of mast workdecks available.
The work deck must be positioned onto the mast and pinned into place with mast raised and
locked into a vertical position. To install the workdeck proceed as follows:
1. Start machine.
2. Apply the fast feed pump approximately 80% to enable oil for leveling the machine.
3. Operate level jacks to level the machine. Monitor the level indicator for true machine
frame level position.
DANGER
Page 30
6. Lock the mast to the machine frame by applying the middle stacker control for mast lock
cylinders.
7. Mast lock engage light illuminates indicating frame mounted cylinders have engaged the
mast table.
8. Engage light is green - Disengage light is red
NOTE!
Mast lock pins will not engage if the machine is not level left to right.
9. Stop the machine engine by standard procedure.
Mounting The Work Deck To Mast Table
Suggested tools
Auto crane
Hammer
3. The deck is adjustable to maintain a horizontal surface. Adjustments and/or fixing the
deck in place is made available with pins at the mast table top front.
4. Utilize a small layer of never seize compound inside the bore and on the pin assembly.
5. Position the rubber dust curtain around the work deck matching mounting hole position
prior to final mounting. Secure rubber curtain with mounting straps with 3/8 bolts and nuts.
Dust curtains may need to be modified to suit the local drilling environment. Angle drilling at
20 or 30 may require two curtains to enable the bottom of the dust hood skirt to make full
circumference contact with the ground condition.
6. Remove dust deflector retainer from dust hood.
7. Remove dust wiper seal retainer from dust hood.
It may be advisable to leave the dust deflector and drill pipe wiper seals out of the dust hood
so they will not become damaged until after drill pipe is added. Installing drill pipe is
explained later in this commission manual.
Page 32
Auto crane
Lifting slings
When applicable open the air supply ball valve for the dust collector air control regulator. Air
regulators may be fitted to the top or bottom of the dust box according to dust collector
model. I
4. Check air regulator pressure and/or calibrate the air regulator to 50 psi for the dust filter
purge cycle.
LOW PRESSURE
APPLICATIONS
HIGH PRESSURE
APPLICATIONS
5. The dust collector timer may need to be calibrated to suit the dust control timed cycle.
Typical on time is 1 second and off time is 6 seconds.
Page 34
6. Open the dust filter doors and tighten the dust filter hold down nuts prior to drilling.
1. Perform a walk around inspection of the dust collector assembly and related components
visually checking for damage and loose accessories.
2. Note any damage to the truck company.
3. Remove tape from the fan exhaust port prior to starting the dust collector.
4. Remove tape from the dust vent ports.
5. Position the auto crane and appropriate lifting sling for lifting the dust collector to the
machine frame left side mounting position.
6. Secure the dust collector and mounting plate with 18 each 1/2 bolts and self locking nuts.
7. Connect three hydraulic hoses to the motor, matching numeric or alpha stamped cap and
plugs to the appropriate motor ports.
8. Connect air supply hose to the air regulator.
9. Connect electrical plug for the electronic timer system.
10. Fit the dust seal to the drop port.
The stationary side mount dust collector may need adjustments once it is started.
1. It may be necessary to calibrate the air regulator to 50 psi for the dust filter purge cycle.
2. The dust collector timer may need to be calibrated to suit the dust control timed cycle.
Typical on time is 1 second and off time is 6 seconds.
Connect Dust Collector Hose
Suggested tools
Secure dust hose to dust collector and workdeck. Use hand cleaner on the pipe connectors
to aid installing the dust hose. Secure dust hose with supplied clamps.
1. Position the dust collector hose onto the dust collector port.
2. Position the dust collector hose onto the dust hood port.
3. Install and tighten the hose clamps accordingly.
Page 36
TIPTON#6 OR #6H
TIPTON#7
REGULATOR
TIMER
MOTOR CONNECTIONS
B PORT IN
A PORT OUT
C PORT DRAIN
Mount the strobe light to the crown of the mast when the mast is horizontal as follows:
1. Place strobe light stand on mast crown mounting pad.
2. Secure with supplied bolts.
3. Plug electrical connectors together.
When drill pipe is shipped inside the drill pipe loader no action is required for loading drill pipe
into the machine.
