Original instructions

REVISION 7-17

Maintenance Manual
d245s
FOR SERIAL NUMBER: 733890
 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 an hazardous situation which,

! DANGER if not avoided, will result in death or serious injury.

Indicates a hazardous situation which,

! WARNING if not avoided, could result in death or serious injury.

Indicates a situation which, if not avoided,

NOTICE may result 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.
 TABLE OF CONTENTS

SAFE OPERATING PRACTICES FOR DRILLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Safety Labels and Signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

USER OBLIGATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Managing Work Related Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Periodic Safety Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
Personal Protective Equipment (PPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

LIMITS OF THIS MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii

Intended Use of This Rig. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
Recommended Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
Manners and Conditions In Which This Machine Should NOT Be Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii

GENERAL HAZARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
Hazard Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
Dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix

WEATHER HAZARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x
Management’s Responsibilities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
Rainfall and Flooding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
Thunderstorms and Lightning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
Exceptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii
Machine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii
Reference Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii

HYDRAULIC PRESSURE RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii

FIRE SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv

Fire Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv
Fire Suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xv

IN CASE OF FIRE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv
Ansul Checkfire 210 Detection and Actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi
Maintenance Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii

ENVIRONMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xviii
Destruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xviii
Recycling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xviii
Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xviii
Incident Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xix

SAFE OPERATING PRINCIPALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xix

COOLANT, FUEL and LUBRICANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

COOLANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

FILL WATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Coolant Conditioner Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

FUEL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Cetane Requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Fuel Cloud Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Fuel Sulphur Content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

CRANKCASE OIL VISCOSITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

LUBRICANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Engine Oils (CH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Lubricating Grease (MPGM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Compressor Oils (COMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Hydraulic Oils (HYDO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Multipurpose - Type Gear Lubricant (MPL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Refrigeration Oil (REF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

REFILL CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

MINIMUM PERFORMANCE STANDARDS FOR HYDRAULIC OILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

AIR COMPRESSOR LUBRICANT RECOMMENDATIONS (Low & High Pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

SECTION 2 PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

SERVICE AND OIL CHANGE INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

MAINTENANCE RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

USE OF CORRECT TOOLS AND PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

OIL SAMPLE ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

WIGGINS SERVICE STATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

THE DRILL MONITOR SYSTEM (DMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

COMPRESSOR AND HYDRAULIC SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Oil Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Mixing Hydraulic Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Initial Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

HEATING, CUTTING AND WELDING EQUIPMENT USAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

RECOMMENDED TORQUE VALUES FOR STANDARD HARDWARE - UNC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

RECOMMENDED TORQUE VALUES FOR STANDARD HARDWARE - UNF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

WHEN REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1

Replace Ether Starting Aid Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1
Check Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1
Check the Cooler Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1

AIR CLEANERS - ENGINE & COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-2

Changing Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-2
Primary Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-2
Safety Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-3
Primary Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-3
Safety Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-4
Body & Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-4
Inspect Dust Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-5

OPERATOR’S CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-5

Change Air Conditioner/Heater Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-5

DUST COLLECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-5

Change the Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-5

UNDERCARRIAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-6
Brake Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-6

EVERY 8 SERVICE HOURS OR DAILY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1
Measure Crankcase Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1
Drain Fuel Water Separator Bowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1

Check Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1
Adding Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1

COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2
Check Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2
Drain Condensate From Air/Oil Receiver Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2
Check Oil Return Line Sightglass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-3
Check Air/Oil Separator Element Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-3

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-3

Check Oil Level in Reservoir Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-3
Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-3
Drain Water From Reservoir Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-4
Check Hydraulic Tank Air Pressure Regulator Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-4
Check Servo Replenishing Filters Dirt Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-4

DRIVESHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-5
Lubricate Pump Driveshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-5

PUMP DRIVE GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-5

Check Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-5

UNDERCARRIAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-5
Check for Debris . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-5

AIR INLET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-6

Check Air Cleaner Element Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-6
Inspect Vacuator Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-6

CENTRAL LUBE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-6

Check Central Lubricator Grease Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-6
Drain Water and Check Pump Oiler Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-6
MISCEALLANEOUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-7
Inspect Winch Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-7
Check Bit/Hammer Lubricator Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-7
Check Feed Chain Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-7

EVERY 50 HOURS OR WEEKLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-1

AIR SWIVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-1

Grease Air Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-1

INITIAL 50 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-1

EVERY 250 HOURS OR MONTHLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-1

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-1
Check Engine Mount Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-1
Change Crankcase Oil and Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-1
Engine Valve Lash (Initial) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-2

ALTERNATOR and AIR CONDITIONER COMPRESSOR V-BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-2

Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-2
Check Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-2
Adjust Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-3

BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-3
Check Battery Electrolyte Level and Clean Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-3

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-3

Change Secondary Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-4
Priming the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-4

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-4

Change Coolant Conditioner Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-4
Check Radiator Mounting Hardware Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-5
Check Cooler Fan Finger Guards and Radiator Blade Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-5

COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-5
Change Main Oil Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-5
Clean Oil Return (Scavenge) Line Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-6
Change or Sample Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-7
Add Oil to the Poppet Lubricant Cavity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-7

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-8

Change the Servo Replenishing Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-8
Change Feed Cylinder Circuit Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-8
Clean Hydraulic Reservoir In-Line Air Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-9
Clean the Water Trap Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-9
Replace the Breather/Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-9
Check Hydraulic Tank Mounting Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-10

PUMP DRIVE GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-10

Clean Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-10

WATER INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-10

Check Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-10
Change Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-11

ROTARY HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-11

Check Gearbox Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-11

FEED SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-12

Check Feed Chain Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-12
Lubricate Feed Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-12
Inspect and Lubricate Chain Sprockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-12

UNDERCARRIAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-13
Check Final Drive Gearbox Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-14

AIR INLET - ENGINE & COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-14

Replace Primary Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-14

CENTRAL LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-15

Clean Water Trap Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-15
Check System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-15

MISCELLANEOUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-15
Check Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-15
Check Intake and Exhaust Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-16
Check Dust Collector Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-16
Check Decals and Nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-16

EVERY 500 HOURS OR 3 MONTHS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-1

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-1
Clean Engine Crankcase Breather (TIER 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-1
Clean Engine Crankcase Breather (TIER 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-1

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-1

Replace Primary Fuel Filter/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-1
Priming the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-2

PUMP DRIVE GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-2

Change Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-2

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-3

Change Return Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-3

ROTARY HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-4

Change Gearbox Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-4

WATER INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-4

Clean Suction Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-4

WINCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-5
Check Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-5

AIR INLET - ENGINE & COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-5

Replace Safety Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-5

MAST and PEDESTAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-6

Inspect the Drill Pipe Safety Hoop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-6
Inspect the Pedestal Welds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-6

EVERY 1000 HOURS OR 6 MONTHS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2F-1

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2F-1

Change Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2F-1

COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2F-1
Re-Torque Compressor Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2F-1
Change Air/Oil Separator Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2F-2
Change Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2F-3
Changing the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2F-4

WINCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2F-4
Change Oil and Clean Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2F-4

ROTARY HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2F-5

Replace Gearbox Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2F-5

MAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2F-5
Check the Torque of the Pivot Block Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2F-5

EVERY 2000 HOURS OR 1 YEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2G-1

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2G-1

Change Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2G-1
Re-Torque Cooler Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2G-2

UNDERCARRIAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2G-2
Change Crawler Final Drive Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2G-2

MAST and PEDESTAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2G-3

Change the Pivot Block Bolts and Hardware (Every 4000 Hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2G-3
Test the Pedestal Welds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2G-3

SECTION 3 MACHINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

SHORT TERM STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Preparation for Short Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Removal from Short Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

LONG TERM STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Preparation for Long Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Removal From Long Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
 SAFE OPERATING PRACTICES FOR DRILLERS

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.

Safety Labels and Signals

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 avoid-
ed, 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
NOTICE
Indicates a situation which, if not avoided, may result in damage to machin-
ery or components.

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.

Safe Operating Practices for Drillers iii

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 main-
tenance.
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!

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

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.

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,

iv
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), compe-
tent, 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?

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.

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 Operator’s 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 imme-
diately, 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.

Safe Operating Practices for Drillers v

• 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 oper-
ated by unauthorized individuals.
• The operator must never permit personnel to ride on the machine except in the passenger compartment.

DANGER
ELECTRICAL SHOCK HAZARD!
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 pow-
er 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 con-
trols and alert other potential users of the drill.
• The operator should not operate the drill without first checking that all personnel protection equipment
(PPE) and machinery guards are in place.
• Raising or lowering the mast, and drilling with an unsupported or unleveled machine can result in exces-
sive structural stress to the machine frames or can cause the machine to overturn.
• 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.

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
BURN HAZARD!
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.

vi
• 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. Per-
forming 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
SKIN INJECTION HAZARD
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.
If injected, SEEK MEDICAL ATTENTION IMMEDIATELY.

DANGER
HIGH PRESSURE INJECTION HAZARD
Pressure in hydraulic systems can be retained for long periods of time. If not
properly released before maintenance people attempt to work on the hydrau-
lic 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.
• 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 con-
tact 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.

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.

Safe Operating Practices for Drillers vii

Limits of This Machine

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 Stability’ topic of the Operator’s manual.

Recommended Operating Conditions

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

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

Modifications

WARNING
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 ap-
proval 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

viii
• 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.

General Hazards

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

WARNING
It is forbidden for personnel to be in the tramming area while the drill is in mo-
tion.
The operator has limited field of vision when tramming.
Always use a ground guide when tramming the drill. Be sure the tramming
area is clear of all personnel before tramming.

TRAMMING
SAFETY ZONE 5 M (15 ft)

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

5 M (15 ft)

Safe Operating Practices for Drillers ix

 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

8m
(25 ft.)

