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DIRECTOR GENERAL BORDER ROADS

GENERAL MAINTENANCE INSTRUCTION NO. 253

ON OPERATION AND MAINTENANCE OF
SELF PROPELLED MEDIUM ROCK DRILL MAKE SANDVIK MODEL DC 122 R

INTRODUCTION:

(a) Self Propelled Medium Rock Drill Make Sandvik model DC 122 R with on board
Compressor fitted with CAT C2.2 Turbo charged Water cooled four cylinder diesel engine
developing output 37kW @ 2800 rpm fully remote controlled, hydraulic and on a 4 wheel
drive carrier.

(b) This GMI gives the technical specification and know how on the operation,
maintenance and repair procedure of Self Propelled Medium Rock Drill Make Sandvik
model DC 122 R to ensure maximum performance and safe/satisfactory operation.
Compliance with procedures given in this GMI will enable to get desired maximum service
from the equipment.

(c) Maintenance of Self Propelled Medium Rock Drill Make Sandvik model DC 122 R
will lead to long life, trouble free operation and less frequent break downs and also to
reduce maintenance cost. The periodic maintenance must be carried out according to the
‘Periodic Maintenance Schedule’ described in this GMI. Daily care, inspection and
Periodic Maintenance are essential for preventing troubles and accidents to ensure
satisfaction and safe operation for prolonging the operating life of the equipment. All
information and instructions given in this GMI is based on the latest Operator’s manual and
service booklet provided by the firm.

AIM:

The instructions are issued as guidelines for general, preventive maintenance

schedule and lubrication of Self Propelled Medium Rock Drill Make Sandvik model
DC 122 R manufactured by M/s Sandvik Asia Pvt Ltd for regular attention to keep the
equipment in good mechanical condition which must be strictly followed.

ACTION BY:

(a) User unit: To carryout periodic inspection and monitor regular/periodical

maintenance as laid down in this instruction and record the tasks done in log book.

(b) Field Workshop :

(i) To carryout and monitor maintenance schedule and oil changes as per
periodical maintenance laid down in the maintenance instructions and to
check the record of maintenance including lubrication.

(ii) To advise the user unit in respect of any lapse noticed.

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(c) Mobile Maintenance Team: To ensure that proper maintenance is carried

out and submit report accordingly to Task Force Commander and OC Wksp
for their necessary action.

DETAILS:

This instruction includes the following aspects:-

a) Operating Procedure – Do’s and Don’ts - Appendix ‘A’

b) Periodic Maintenance schedule - Appendix ‘B’
c) Technical Specification - Appendix ‘C’
d) Oil filling capacity/periodicity for change and - Appendix ‘D’
recommended lubricants for change

Sd/xxx
(Deepak Kumar)
EE (E&M) NFSG
Joint Director (Tech)
For Dir Gen Border Roads

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Appendix ‘A’
OPERATING PROCEDURE - DO’s & DON’Ts

1. Carry out maintenance and repair work only when the rig is not running. Make sure that the
rig cannot be started unintentionally during maintenance work.

2. Avoid using full percussion pressure. When the drill bit is not in contact with the rock, full
percussion pressure strain the accumulator membranes and causes unnecessary wear of the
flushing housing and cavitations in the percussion mechanism. Such idle drilling is especially
dangerous when drilling upward and cleaning holes by pumping.

3. Proper shank lubrication is necessary. Inadequate lubrication quickly causes serious

damage to the rock drill. Inadequate lubrication causes the chuck and the shank to overheat and
this leads to rapid wear of these component. Overheating of the shank also causes shank breakage.

4. Wear hearing protections when the power pack is running.

5. Before run ensure using a double nipple, connect the hoses of power pack to make a loop
so that the lines of both pumps form their own closed circuits. Turn on the power pack, pull the
levers of both control valves in to operating position, whereby oil starts flowing through the systems
in free circulation. Allow the power pack to run for about 3 minutes, after which it is ready for the run.