Remove any shipping restraints prior to using the drill pipe loader system.
When drill pipe is shipped separated use caution when loosening the restraints if the drill
pipe is transported on wood cribbing or on the transport trailer.
Page 38
DIMENSION
WEIGHT
7 x 35 X 0.50
7 5/8 X 35 X 1.0
8 5/8 X 35 X 0.906
Drill pipe weights may vary from this chart according to a specific part number, dimension
and wall thickness.
DRILL PIPE ON
WOOD CRIBBING
Drill pipe must be lifted with overhead crane and appropriate weight rated lifting slings.
Use a balanced two point contact for lifting drill pipe from the wood cribbing or ground position.
LIFT DRILL PIPE WITH TWO LIFTING SLINGS
BOX END
PIN END
Lift and balance drill pipe in a horizontal position. Set the drill pipe on smooth ground beside
the machine frame.
WARNING
Remove all unnecessary personnel from the work area during drill pipe loading procedures.
Load Drill Pipe Method 1
The drill supervisor and/or mine management have to approve of this method because it
does require personnel to be in the mast for a limited part of the drill pipe loading process.
Loading drill pipe from ground level into the horizontal mast with a overhead crane is a safe
means of installing drill pipe.
A top sub must be in the rotary head to perform this task.
Tools Required
safety approved nylon lifting sling at least 2 inch (52 mm) wide or 1/2 inch wire rope in
good service condition
crane operator
Three persons should be communicating during the drill pipe installation procedure.
Crane operator must communicate with the mechanic working in the mast to lift and position
the drill pipe.
Mechanic must communicate with the crane operator for positioning the drill pipe and the drill
operator for threading drill pipe onto the rotary head.
Drill machine operator must communicate with the mechanic for threading drill pipe to rotary
head and maintaining rotary head hose position.
Sandvik Mining and Construction
Page 40
WARNING
All personnel must clear the mast and be in clear view of the drill operator prior to the
operator raising the mast into position for loading drill pipe into pipe loader.
All personnel must wear appropriate PPE for the assigned task. The personnel assigned to
work in the horizontal mast must use a safety harness and a site specified length lanyard.
1. Start the machine
2. Operate at low idle speed
3. Level the drill machine frame
4. Rotary head at top of mast clear of the loader top plate
5. Two lifting slings attached to drill pipe
6. Crane operator lifts the drill pipe so the pipe is balanced horizontally
7. Mechanic and crane operator position drill pipe in the mast
8. Mechanic removes both pin and box thread protectors from the drill pipe
9. Drill operator set rotation torque control to minimum setting so not to over torque drill pipe
threads during the threading process
APPLY FEED DOWN
TORQUE
CONTROL
MINIMUM
FEED PUMP
ON 10%
ROTATION
ON SLOW
PRESSURE
CONTROL
MINIMUM
10. Drill operator set pressure control to minimum setting during the drill pipe threading process
22. Drill operator index and lock the loader to new position for adding new drill pipe
23. Drill operator use feed system to raise rotary head to top of mast clear of the loader top
plate
Page 42
Safety must be expressed prior to and during the drill pipe and drill tool loading process.
All personnel must understand the dangers involved when working with heavy drill pipe and
drill tools on any blasthole drill machine.
Load Drill Pipe Method 2
The drill supervisor and/or mine management have to approve of this method as it requires
the mast to be raised and lowered numerous times during the drill pipe loading process.
This method does not require personnel to be in the mast during the drill pipe loading process.
Loading drill pipe from ground level is a safe means of installing drill pipe.
A top sub must be in the rotary head to perform this task.
Tools Required
safety approved nylon lifting sling at least 2 inch (52 mm) wide or 1/2 inch wire rope in
good service condition
Two persons should be communicating during the drill pipe installation procedure.
Sandvik Mining and Construction
Page 43
WARNING
All personnel must clear the mast and be in clear view of the drill operator prior to the
operator raising or lowering the mast.
All personnel must wear appropriate PPE for the assigned task.