8m
(25 ft.)

Dust

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

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

x
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.

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:

• 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 blastholes 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 4.2 kph (2.6 mph).

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 posi-
tion 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.

Thunderstorms And Lightning

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

Safe Operating Practices for Drillers xi

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 worksite.

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.

• Equipment operators shall retrieve drill pipe from blastholes, secure drilling tools and lower mast to a hor-
izontal 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. Ade-
quate 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.

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 communication

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 a enclosed vehicle or adequate shelter. Maintain a dis-
tance greater than 92 m (100 yards) to prevent electrical draw in the event lightning did strike the mining
equipment.
xii
• 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.

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.

Reference Material
• MSHA Holmes Safety Association Bulletin April 2001
• Federal Metal and Non-metallic Mine Safety and Health Standards 30CRF 56/57/58 Ninth Edition (1999).
• National weather service (www.noaa.gov)

Hydraulic Pressure Release

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.

• Release the hydraulic pressure at the hydraulic tank.
• Do not check for leaks with hands.
• The technician must release the hydraulic hose fittings slowly at first to minimize potential high pressure
hydraulic oil or PSO pressure squirting out through the hose fitting. Oil will drain out the loosened hose fit-
ting.
• With the hose fitting slightly loose, manually rock the hose from side to side.

Safe Operating Practices for Drillers xiii

• Slowly open the hydraulic hose fitting and alternate the hose fitting to release residual hydraulic oil pres-
sure while maintaining a barrier between the hydraulic fitting and technician.

WARNING
FALLING LOAD HAZARD
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, ME-
CHANICALLY SUPPORT AND SECURE the load prior to performing any re-
pair work.
NEVER attempt to work on hydraulic cylinders without adequate safety train-
ing. 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 rotary head 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.

1. Determine if mast is vertical or horizontal.

• If vertical, lock and support the rotary head in position so that it cannot fall.
• If horizontal, lock the rotary head into position so it does not move.
2. Disconnect the pilot line to the valve.
3. Connect a portable hydraulic pump to the pilot line input on the valve.
4. Pump the portable hydraulic pump to achieve sufficient pressure to open the holding valve and discharge
pressure between the holding valve and the cylinder.
5. After pressure has been released, disconnect hose slowly and drain off any residual oil and pressure.
Have a pan beneath the valve to catch spilled oil.
Contact your Sandvik representative for a copy of service bulletin SB243A for more information on releasing
stored hydraulic circuit pressures.

Fire Safety

Fire Prevention

DANGER

FIRE HAZARD!
Smoking and open flame are prohibited in the vicinity of this machine.

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:

xiv
• Gases emitted from batteries
• Diesel fuel and its vapors
• Hydraulic oil
• Engine oil
• Compressor oil
• Engine starting fluid
Further preventive measures include:

WARNING
FIRE HAZARD!
Vegetation, coal dust, oily surfaces, and oily rags can catch fire and cause
serious injury or death.
Keep the machine clean of vegetation, coal dust, oil, 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 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 cyl-
inders 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.

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:

Safe Operating Practices for Drillers xv

1. Turn the machine off.
2. Quickly actuate the fire suppression system by pulling
the safety ring pin and pushing down the plunger on the
actuator.
3. Get away from the machine. Take a hand portable extin-
guisher along if you can.
4. 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 dan-
gers 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 extin-
guisher. This standby should be maintained until all possibility of reignition is past.
• Read the attached documents concerning the fire suppression system specific to your drill. Exposure to
the fire suppression chemical use during a fire may be a hazard to your health.

Ansul Checkfire 210 Detection and Actuation System

This equipment is monitored with a CHECKFIRE 210 Detection and Actuation System which is typically
connected to an ANSUl.s A-101 or LVS Fire Suppression System for 24-hour fire suppression. The operator
of the equipment should be provided with hands-on training by Authorized ANSUL Distributors or the end
user.

This section is a quick-reference guide for basic operation of the CHECKFIRE 210 System. Two buttons on
the display module and manual actuators provide operator control.

IN CASE OF FIRE: Manual Actuation

1. Safely bring equipment to complete stop, set brake and shut off ·engine.
2. Break visual seal and open guard door.
3. Push the red “PUSH To Activate I Alarm When Lit” button.
4. Release circuit immediately activates the connected fire suppression system (if included, pressure switch
activates auxiliary operation). See Note below.
5. Safely exit equipment and stand-by with supplemental firefighting equipment.
6. Optional manual actuation: Pull ring pin and strike red button on electric or pneumatic manual actuator.

NOTE: The red “PUSH To Activate I Alarm When Lit” LED and sounder remain steady-on for 10 sec. during
initiation (release) of fire suppression system. Post release: Detection 1 and/or Detection 2, Shutdown,
and Release LEDs and sounder continue to pulse 1 x 10 sec. If safe to re-enter equipment, push
“DELAY/Reset/Silence” button to silence sounder for two hours.