6. Connect the rock drill according to the hydraulic flow chart.

7. Make sure that there is enough oil in the tank and control valve and levers are in neutral
position.

8. Never detach a pressure accumulator before verifying that the pressure has been released,
before removing the accumulator from the rock drill.

9. Never heat an accumulator to temperature over 1000C.

10. Do not disassemble a pressurized accumulator (if an accumulator cannot be depressurized,

it must be disposed of properly).

11. Do not try to depressurize an accumulator using false methods e.g. drilling a hole through
diaphragm.

12. Do not use any other methods, than described in the manual, to depressurize or
disassemble an accumulator.

13. Do not drill a hole through the diaphragm or any other part of an accumulator.

14. Before resetting, check that the rod handling and drilling joysticks are not in the operating
position.

15. Do not go under an unsupported rig. Do not disconnect hydraulic hoses or valves unless you
are certain that the system has no static load. Remove all static loads always before starting repair
work by a mechanical support or by driving a cylinder to its extreme position.

16. Do not add cold coolant to a hot engine. Doing so could damage the cylinder head.

17. Do not fill the filter with fuel prior to installation.

18. Adjust engine’s idle speed to 1500 rpm with the adjusting screw.

19. Do not mix different type of oils.

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20. Run the engine at the low idling (at least 3 minutes) to cool the engine slowly and then stop
the engine.

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

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

23. Rock drill pressure accumulators are field with Nitrogen N2 gas. Before removing the
pressure accumulators from the rock drill, release the accumulator pressure by opening the filling
valve.

24. Check the emergency stops and safety equipments like Fire extinguisher, Pressure gauges,
Indicators, Tramming and working lights, Parking brake, Tramming brake, Inclination gauges and
Warning labels for proper functioning and condition before the start of each shift and after tramming.

25. Make sure that the dust collector system well and effectively at all times. Make sure that the
suction head is firmly against the ground during drilling and suction rubbers/hoses are in good
conditions/tight. Also ensure dust collector filters are in good conditions.

26. The engine is stopped automatically, if (a) the oil pressure sinks to low, and the indicator
lamp lights on the instrument panel (b) compressor temperature rises above 1150C, and the
indicator lamp lights on the instrument panel (c) the engine coolant temperature rises too high, and
the indicator lamp lights on the instrument panel.

27. Do not start the engine by towing.

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

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

30. Never exceed maximum allowed inclination angles (when drilling or tramming).

31. When using the winch, always make sure that the winch drum has a minimum of three loops
of cable. Merely locking the cable in the drum is inadequate because the cable is subjected to
tugging.

32. If the inclination of the drilling site is greater than 10 degrees, secure the rig by attaching a
winch cable to a firm location on the uphill side. If the terrain inclination is more than 20 degrees, a
winch must be used.

33. Make sure that all control levers are in the middle position before you start the power pack.

34. Ensure that rock drill lubrication is working. Faults arise in the rock drill very quickly if shank
lubrication does not operate correctly. Proper shank lubrication is also necessary.

35. The engine is equipped with a suction fan. Clean the radiator by blowing air from the fan
side.

36. If the oil level in the tramming gear rises, the shaft seal of the hydraulic motor is probably
damaged.

37. When the shank lubrication is working properly it is normal, that the drill steel is oily up to
about 25 cm (1 ft) from the rock drill. Make sure that air comes out through the shank lubrication
exhaust hole (on the feed side of the front cover).
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Appendix ‘B’
PERIODIC MAINTENANCE SCHEDULE