1. Start the machine
2. Operate at high idle speed
3. Level the drill machine frame
DANGER
Operating near or contacting a power line with any part of the machine can result in
electrocution. Do not lower 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
4. Have the operator raise the mast to a vertical position
5. Have the operator lower the rotary head to the bottom of the mast
6. Mechanic secure a single lifting strap to drill pipe at approximately 1/3 point of the drill
pipe length
7. Mechanic use autocrane and lift the drill pipe
8. Remove the thread protector from the pin end of the drill pipe
9. Have the operator lower mast to a acceptable angle (approximately 40 + 5) to allow
proper drill pipe alignment through the mast table
10. Mechanic apply some koppercoat thread grease to the drill pipe threads
11. Mechanic position drill pipe angle to correspond with the mast angle
12. Mechanic position drill pipe through the dust hood and mast table being cautious not to
damage dust hood or drill pipe threads
NOTE!
Do not use table bushing as it consumes the table opening diameter. The big table opening
allows easier drill pipe maneuvering.
Page 44
13. Drill operator set rotation torque control to minimum setting so not to over torque drill pipe
threads during the threading process
APPLY FEED DOWN
TORQUE
CONTROL
MINIMUM
FEED PUMP
ON 10%
PRESSURE
CONTROL
MINIMUM
ROTATION
ON SLOW
14. Drill operator set pressure control to minimum setting during the drill pipe threading process
15. Drill operator place the feed pump on 10%
16. Drill operator move feed control to the down position
NOTE!
Assure top sub and drill pipe thread alignment is proper prior the connecting threads to minimize cross threading
17. Drill operator thread rotary head top sub onto pin end of drill pipe
18. Drill operator stop the rotation so not to wrap the lifting strap around the drill pipe with
excess torque or rotation
19. Drill operator use slow feed to move feed up raising drill pipe box end above dust hood
20. Mechanic observe slow feed mode that drill pipe does not contact dust hood
21. Mechanic remove lifting strap from drill pipe
22. Drill operator shall raise mast to a vertical position and apply lock mast control
23. Drill operator use slow feed to raise drill pipe so box end clears drill pipe loader seat plate
24. Drill operator uses loader components to set drill pipe into open loader pocket
25. Drill operator index and lock the loader to new position for adding new drill pipe
26. Repeat steps 4 through 25 as needed to load required number of drill pipe into the loader
assembly
Add drill tools according to required drilling method
1. Mechanic to place table bushing into table
2. Drill operator move the feed down so drill pipe is centered through the table bushing
3. Mechanic and operator connect customer supplied bit sub and rotary bit and/or hammer
and drill bit to drill string under the dust hood
4. Connect the appropriate drill tools according to procedures noted in drill tool section of
this manual.
PREDELIVERY CHECKS
Fluids must be checked and grease points must be lubricated prior to machine commissioning. It is up to the local region and servicing dealer to provide the proper fluids necessary to
maintain this machine in the working environment.
Refer to the factory fill spec page for compartment locations and quantity.
Lubricate the Central Grease Points
There are two variations of grease systems. All require some form of maintenance.
Page 46
Manual grease points for pins and bushings, rotating sprockets, rotating drive shafts, loader
pivot shafts, power breakout tools and rotary head swivel bearings. There are as many as 34
points to lubricate as needed upon new machine commissioning.
In all lube applications there are 11 rotating or moving grease points that require initial
grease, to be serviced by a hand held grease gun.
1. Inspect the four grease containers fixed to the carrier sprocket. Fill these containers with
the hand held grease gun as needed, and at 250 hour intervals.
2. Drive shaft yoke and u joint zirks
3. Rotary head air swivel joint
Automatic grease systems are a timed cycle for grease injection at stationary lube points. It is
suggested to adjust the timed lube cycle to minimum time during new machine commissioning period. Confirm all lube points receive grease then rest timed lube cycle to suit the ambient operating condition.
MANUAL TIMER SYSTEM
Refer to service literatur 006113-000 centralube system timer calibrations for setting grease
cycles to meet local equipment lubrication requirements.
Grease adapters that were opened for transit (mast related grease points) may have air
trapped in the lube line. The technician may need to purge air from the grease line during the
commissioning process. All grease injectors have a manual lube point in order to address no
lube situations.