IN CASE OF FIRE: Automatic System Operation

1. Detector(s) registers alarm condition in hazard area and initiates the time delay notification on display
module.
2. “PUSH To Activate I Alarm When Lit” plus Detection 1 and/or Detection 2 LEDs plus sounder:
a. Pulse 2 x 1 sec. until last 5 sec. of TD1.
b. Then pulse 4 x 1 sec. with Shutdown LED at start of final 5 sec. (See DELAY/RESET/SILENCE

xvi
 (grey) button below for TD1 restart).
c. Only Shutdown LED is steady-on for 1 sec. indicating TD1 transferring to TD2 {restart no longer
available).
d. Pulse 4 x 1 sec. with Shutdown LED during TD2.
e. Steady-on 1 O sec. with Shutdown LED during initiation (release) of fire suppression system (if
included, pressure switch activates auxiliary operation).
3. As soon as time delay begins: Safely stop equipment, set brake, shut off engine, and exit. Standby with
supplemental firefighting equipment.
4. Post release: LEDs and sounder pulse 1 x 10 sec.

DELAY/RESET/SILENCE (Gray) Button

1. Restart Time Delay: Press and release for each restart of TD1 during alarm condition. (Limit: 2 restarts or
Unlimited.)
2. Must be initiated before last second of TD1. (No response after TD1 until post release.)

NOTE: Press and hold will not extend time delay period.

3. Silence sounder (post discharge or fault notification) for two hours: Press and release to silence sounder;
LED fault indication will continue until fault is cleared. Any new fault or detection event will reactivate
sounder.

FRONT PANEL INDICATORS

1. Power LED
• Green steady-on indicates normal external power.
• Green pulsing 1 x 3 sec. indicates normal Internal power.
• Amber pulsing 1 x 3 sec. indicates external power fault; system is operating on internal power.
Contact Authorized ANSUL Service Technician.
• Amber pulsing 1 x 1 O sec. with sounder indicates internal or external power fault. Contact Autho-
rized ANSUL Distributor for service.
• Off indicates no system power. Contact Authorized ANSUL Distributor for service.
2. All other LEDs
• LED off indicates normal status.
• Amber or red pulsing with sounder: Contact Authorized ANSUL Distributor for service.

WARNING
FIRE HAZARD!
Any fault indication may cause the fire detection and actuation system to not
function properly.
Immediately contact an Authorized ANSUL Distributor for service.

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 4 provides instructions for periodic Mechanical Inspections to the
maintenance and operating personnel for components and equipment installed.

Safe Operating Practices for Drillers xvii

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 5 of the Operator’s Manual contains the Operator Maintenance Check List and description of
how maintenance tasks requiring a low level of technical skill should be carried out.

Maintenance tasks requiring a high level of technical skill include:

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

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.

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.

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.

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 proce-
dures. Tubes (hydraulics etc.) must be cleaned before they are disposed of.

xviii
• 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.

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:

• 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.

Safe Operating Principals

• Follow local and Governmental Safety regulations.
• Designate a lead assembly person for the assembly process.
• Perform a site specific risk analysis prior to commencing machine assembly.
• Follow the guidelines prescribed in this manual for assembly and commissioning the new drill machine.
• File the required commissioning paperwork as needed to the proper authorities.

Safe Operating Practices for Drillers xix

xx
 SECTION 1

COOLANT, FUEL and of water/glycol solution is recommended. Use

ethylene glycol or propylene glycol to protect
LUBRICANT against freezing and boiling.
SPECIFICATIONS
Freeze Boil
Concentration
COOLANT SPECIFICATIONS Protection Protection

50 Percent -36°C (-33°F) 106°C (223°F)

Always use a mixture of approved fill water,
antifreeze and Cooling System Conditioner. 60 Percent -52°C (-62°F) 111°C (232°F)
(Ethylene Glycol Only)

Refer to the engine manufacturer for detailed

specifications, or Caterpillar® form SEBD0518.
Coolant Conditioner Elements

FILL WATER Coolant conditioner elements should be used to

maintain a 3 to 6% concentration of conditioner
Always add conditioner to coolant water. Never in the coolant. Use a precharge element when
use plain water only in the cooling system. filling the system or changing coolant. Install a
new maintenance element after every 250
Acceptable water for use in the preparation of hours of service.
ethylene glycol type antifreeze and water mix-
ture is shown in the follow chart.
FUEL SPECIFICATIONS
ACCEPTABLE WATER
Caterpillar® manufactured diesel engines have
the ability to burn a variety of fuels. These fuels
Property Maximum Limit ASTM Test are divided into two categories: Preferred or
Permissible.
Chloride (CL) 40 mg/L ‘D512’
(2.4 grains/US gallon ‘D4327’
Preferred fuels provide maximum engine ser-
Sulphate (SO4) 100mg/L ‘D516’ vice life and performance. These fuels are distil-
(5.9 grains/US gallon) late fuels and are commonly called; fuel oil,
Total Hardness 170 mg/L ‘D1126’ furnace oil, diesel fuel, gas oil or kerosene.
(10 grains/US gallon
Permissible fuels are crude oils or blended
Total 340 mg/L ‘D1888’
Solids (20 grains/US gallon
fuels. Use of these fuels can result in higher
maintenance costs and reduced engine service
Acidity pH of 5.5 to 9.0 ‘D1293’ life.