Service intervals in hours Remarks

Maintenance work Daily 50 250 500 1000 1500 3000
GENERAL MAINTENANCE
Clean the rig * * * * * *
Test the fire extinguisher and *
refilling
Check suction hoses and there *
connections of engine and
compressor
Check the operation of the gauges *
Check for possible oil leaks during *
drilling
BOOM
Grease all the greasing points * * * * * * *
Check the cradle and feed * * * * * *
clearance (i.e. 0.50 mm)
Check the welding of boom and * * * *
cradle
Check the mountings of hydraulic * * * *
cylinders
Check the tightening torque of the * * * *
cylinder taper pin bolts
FEED
Check the tightness and condition *
of the feed chain
Lubricate all the greasing points * * * * * * *
Check rock drill carriage/feed rail * * * * * *
clearance
Check the clearances of the * * * *
sprocket wheel bearings
Check condition of the retaining * * * * *
centralizer jaws
HYDRAULIC ROCK DRILL
Check shank lubrication oil level *
and top up if necessary and its
function (There should be 30 to 50
drops/min during drilling).
Adjust/clean if necessary
Check the condition of the chuck *
Check condition of flushing pipe *
Check the mounting of rock drill *
Check condition of accumulator * * * * * *
valves and pressures
Check the tightness of the pressure * * * * * *
accumulator bolts
Check the tightness of the front * * * * * *
cover bolts
Check the tightness of the rear * * * * * *
cover bolts

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Maintenance work Service intervals in hours Remarks

Daily 50 250 500 1000 1500 3000
DUST COLLECTOR SYSTEM
Lubricate the grease nipples of the * * * * * *
cut-off cylinder and the butterfly
valve
Check suction head rubbers * * * * *
Check the operation of the cut-off * * * * *
cylinder and the butterfly valve
Check the condition of the impact * * * * *
plate
CARRIER
Lubricate the greasing points * * * * * *
Check the condition and mounting * * * * * *
of winch rope
Check the electrolyte and * * * * * *
connections in the batteries
Check the operation of brakes * * * * *
Check the winch oil level from plug * * * * *
Check the welding seams * * * *
Change the Final Drive Oil * *
Change of Winch Oil * *
DIESEL ENGINE
Check the engine oil level *
Check the engine coolant level *
Check the tightness and condition *
of the V-belt
Drain water from water collector *
Check air intake lines and * * * * * *
connections
Clean the cooler/radiator core * * * * * *
Change the engine oil * * * * *
Change the oil filter * * * * *
Check the engine grounding * * * * *
Change the air filter * * * *
Check the Water Pump for Leaks * * * *
Change the safety filter element * *
Check the Valve Clearance * *
Check the Tightness of the * *
Cylinder Head Bolts
Check the engine vibration * *
dampers
Check the injector nozzles * *
Clean the crankcase breather * *

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Maintenance work Service intervals in hours Remarks
Daily 50 250 500 1000 1500 3000
Change the engine coolant and * *
replace the engine thermostat
Check the water pump, the starter * *
motor and the alternator
FUEL SYSTEM
Check the fuel level *
Drain fuel tank water trap * * * * * *
Change the fuel filter (pre-filter) * * * * *
Change the fuel filter/water * * * * *
separator
Change the fuel tank breather * * * *
Clean fuel tank * *
HYDRAULIC SYSTEM
Check the hydraulic oil level *
Replace the hydraulics return filters * * * *
Change the hydraulic oil * *
Clean Hyd oil receiver * *
Replace the hydraulic oil receiver * * * *
breather
PNEUMATIC SYSTEM
Check the compressor oil level *
Check the compressor air intake * * * * * *
lines and connections
Check the compressor belt tension * * * * * *
(i.e. 7.5 mm)
Change the air filter * * * *
Change the compressor oil * * * *
Change the compressor oil filter * * * *
Check the shut down temperature * * * *
switch
Clean the oil regeneration line * *
strainer and orifice
Change the safety filter element * *
Change the oil separator element * *
Clean the compressor oil receiver * *

General Maintenance Instructions :-

(i) Park the rig on a steady and level surface.

(ii) Ensure that the rig cannot move by itself. Lift the rig on to the jacks, or use a safety
brake and tire wedges.
(iii) Always stop the rig before commencing maintenance procedure. Prevent
accidental starting of the rig by turning the main switch off or removing the ignition
key.