Service Lubricator Reservoir (DTH Applications)
Suggested tools
The lubricator is a timed cycle of oil injection for DTH hammer and bit lubrication. The timer is
inside the operator station lower electric junction box.
Calibrate the timed cycle for 1 second on time and 6 to 8 seconds off time.
Page 48
Rock drill fluid level is visible in the linear gauge and with the reservoir decal.
In some cases it may be necessary to purge the air and rock drill oil from the pump and lube
line. Refer to service literature 011353-000 for details on lube pump calibrations.
1. Purge the air and oil from the pump at the vent port
2. Purge the air and oil at the air line check valve positioned on the mast air pipe connection
Inspect Engine fluids
Check engine oil level per engine dipstick level marks.
Check engine coolant level to be in site glass.
Inspect Compressor Oil Level
Drain condensation from air receiver tank drain ball valve prior to starting the machine.
Compressor fluid level is noted on the air receiver reservoir decal.
If oil is required the machine must be stopped and receiver air pressure must be zero.
The fill plug is vented and sealed with a oring. Open the fill plug from the adapter port. Fill to
appropriate level with appropriate, clean synthetic compressor oil.
Mineral and synthetic base gear oils of the proper grade for the operating environment are
acceptable for rotary head gearbox fluids.
Note overfilling the rotary head gearbox can lead to oil venting out of the breather vent during
a drilling condition.
Page 50
COMPONENT
FLUID BRAND/GRADE
LOCATION
CAPACITY
ENGINE OIL
CATERPILLAR
18 GALLONS
68 LITER
OR
CUMMINS QSK19
21 GALLONS
79.4 LITERS
ENGINE COOLANT
25 GALLONS
95 LITER
DIESEL FUEL
NUMBER 2 DIESEL
600 GALLON
2274 LITERS
COMPRESSOR OIL
80 GALLONS
303 LITER
HYDRAULIC OIL
TANK REFILL
230 GALLONS
872 LITER
SYSTEM REFILL
320 GALLONS
1213 LITERS
EP 90
SHC 75X90
5.5 QUARTS
5.5 LITERS
Page 52
EP 90
SHC 75X90
7.75 QUARTS
7.3 LITERS
ROTARY HEAD
EP 90
SHC 75X90
5.5 GALLONS
21 LITER
10W30
3.4 GALLONS
13 LITER
WINCH DRUM
EP 90
2 QUART
2 LITER
OVERHANG ADAPTER
12 OZ
355 ML
12 OZ
355 ML
SAE 30
1 QUART
1 LITERS
WATER TANK
WITH DUST COLLECTOR
H2O
200 GALLONS
757 LITERS
WATER TANK
WITHOUT DUST COLLECTOR
H2O
LUBRICATOR TANK
400 GALLONS
1514 LITERS
OR
550 GALLONS
2082 LITERS
10 GALLONS
38 LITERS
OR
30 GALLONS
113.5 LITERS
Page 54
THREAD GREASE
KOPPERKOAT OR EQUIVELENT
P/N 024178-003
5 GALLON
20 LITER
NLGI 1 OR NLGI 2
30 OR 55 LB
13.6 OR 25 KG
SAE 20
30 GALLONS
113.5 LITERS
COOLANT SPECIFICATIONS
Always use a mixture of approved fill water, antifreeze and Cooling System Conditioner.
Refer to the engine manufacturer for detailed specifications, or Caterpillar form SEBD0518.
FILL WATER
Always add conditioner to coolant water. Never use plain water only in the cooling system.
Acceptable water for use in the preparation of ethylene glycol type antifreeze and water mixture is shown in the follow chart.
ACCEPTABLE WATER
Property
Maximum Limit
ASTM Test
Chloride (CL)
40 mg/L
(2.4 grains/US gallon
D512
D4327
Sulphate (SO4)
100mg/L
(5.9 grains/US gallon)
D516
Total Hardness
170 mg/L
(10 grains/US gallon
D1126
Total
Solids
340 mg/L
(20 grains/US gallon
D1888
Acidity
pH of 5.5 to 9.0
D1293
Antifreeze
For optimum performance a 1:1 (50/50) mixture of water/glycol solution is recommended.