ppm = parts per million Refer to Caterpillar® form SEBU6251 for a

detailed summary of preferred fuels and their
specifications.
Antifreeze

For optimum performance a 1:1 (50/50) mixture

Coolant, Fuel and Lubricant Specifications - Page 1-1
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.
Fuel Cloud Point
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 high-
est 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 recommenda-
tions.

The cloud point of the fuel is the temperature

that allows some of the heavier components in
the wax to solidify in the fuel. Wax in the fuel is
not a contaminant, it is an important element of
No.2 diesel fuel. Fuel waxing can plug the fuel
filters in cold weather. Fuel heating attachments
can minimize fuel filter waxing and are available
from your Sandvik Mining and Construction or
Caterpillar® dealer.
Fuel Sulphur Content
LUBRICANT SPECIFICATIONS
General
The classifications listed below follow S.A.E.
J183 classifications. The MIL specifications are
USA Military Specifications. The following defi-
nitions will be of assistance in purchasing lubri-
cants. The specific classifications for this
machine are found on the Lubricant Chart.

The percentage of fuel sulphur content will

affect the engine oil and filter change intervals. Engine Oils (CH)

Only use oils that meet Engine Service Classifi-

CRANKCASE OIL VISCOSITIES cation CH (MIL-L-2104D).

At the factory, this machine was filled with BP

Viscosity Grade Minimum Maximum
15W - 40. Consult the Caterpillar form
Temperature Temperature SEBU5939 for a listing of CH oil brands.
SAE 0W-20 -40°C (-40°F) 10°C (50°F) NOTE!
SAE 0W-30 -40°C (-40°F) 30°C (86°F) The engine oil and filter should be changed
after the first 50 hours of service on new and
SAE 0W-40 -40°C (-40°F) 40°C (104°F)
reconditioned engines.
SAE 5W-30 -30°C (-22°F) 30°C (86°F)

SAE 5W-40 -30°C (-22°F) 50°C (122°F)

Lubricating Grease (MPGM)
SAE 10W-30 -18°C (0°F) 40°C (104°F)

SAE 10W-40 -18°C (0°F) 50°C (122°F) Use only multi-purpose grease (MPGM) which
contains 3 to 5% molybdenum disuphide. NLGI
SAE 15W-40 -9.5°C (15°F) 50°C (122°F) No, 2 Grade is suitable for most temperatures.
SAE 30 0°C (32°F) 40°C (104°F) Use NLGI No. 1 or No. 0 Grade for extremely
low temperatures.
SAE 30 5°C (41°F) 50°C (122°F)

Page 1-2
Compressor Oils (COMP) Refrigeration Oil (REF)

As with any oil Do not mix different types of oils. Use an ISO 100 refrigeration oil.
Contamination of synthetic oils with traces of
AFT may lead to foaming or plugging of orifices.
REFILL CAPACITIES
When operating between 80 and 100°F (27 and
38°C) and with relative humidity above 80%, a
synthetic hydrocarbon type fluid is recom-
COMPONENT GALLON LITRE
mended. Currently, Shell Corena is used at the
factory unless the receiver tank decal indicates RECEIVER TANK 70 265
otherwise. FUEL TANK 200 757

NOTE! HYDRAULIC TANK 135 511

Compressor oil change intervals will change PUMP DRIVE GEARBOX 3 qt. 3
depending on the type of oil used. The oil manu- ROTARY DRIVE GEARBOX 5.5 21
facturers recommendations supersede the rec-
ommended interval suggested in this manual. CENTRALIZED LUBRICA- 30 lb. 13.5 kg
TIONS SYSTEM or or
55 lb. 208 kg

Hydraulic Oils (HYDO) BIT LUBRICATOR TANK 10 38

ENGINE CRANKCASE 9 34
Use industrial-type hydraulic oils that are certi- COOLANT 25 95
fied by the oil supplier to have anti-wear,-foam, - (CATERPILLAR C15)
rust, and -oxidation additive properties for approximately
heavy duty usage. WINCH 2 pt. 1

At the time of shipment this machine was filled CRAWLER FINAL DRIVE (ea.) 2 8

with Citgo 32 AW hydraulic oil. WATER INJECTION 230 870

TANK(WO/DUST COLLECTOR

WATER INJECTION TANK(W/ 120 454

Multipurpose - Type Gear Lubricant (MPL) DUST COLLECTOR

WATER INJECTION PUMP 1 qt. 1

Use Gear Lubricant Classification GL-5 (MIL-L-
2105B) EP140. Use SHC 75 x 90 in cold ambi-
ent conditions and SHC 5 x 90 in arctic condi-
tions.