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(iv) Wash the rig before maintenance do not use solvents that contain aromatic or
chlorinated hydrocarbons. Using mineral-oil-based fuel, such as gasoline, diesel,
or petroleum, as detergent is also forbidden! These substances can cause
deterioration, cracking, or softening of rubber and plastic parts.
(v) Clean the area around the filling cap thoroughly before adding fuel or oil.
(vi) When replacing the filters or changing oils, ensure that the oil added is pure. A
high particle content in the oil (e.g., the filter becomes clogged rapidly) can
indicate some kind of fault. Find out the reason for this situation before more
serious damages is done.
(vii) Reinstall protective rails and covers after maintenance.
(viii) Ensure that the hoses and cables cannot get entangled or tightened during use of
the rig.

Daily Maintenance:-

(i) Check for possible oil leaks.

(ii) Check the hoses and hose connections.
(iii) Check that the end of the flushing pipe is intact.
(iv) Check the tightness and condition of the feed chain.
(v) Check the tightness and condition of bolts and nuts. If a self locking not has
loosened, it must be replaced. If a normal bolted joint loosens repeatedly, use a
self-locking not or chemical locking agent.
(vi) Check and ensure one level daily using the dipstick, the oil level must be between
the upper and lower markings on the dipstick.
(vii) Check the coolant level daily the coolant level should be between the marks in the
expansion tank.
(viii) Check the tightness of v belt the deflection of the belt should be 10-15 mm.
(ix) Service air indicator must be checked daily by pressing the button on the top (The
filter cartridge must be replaced whenever the service indicator shows red or
according to maintenance schedule, whichever comes first).
(x) Check oil level in the hydraulic receiver with the sight glass. The oil level should be
in the middle of the sight glass.
(xi) Check amount of fuel from the fuel sight glass.

Weekly Maintenance:-

(i) Check the accumulator filling valves and their cover plugs, and the tightness of the
accumulator fastening bolts.
(ii) Check accumulator pressures.
(iii) Check the condition of the chuck, rotation bushing and rotation bushing bearing.
(iv) Check the tightness of the front and rear cover bolts.
(v) Wash the feed & boom.
(vi) Tighten all bolt and nuts of boom.

Monthly Maintenance:-

(i) Check the sprocket wheel bearings.

(ii) Measure all sliding clearances and adjust if necessary.
(iii) Wash inside of shank lubricator.

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Appendix ‘C’

TECHNICAL SPECIFICATION

Description Self propelled Medium Rock Drill Make

Sandvik model DC 122 R
POWERPACK
Engine Type CAT C 2.2 Turbocharged water cooled
four cylinder diesel engine, Hyd pumps
and on-board Compressor
Engine output 37 kw @ 2800 rpm
Transmission Type Direct /Polygroove belt
Hydraulic pumps Three gear pumps
Screw Compressor type Enduro 3
Air flushing capacity/output 1.2 m3/minute
Flushing Air pressure 4 to 8 bar
Maximum operating pressure 8 bar
Air Cleaner 2 Pcs
Fuel tank 75 litres
Average fuel consumption 4 to 6 ltrs/hour
Maximum operating altitude 3000 meters
Fuel saving system Standard

HYDRAULIC ROCK DRILL

Rock Drill Type HEX I, Hydraulic
Drill rod diameters HEX 19 x 108 mm
HEX 22 x 108 mm
HEX 25 x 108 mm
Operating Pressure 100 to 160 bar
Pressure rate 82 Hz
Percussion output power 5.5 kW
Maximum rotation torque 100 Nm/120 bar
Shank lubrication Air / oil mist
Flushing Air
Shank lubrication oil consumption 50 to 100 gm per hour
Shank lubrication air consumption 200 to 400 ltr per minute
Shank lubrication air pressure 6 to 8 bar
Weight 46 kg
FEED
Chain feed type CF 100 x 32 / HEX I, incl. One set of Jaws