Use ethylene glycol or propylene glycol to protect against freezing and boiling.
Concentration
Freeze
Protection
Boil
Protection
50 Percent
-36C (-33F)
106C (223F)
60 Percent
(Ethylene Glycol Only)
-52C (-62F)
111C (232F)
Page 56
FUEL SPECIFICATIONS
Caterpillar manufactured diesel engines have the ability to burn a variety of fuels. These
fuels are divided into two categories: Preferred or Permissible.
Preferred fuels provide maximum engine service life and performance. These fuels are distillate fuels and are commonly called; fuel oil, furnace oil, diesel fuel, gas oil or kerosene.
Permissible fuels are crude oils or blended fuels. Use of these fuels can result in higher
maintenance costs and reduced engine service life.
Refer to form SEHS7067 from Caterpillar for a detailed summary of preferred fuels and
their specifications.
Cetane Requirement
The cetane number of the fuel has an effect on the ability of the engine to start. Also, the cetane number has an effect on the interval of time before the engine runs smoothly. The minimum fuel cetane number recommended for this engine is 40.
Viscosity Grade
Minimum
Temperature
Maximum
Temperature
SAE 0W-20
-40C (-40F)
10C (50F)
SAE 0W-30
-40C (-40F)
30C (86F)
SAE 0W-40
-40C (-40F)
40C (104F)
SAE 5W-30
-30C (-22F)
30C (86F)
SAE 5W-40
-30C (-22F)
50C (122F)
SAE 10W-30
-18C (0F)
40C (104F)
SAE 10W-40
-18C (0F)
50C (122F)
SAE 15W-40
-9.5C (15F)
50C (122F)
SAE 30
0C (32F)
40C (104F)
SAE 30
5C (41F)
50C (122F)
NOTE !
The minmum Total Base Number (TBN) of the oil used must be 20 times the percentage of
fuel sulphur (TBN as measured by the ASTM D2896 method). If the sulphur content is
greater than 1.5%, choose and oil with the highest TBN that meets one of these classifications: API CF, API CF-4, API CG-4, API CH-4, or API CI-4 . Consult your Caterpillar dealer
or form SEBU6251 for correct engine oil recommendations.
LUBRICANT SPECIFICATIONS
General
The classifications listed below follow S.A.E. J183 classifications. The MIL specifications are
USA Military Specifications. The following definitions will be of assistance in purchasing lubricants. The specific classifications for this machine are found on the Lubricant Chart.
Page 58
NOTE!
The engine oil and filter should be changed after the first 50 hours of service on new and
reconditioned engines.
AMBIENT
TEMPERATURE
CHANGE
INTERVAL
ISO
LUBRICANT
DESCRIPTION
1000 Hours
32
500* Hours
32
1000 Hours
32
Chevron HiPerSYN
1000 Hours
32
1000 Hours
32
1000 Hours
32
Royco 432
1000 Hours
32
1000 Hours
32
1000 Hours
32
1000 Hours
32
1000 Hours
46
Chevron HiPerSYN
1000 Hours
46
Citgo CompressorGuard
1000 Hours
46
500* Hours
46
1000 Hours
46
1000 Hours
46
Royco 446
1000 Hours
46
1000 Hours
46
1000 Hours
68
1000 Hours
68
Page 60
LUBRICANT
BRAND NAME
MANUFACTURER
ISO
22
ISO
32-46-68
ISO
100
X
ACCITE HIDRAULICO MH
PETROLEOS MEXICANOS
AMOCO AW OIL
ANTECH
EXXON/ESSO
ASHLAND VG
32
BARTRAN HV
BP OIL CO.
BRESLUBE VG
BRESLUBE LTD.-CANADA
OIL CANADA
CANVIS AW
BP OIL CO.
LOWE OIL
CHEVRON AW
CHEVRON
CITGO AW
CITGO
DECOL ANTI-WEAR
SHELL CANADA
DTE 24-25-26
DURO AW
ARCO
EAL SYNDRAULIC
ELF OLNA DS
ELF/ANTAR
BP OIL CO.
EPPCO UNIVIVERSAL GP
GULF HARMONY AW
GULF R&D
GULF USA
HIDRALUB EP
MARAVAN S.A.