Coolant, Fuel and Lubricant Specifications - Page 1-3

 6-05

RECOMMENDED LUBRICANT VISCOSITIES

OUTSIDE °F -22 -4 +14 +32 +50 +68 +86 +104 +122
TEMPERATURE °C -30 -20 -10 0 +10 +20 +30 +40 +50

SAE 5W -20(SPC)
ENGINE CRANKCASE SAE 5W-20
CH-4 SAE 10W
SAE 10W-30
SAE 15W-40
SAE 30
SAE 40

-40°F ISO 32
COMPRESSOR
ISO 46

COMP ISO68
Note oil change intervals

CD SAE 10W
UNDERCARRIAGE, CD SAE 30
FINAL DRIVE GEARBOX CD SAE 40W
MPL
CD SAE 50W

32AW
HYDRAULIC SYSTEM 46AW
HYDO 68AW
100AW

WATER INJ. PUMP - CH SAE 30

SAE 10W-30

ROTARY HEAD, WINCH and GL-5 EP 90

PUMP DRIVE GEARBOX
SHC 75W-90
MPL
SHC 5W-90

HAMMER OIL ISO 46-100

RDO ISO 100-220
220-460

Page 1-4
 996
EQUIVALENT HYDRAULIC OILS

LUBRICANT ISO ISO ISO ISO

MANUFACTURER
BRAND NAME 22 32-46-68 100 150

ACCITE HIDRAULICO MH PETROLEOS MEXICANOS X X

AMOCO AW OIL AMOCO OIL CO. X

AMOCO RYDON OIL MV AMOCO OIL CO. X X

ANTECH EXXON/ESSO X

ASHLAND VG ASHLAND OIL CO. 32

BARTRAN HV BP OIL CO. 46 & 68

BRESLUBE VG BRESLUBE LTD.-CANADA X X

CANADIAN OIL MOXY T OIL CANADA X X X

CANVIS AW BP OIL CO. X X

CHAMPION SUPER GRADE LOWE OIL X

CHEVRON AW CHEVRON X

CITGO AW CITGO X X X

D-A WEAR GUARD II VG D-A LUBRICANT CO.-USA X

DECOL ANTI-WEAR SHELL CANADA X X X

DTE 24-25-26 MOBIL OIL CORP. X

DURO AW ARCO X X

EAL SYNDRAULIC MOBIL OIL CO. X

ELF OLNA DS ELF/ANTAR X

ENERGOL HLP-HD SERIES BP OIL CO. X X

EPPCO UNIVIVERSAL GP EPPERT OIL CO. X

GULF HARMONY AW GULF R&D X

GULF SYNFLUID SL H__AW GULF USA X

HIDRALUB EP MARAVAN S.A. X X

HARMONY AW GULF CANADA LTD. X X

HYDRAFLOW PETRO CANADA X X X

HYDRALUBE AW LUSCON IND. X X

HYDRELF DS ELF 46 & 68

HYSPIN AWS-AD CASTROL INC. X

HYTAC DISTAC LUBRICANTS X X

KENOIL R&O AW KENDALL REFINING CO. X X

LUSCON HD LUSCON IND. X X

MARATHON MULTI. VG MARATHON PETROLEUM X X

MOBIL HYD. OIL NZ MOBIL OIL CO. X

MOBIL HYD. OIL ZF MOBIL OIL CO. X

MYSTIK AW/AL CATO OIL & GREASE CO. X X

(Page 1 of 2)

Coolant, Fuel and Lubricant Specifications - Page 1-5

996
LUBRICANT ISO ISO ISO ISO
MANUFACTURER
BRAND NAME 22 32-46-68 100 150

NERVOL FLUID SH2 NERVOL X X X

NUTO-H EXXON/ESSO X X X

NUTO-HP EXXON/ESSO 32 & 46

NUTO-H PLUS EXXON/ESSO X

NYCO HYD. OIL NYCO LUBRICANT CORP. X X

ORLY AGENA ORLY INTERNATIONAL X

ORLY GALA ORLY INTERNATIONAL X

ORLY HYDRO ORLY INTERNATIONAL X

PACER POWER V PACER LUBRICANT INC. X X X

PARADENE ANTI-WEAR AW DRYDEN OIL CO. - USA X X X

PEAK HYDRA AW SERIES PEAK OIL CO. 46 & 68 X

PEN PREMIUM EP PENTAGON CORP. 32 & 68 X

PENNZBELL AW PENNZOIL PROD. CO. X X

PENNZOIL AW PENNZOIL PROD. CO. X X X

PENNZOIL AWX PENNZOIL PROD. CO. X X

RANDO OIL HD TEXACO INC. - USA X X

ROL ANTELITTERAM HVI ROL RAFFINERIA X

ROYAL AW EPPERT OIL CO. X

ROYAL PREMIUM VG EPPERT OIL CO. X

RYKON OIL AMOCO OIL CO. X

SELCO SF 330 SELCO X X X

SHARLU HYDROFLUIDS AW SHARJAH NATIONAL LUBE OIL X

CO. LTD.