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Length of feed 4540 mm
Rock drill travel 3300 mm
Maximum length of starter rod 3200 mm hexagonal or 10 feet, R23 MF
Hole depth with starter rod 2800 mm (9’ 2”)
Maximum length of two rods 6400 mm (21 feet)
Hole depth with second rod 6000 mm (19’ 8”)
Feed / pull out force 3.7 kN
Front Centralizer Manual
Travelling Centralizer Manual
Feed Extension Travel 600 mm (2’)
Feed Swing +/- 470
Feed tilt 1100
Weight without steels 155 kg
BOOM
Boom Type DB 120, articulated
Boom Length 3800 mm (3.8 m)
Boom Swing +/- 430
Drilling coverage on flat 10 m2
Collaring height +2.2 m / -4.0 m
Horizontal Holes Sideways, forwards
HYDRAULIC SYSTEM
Hydraulic system type Open centre, pilot control
Filtration rate 10 micron abs.
Cooling capacity Up to +500C ambient
Hydraulic oil tank 45 litres
Shank lubrication device WL 30
CONTROL SYSTEM
Tramrock TA 132 E / 120 Remote Controlled
Antijamming system Controlled by I/O-module and software
Voltage 24V DC
Boom and Drilling control Radio Remote
Driving and Jack control Radio Remote
DUST COLLECTOR
Dust Collector Type DC 120, Hydraulic
Suction hose 75 m

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Capacity/Vacuum 5 m3/min at 855 mm vacuum H2O
Filter elements/material 6 pcs/fiber
Total filter surface 4.8 m2
Hydraulic motor output 3 kW
Hydraulic motor maximum pressure 125 bar
Hydraulic motor speed 5800 rpm
Weight 90 kg
Total height 1324 mm
CARRIER
Carrier Type Rubber tyred, 4-wheel drive
Ground clearance 300 mm
Tramming force 20 kN
Tramming speed 3.6 km/hour
No. of Hydraulic Jacks 4
No. of working lights 4
Others
Total weight 2850 kg
Total width 1.8 m (1800 mm)
Total height 2.1 m (2100 mm)
Total length 4.6 m (4600 mm)
Hole diameter 22 to 45 mm
Production capacity 300 to 540 m3 / 8 hour

Jaws For Drill Steels

Drill steel type Drill steel diameter Recommended hole

diameter

Hexagonal steels 19 mm 22 to 27 mm
Hexagonal steels 22 mm 28 to 45 mm
Hexagonal steels 25 mm 35 to 45 mm
MF rods R23 33 to 45 mm
Shank adapter/shank rod R23 33 to 45 mm
Shank rod Alpha 250 25 mm 35 to 45 mm

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Appendix ‘D’
OIL FILLING CAPACITIES AND PERIODICITY FOR CHANGE

Item Quantity 50 Hrs 250 Hrs 500 Hrs 1000 Hrs 1500 Hrs 3000 Hrs
Engine Oil 8.20 litres * * * * *
Hydraulic Oil 45 litres * *
Compressor Oil 6 litres * * * *
Final Drive Oil (4 pcs) 0.70 litres * * * *
Winch Oil 0.70 litres *
Engine cooling system 10 litres *

RECOMMENDED LUBRICANTS FOR CHANGE

S/ Item Kind of Classifica- Ambient Grade Periodicity for change

No fluid tion (SAE) tempera-
ture
a) Diesel Engine Engine oil SAE 0W- -40 to API CJ-4 multigrade oil Initial oil and oil filter
20 +10 ºC element change at 250
SAE 0W- -40 to API CI-4 multigrade oil Hrs and thereafter ever
30 +30 ºC that meets Caterpillar 250 hrs
ECF-1-a or ECF-2
SAE 0W- -40 to specifications
40 +40 ºC Note:
SAE 5W- -30 to API CH4 multigrade oil Indian Oil Servo
30 +30 ºC that meets Caterpillar 15W40 an API Cl-4 or
ECF-1-a or ECF-2 any equivalent grade
SAE 5W- -30 to
specifications engine oil
40 +40 ºC
manufactured by any
SAE 10W- -20 to API CG-4 multigrade oil other company can be
30 +40 ºC that meets Caterpillar used in place of CAT
SAE 15W- -15 to ECF-1-a or ECF-2 15W 40
40 +50 ºC specifications
b) Compressor Mineral- SAE 5W- -20 to Mineral-based engine Initial oil change at 500
based 20 +35 ºC oil or synthetic Hrs. If the operating
engine oil SAE 10W -10 to compressor oil can be temperature is
+30 ºC use in the compressor continuously over 90ºC,
the oil change interval
SAE 20W- 0 to +40 for mineral-based oils is
20 ºC 250 engine hours (500
SAE 10- -5 to +60 engine hours for
30 ºC synthetic compr oils).