HARMONY AW
ISO
150
46 & 68
LUBRICANT
BRAND NAME
MANUFACTURER
ISO
22
ISO
32-46-68
ISO
100
ISO
150
X
HYDRAFLOW
PETRO CANADA
HYDRALUBE AW
LUSCON IND.
HYDRELF DS
ELF
HYSPIN AWS-AD
CASTROL INC.
HYTAC
DISTAC LUBRICANTS
KENOIL R&O AW
LUSCON HD
LUSCON IND.
MARATHON MULTI. VG
MARATHON PETROLEUM
MYSTIK AW/AL
NERVOL
NUTO-H
EXXON/ESSO
NUTO-HP
EXXON/ESSO
32 & 46
NUTO-H PLUS
EXXON/ESSO
ORLY AGENA
ORLY INTERNATIONAL
ORLY GALA
ORLY INTERNATIONAL
ORLY HYDRO
ORLY INTERNATIONAL
PACER POWER V
PARADENE ANTI-WEAR AW
46 & 68
PEN PREMIUM EP
PENTAGON CORP.
32 & 68
PENNZBELL AW
PENNZOIL AW
PENNZOIL AWX
RANDO OIL HD
ROL RAFFINERIA
ROYAL AW
ROYAL PREMIUM VG
RYKON OIL
SELCO SF 330
SELCO
SHARLU HYDROFLUIDS AW
SHOSEKI W-R
STAR PREMIUM VG
46 & 68
32, 46 & 56
X
Page 62
LUBRICANT
BRAND NAME
MANUFACTURER
ISO
22
ISO
32-46-68
ISO
100
ISO
150
SUNVIS 8__ WR
SUNCOR or SUNTECK
CONOCO
TELLUS
TELLUS
TOTAL AZOLI A ZS
J.W.LANE
46 & 68
TEXACO REFINERY
UNION UNAX AW VG
UNIVIS N
X
32 & 46
EXXON/ESSO
UNIVIS N PLUS
EXXON/ESSO
UNIVIS SHP
EXXON/ESSO
32 & 46
YUKONG SUPERVIS
YUKONG LTD.
46
(46AW)
68
(68AW)
100
(100AW)
150
215
315
465
Gravity: API
31.1
30.3
29.5
28.9
30.04
5.26
42.70
6.57
62.9
8.43
96
11.03
Viscosity, SSU
100F (37.8C)
210F (98.9C)
155
43.9
220
48.2
325
54.6
500
64
Viscosity Index,
ASTM D 2270
106
105
104
99
Interfacial Tension,
D 971
77F:dyn/cm
31
31
31
32
400 (205)
405 (208)
450 (233)
465 (241)
425 (219)
430 (222)
470 (244)
490 (255)
455 (235)
470 (244)
500 (260)
545 (285)
Pour: F (C)
-25 (-32)
-25 (-32)
-20 (-29)
+5 (+15)
L0.5
L0.5
L1.0
L1.5
Carbon Residue,
Ramsbottom:%
0.30
0.30
0.36
0.37
Passes
Passes
Passes
Passes
Passes
Passes
Passes
Passes
0.68
0.68
0.68
0.68
2000+
2000+
2000+
1500+
40-40-0 (3)
40-40-0 (3)
40-40-0 (4)
40-40-0 (6)
217 (103)
220 (105)
228 (109)
234 (113)
Page 64
Page 66
CHUCK ADAPTER
API THREAD
DTH
RETAINING RINGS
DRILL BIT
API
THREAD
ROTARY
HOLDING WRENCH
The holding wrench must be fully retracted so the new table bushing will fit into the adapter.
Table bushings are shipped inside the accessory crate. There are three variations of bushings built for specific drilling applications.
Place the bushing into the table adapter so the flat joints align.
Purge New Drill Pipe
It is recommended to blow air through new drill pipe prior to placing the drill tools in service.
The purpose is to clean the drill pipe of any foreign substance prior to connecting expensive
drilling tools such as down the hole hammers and drill bits.