SHOSEKI W-R SHOWA OIL LTD.-JAPAN X 32, 46 & 56

STAR PREMIUM VG EPPERT OIL CO. X

SUNVIS 8__ WR SUNCOR or SUNTECK X X X

SUPER BLUE HYD. OIL AUTOLINE OIL CO. X X X

SUPER HYD. OIL VG CONOCO X X

TELLUS SHELL CANADA LTD. X X X

TELLUS SHELL CO. - USA X X

TERRAPIN IND. OIL AUTOLINE OIL CO. X X X

TOTAL AZOLI A ZS J.W.LANE 46 & 68 X

TRC HYD. OILS VG TEXACO REFINERY X

UNION UNAX AW VG UNION OIL - USA 32 & 46 X X

UNIVIS N EXXON/ESSO X X

UNIVIS N PLUS EXXON/ESSO X X

UNIVIS SHP EXXON/ESSO 32 & 46

YUKONG SUPERVIS YUKONG LTD. X

(Page 2 of 2)

Page 1-6
 MINIMUM PERFORMANCE STANDARDS FOR HYDRAULIC OILS

The following are typical properties of hydraulic oils for use in severe duty applications of axial pis-
ton and vane pumps. Any oil which meets these or similar properties or which is listed in the
approved list of Equivalent Hydraulic Oils may be used.

32 46 68 100
ISO VISCOSITY GRADE
(32AW) (46AW) (68AW) (100AW)

ASTM Viscosity Grade No.

(Saybolt) 150 215 315 465

Gravity: API 31.1 30.3 29.5 28.9

Viscosity, Kinematic: cSt

104°F (40.0°C) 30.04 42.70 62.9 96
212°F (100.0°C) 5.26 6.57 8.43 11.03

Viscosity, SSU
100°F (37.8°C) 155 220 325 500
210°F (98.9°C) 43.9 48.2 54.6 64

Viscosity Index,
ASTM D 2270 106 105 104 99

Interfacial Tension,
D 971
77°F:dyn/cm 31 31 31 32

Flash, P-M: °F (°C) 400 (205) 405 (208) 450 (233) 465 (241)

Flash, OC: °F (°C) 425 (219) 430 (222) 470 (244) 490 (255)

Fire, OC: °F (°C) 455 (235) 470 (244) 500 (260) 545 (285)

Pour: °F (°C) -25 (-32) -25 (-32) -20 (-29) +5 (+15)

Color, ASTM D 1500 L0.5 L0.5 L1.0 L1.5

Carbon Residue,
Ramsbottom:% 0.30 0.30 0.36 0.37

Rust Preventive Test,

ASTM D 665
Procedure A, 24 hr Passes Passes Passes Passes
Procedure B, 24 hr. Passes Passes Passes Passes

Neutralization No.
ASTM D 974
Total Acid No. 0.68 0.68 0.68 0.68

Oxidation Test, ASTM D 943

Time Oxidized
Hr. to 2.0 Acid No. 2000+ 2000+ 2000+ 1500+

Emulsion, FTMS 791 3201,

180°F
Dist. Water: Minutes 40-40-0 (3) 40-40-0 (3) 40-40-0 (4) 40-40-0 (6)

Aniline Point, ASTM

D 611: °F (°C) 217 (103) 220 (105) 228 (109) 234 (113)

Coolant, Fuel and Lubricant Specifications - Page 1-7

 AIR COMPRESSOR LUBRICANT RECOMMENDATIONS (Low & High Pressure)

Sandvik Mining and Construction encourages the user to participate in an oil analysis program with the oil
supplier. This could result in an oil change interval differing from what is stated in these tables.

NOTE!
Mixing synthetic oils with an ATF may lead to operational problems, foaming, or plugging of orifices. Do not
mix different types of fluids.

AMBIENT CHANGE LUBRICANT

ISO
TEMPERATURE INTERVAL DESCRIPTION

-40°F to +95°F (-40°C to +35°C) 1000 Hours 32 Mobil SHC-624, 924 & 1024

-40°F to +100°F (-40°C to +38°C) 1000 Hours* 32 Mobil Rarus 424

-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Chevron HiPerSYN

-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Chevron Tegra Synthetic

-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Shell Corena PAO

-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Royco 432

-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Conoco Syncon R&O

-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Texaco Cetus PAO

-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Valvoline Syn Guard CP

-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Petro-Canada Super SCF32

-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Morris Lubricates, Air Force 8000 FS