Synthetic ISO VG -30 to If the operating

compress 32 (40º C) +40 ºC temperature is
or oil continuously over
100ºC (ambient
ISO VG -20 to
temperature over 40ºC)
46 (40º C) +60 ºC
or below -20ºC (In arctic
conditions), synthetic
compr oil must be used.
c) Transmission Transmis- API GL-5, Mineral based oil or At every 3000 hrs.
(Winch) sion oil SAE 80W- synthetic oil
90 or
synthetic
SAE 75W-
90
d) Transmission Transmis- ISO VG -35 to + Mineral based oil or Initial oil change at 500
(Tramming sion oil 100 60 ºC synthetic oil Hrs & thereafter every
gear) 500 hrs
ISO VG -25 to + Mineral based oil or
220 80 ºC synthetic oil
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e) Lubrication Grease Alvania EP Grease 2 (SHELL)
grease Mobilux EP 2 (MOBIL)
Energrease LS-EP2 (BP)
Beacon EP 2 (ESSO)
Gulfcrown Grease EP 2 (GULF)
Speeroll AP 2 (CASTROL)
Marfax All Purpose (TEXACO)

f) Engine Coolant Cat ELC -37 ºC Caterpillar Extended life

coolant 100% coolant is a red
ethylene glycol based
Cat ELC -38 to - fluid. Only this same
80% + 20% 52 ºC Cat ELC fluid or distilled
ELC water can be added to
concentra- the cooling system.
te added
g) Shank Rock drill Torcula +12 to Lubricant Ambient
Lubricator oil 100 (Shell) +55ºC Tempera-
ture
Torcula 32 -10 to Energol -10 to
(Shell) +38ºC RD-E 46 +38ºC
(BP)
Tellus oil -30 to Energol -32 to
R10 (Shell) +18ºC RD 50S +580C
(BP)
Gulfstone +12 to Rock Drill +18 to
100 (Gulf) +55ºC Lube X 68 +55ºC
(Texaco)
Gulfstone -5 to Rock Drill -10 to
46 (Gulf) +35ºC Lube X 32 +38ºC
(Texaco)
Merit -25 to RD oil 100 +12 to
15 (Gulf) +18ºC (Castrol) +55ºC

Energol +12 to Hyspin -30 to

RD-E l00 +55ºC VG 10 +18ºC
(BP) (Castrol)
h) Hydraulic Engine oil SAE +25 to Only use in high-quality
system in the Hyd 5W-20 +42 ºC oils.
system Following oils and fluids
SAE +28 to are suitable for
5W-30 +45 ºC Hydraulic systems.
(a) Shell Rimula R3
SAE +28 to (engine oil)
10W-30 +50 ºC (b) Shell Tellus S
(hydraulic oil)
SAE +38 to
10W-40 +60 ºC

SAE +18 to
10W +30 ºC

SAE +32 to
20W-20 +45 ºC

SAE 30 +38 to
+52 ºC

Note:
(a) Never mix two different brands of oil in any system of the machine.
(b) Do not mix one brand of Coolant/Antifreeze with a different brand.
(c) 50 Hrs, 250 Hrs and 500 Hrs maintenance are also to be carried out at the time of 1000 Hrs
maintenance.
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