WARNING
This task must be performed with drill pipe connected to the rotary head and the machine
operating at low idle speed. Momentarily turn the air on for a short burst of air to blow through
the open drill pipe. Turn the air off.
Page 68
Rotary application:
The operator and the assembler will be communicating to connect drill tools to the drill string.
PPE is required for this task.
1. Place the drill bit on solid ground under the drill table.
2. Operate feed down so bit sub and drill pipe are passing through the table bushing
3. Stop the feed down mode as the bit sub threads engage the drill bit threads
4. Slow rotate the bit sub and drill bit threads together so the two shoulders contact taking
necessary steps not to cross thread the drill tools.
DTH application:
The operator and the assembler will be communicating to connect drill tools to the drill string.
PPE is required for this task.
1. Place the new drill bit onto the blank bit breakout plate, mark the bit diameter on the breakout plate, cut the breakout plate to suit the dimension of the bit, a welder with cutting
tools will be required to cut the breakout plate
2. Remove the chuck adapter from the hammer case
3. Lubricate the new drill bit splines and the chuck adapter threads with a thin coating of
thread grease
#1
#3-4-5
6. Install the chuck adapter and drill bit into the hammer case and hand tighten
7. Lubricate the hammer API threads with thread grease
8. Prep the hammer by pouring 1 quart (1/2 liter) of clean rock drill oil into the hammer case,
the check valve may need to be opened to prelube the internal hammer components
#8
#9-10-11-12
9. Place the hammer and bit on solid ground under the drill table.
10. Operate feed down so the drill pipe passes through the hammer bushing
11. Stop the feed down mode as the drill pipe threads engage the hammer threads
Page 70
12. Slow rotate the drill pipe and hammer threads together so the two shoulders contact taking necessary steps not to cross thread the drill tools.
NOTE!
Drill bits, chuck adapters and hammer threads will tighten as the drilling cycle commences.
Rotary drill bits, hammers and hammer bits are consumable items that wear according to
ground conditions. Operators must inspect the drill tools on a regular basis to assure they are
in good operating conditions.
Change drill bits as needed with proper breakout tools. Breakout tools are a necessary item
to loosen threads and the drill bit from bit subs or hammer cases. Breakout tools must be
accessible to the operator.
In some cases removing drill bits requires a second person.
Breakout Tools
Break out tools are required to remove drill bits and hammers from the drill string. Stow breakout tools in a safe location until they are needed.
The pipe tong will be used on drill pipe and sub connections.
The petol wrench and chain attachment will be used on down the hole hammers.
Bit baskets are blank plates to be cut to fit a customer supplied drill bit diameter. The bit basket fits into the mast table and the bit will fit and lock into the basket for removal.
J WRENCH
TONG WRENCH
PETOL WRENCH AND CHAIN
Do not use the tong wrench on hammer cases as the squeezing action of the tong pipe dies
can damage the circumference of hammers.
manufacture address
machine model
6 digit machine serial number
patent numbers
Page 72
Engine
The engine must be registered on Caterpillar web page at www.cat.com. Go to the tab
marked Engines and then Service & Support then go to Engine Warranty Registration and
complete the form.
Engine specific numbers are located on the engine cylinder head or valve cover.
You are encouraged to read the complete Caterpillar Limited Warranty from Caterpillar. It
details terms and conditions which must be met in order to qualify under the warranty.
Undercarriage
The undercarriage must be registered with Caterpillar OEM Solutions Group. The warranty
registration may be completed by visiting www.componentsformoems.com
Undercarriage specific numbers are located on the left and right track side frame.
You are encouraged to read the complete Caterpillar Warranty from Caterpillar. It details
terms and conditions which must be met in order to qualify under the warranty.
Compressor
The compressor warranty will be administered by Sandvik Mining and Construction upon
return receipt of the machine start up documents.
Sandvik Mining and Construction
Page 73
Page 74
Address
Worksite Address
City,State,Zip
Phone
Contact Person
Phone
Phone
Distributor Name
Address
Drill Model
Delivery Date
Operation of accessories
Proper instrument readings
Driving or moving drill
Shut down procedures
EXAMPLE FORM
The product described above was received by the customer in satisfactory condition and the customer acknowledges that the Driltech Mission
warranty is hereby accepted as part of the sales agreement for this product. The customer has received a thorough briefing on correct operation,
and proper maintenance and service procedures for this product.
CUSTOMER REPRESENTATIVE
TITLE
DATE
TITLE
DATE
NAME
DISTRIBUTOR REPRESENTATIVE
NAME
Fire Suppression
Factory installed fire suppression systems require local representation at new machine commission time. Upon inspection of the fire equipment the local representatives are responsible
to certify the system and submit the proper warranty documentation.
Page 76
Torque
Grade 5
Ft.Lb. (Kg/M)
Torque
Grade 8
Ft.Lb. (Kg/M)
1/4
6 (.8)
9 (1.2)
5/16
12-14 (1.5)
17-19 (2)
3/8
22-24 (3)
31-34 (4.5)
7/16
36-39 (5)
50-55 (7)
1/2
54-59 (8)
76-84 (11)
9/16
77-85 (11)
110-120 (15-16.5)
5/8
107-118 (15-16)
153-166 (21-23)
3/4
190-210 (26-29)
270-292 (37-40)
7/8
280-310 (38-43)
437-475 (60-66)
425-460 (59-63)
650-710 (90-98)
1-1/8
570-620 (79-86)
930-1000 (128-138)
1-1/4
810-870 (112-120)
1310-1410 (181-195)
1-3/8
1060-1140 (146-157)
1730-1850 (239-256)
1-1/2
1410-1510 (195-209)
2290-2460 (316-340)
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.
Torque
Grade 5
Ft.Lb. (Kg/M)
Torque
Grade 8
Ft.Lb. (Kg/M)
1/4
7 (1)
10-11 (1.5)
5/16
14-16 (2)
20-22 (3)
3/8
25-28 (3.5)
35-39 (5)
7/16
39-43 (6)
55-61 (8)
1/2
63-69 (9)
86-94 (12)
9/16
87-95 (12-13)
123-134 (17-18.5)
5/8
126-138 (17-19)
171-187 (24-26)
3/4
213-233 (30-32)
300-328 (42-45)
7/8
312-338 (43-46)
480-520 (66-72)
466-504 (64-70)
715-770 (99-106)
1-1/8
640-695 (89-96)
1040-1120 (144-155)
1-1/4
900-960 (124-133)
1460-1560 (202-216)
1-3/8
1210-1300 (167-180)
1970-2100 (272-290)
1-1/2
1585-1700 (167-180)
2570-2750 (272-290)
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.
Page 78
CONVERSION FACTORS
The following conversion factor chart is for reference purpose. It is based in US standards for
metric conversions and may be administered in system calculations.
MULTIPLY
FACTOR
TO OBTAIN
ATMOSPHERES
1.011325
BAR
ATMOSPHERES
29.9213
IN OF HG @ 32 F
ATMOSPHERES
101.325
KILOPASCALS
ATMOSPHERES
14.6960
PSI
BAR
1.1097
ATMOSPHERE (TECH)
BAR
14.504
PSI
CENTIMETERS
0.3937
INCHES
CUBIC FEET
0.02832
CUBIC METERS
CUBIC FEET
7.48052
GALLONS
CUBIC FEET
28.32
LITERS
CUBIC INCHES
16.39
CC
CUBIC YARDS
0.7646
CUBIC METERS
FEET
0.3048
METERS
FOOT-POUNDS
1.356
NEWTON METERS
GALLONS
231
CUBIC INCH
GALLONS
3.785
LITERS
INCH
2.54
CENTIMETER
INCH
25.40
MILLIMETER
KILOGRAMS
2.20462
POUNDS
KILOMETERS
0.6214
MILES
KILOWATTS
1.341
HORSEPOWER
LITERS
61.02
CUBIC INCH
LITERS
0.2642
GALLONS
METERS
100
CENTIMETER
METERS
39.37
INCHES
MILLIMETERS
0.03937
INCHES
MILLIMETERS
0.1
CENTIMETERS
0.06895
BARS
6.89476
KILOPASCALS
TONS (SHORT)
2000
POUNDS (LBS)
TONS (SHORT)
0.90718
TONS (METRIC)
Page 80