+30°F to +100°F (-1°C to +38°C) 1000 Hours 46 Chevron HiPerSYN

+30°F to +100°F (-1°C to +38°C) 1000 Hours 46 Citgo CompressorGuard

+30°F to +100°F (-1°C to +38°C) 1000 Hours 46 Conoco Syncon R&O

+30°F to +100°F (-1°C to +38°C) 1000 Hours 46 Petro-Canada Super SCF46

+30°F to +100°F (-1°C to +38°C) 1000 Hours 46 Royco 446

+30°F to +100°F (-1°C to +38°C) 1000 Hours 46 Texaco Cetus PAO

+30°F to +100°F (-1°C to +38°C) 1000 Hours 46 Valvoline Syn Guard CP

+30°F to +100°F (-1°C to +38°C) 1000 Hours* 46 Mobil Rarus 425

+30°F to +100°F (-1°C to +38°C) 1000 Hours 46 Morris Lubricates, Air Force 8000 FS

+80°F to +120°F (+27°C to +49°C) 1000 Hours 68 Conoco Syncon R&O

+80°F to +120°F (+27°C to +49°C) 1000 Hours 68 Mobil SHC-626, 926 & 1026

+80°F to +120°F (+27°C to +49°C) 1000 Hours 68 Morris Lubricates, Air Force 8000 FS

When operating between +27 and 38°C (+80 and 100°F) with a relative humidity above 80%, synthetic
hydrocarbon type fluid Mobil SHC or equivalent as recommended above should be used.

All lubricant recommendations are based on 1200 rpm maximum WARM-UP speed.

* 500 Hours for High Pressure Compressors

Page 1-8
 SECTION 2 Use the hourmeter to determine when each ser-
vice is due. Calendar intervals (daily, weekly,
PREVENTIVE MAINTENANCE monthly, etc.) may be used if they allow for
more convenient maintenance scheduling, pro-
vided they approximate the hourmeter readings.
GENERAL
When performing scheduled maintenance, all
This section of the manual provides a step-by-
services due at more frequent intervals should
step guide to performing scheduled lubrication
also be performed. For example, at “Every 250
and maintenance for your drill. A thorough study
Hours or Monthly” service, also perform the
of this manual is recommended before mainte-
items listed at “Every 50 Hours or Weekly” and
nance of the machine is attempted.
“Every 8 Hours or Shift Change.”
Careful attention should be given to the service
The recommended maintenance schedule is
and maintenance instructions for the various
designed for average conditions. When operat-
components and systems of the machine.
ing in temperature extremes, dusty or wet con-
Experience indicates that the procedures
ditions, the period between maintenance
described herein are preferred practices and
operations should be shortened. For example,
that failure to comply with them can materially
check fluid levels more frequently than the rec-
shorten the useful life of the equipment and/or
ommended intervals if leaking is suspected or
reduce its standard performance.
observed.
Some photographs in this section may show
A number of services may need to be per-
details or attachments that are different from
formed on a “When Required” basis, as deter-
your unit, due to optional equipment and/or
advancement of product design. Contact your mined by service indicators on the machine
Sandvik Mining dealer for details of lubrication
or maintenance not covered in this publication.
MAINTENANCE RECOMMENDATIONS
The parts manual should be referred to when it
Wipe grease fittings clean and ensure that
is necessary to order repair parts. For prompt
grease gun nozzles are clean before injecting
and efficient parts service, contact your
grease.
Sandvik Mining dealer, giving the model and
serial number of the machine, along with the
Always keep caps, plugs, dipstick tubes and
part number and description of the items
their surroundings clean before removing for
required, as their personnel are fully qualified to
servicing.
assist and advise you on any service or opera-
tional problems that may be encountered.
When servicing, watch for:
Sandvik Mining Field Representatives are also
• Leaks
available to you for advice and assistance on
special problems. • Fire hazards (accumulated fuel, oil, grease,
debris)
• Loose or missing hardware
SERVICE AND OIL CHANGE INTERVALS • Signs of wear
• Damage
The Lubrication and Maintenance Charts that
follow list items according to the service interval.
Preventive Maintenance - Page 2-1
USE OF CORRECT TOOLS AND PROCE-
DURES
When servicing the drill, use the correct tools
and tensioning procedures outlined in this man-
ual. Overtighting plugs, filter, adaptors, etc. will
cause undue stress on components and may
weaken or fracture the component under pres-
sure. Remember, if you are unsure as to the
correct procedure in performing a job, DO NOT
attempt to start it.
When filling the hydraulic reservoir, always
check the oil level with the cylinders fully
retracted. If oil is added when the cylinders are
extended, the increase in volume of oil to the
tank may cause the tank to overfill and rupture
when the cylinders are retracted.
OIL SAMPLE ANALYSIS
Sandvik Mining encourages the user to partici-
pate in an oil analysis program with an oil sup-
plier or engine manufacturer. Periodically
analyzing the oil monitors the conditions of both
the machine components and the oil itself.
Also, using an oil analysis program could result
in oil change intervals differing from those
stated in this manual.
Following the instructions of your program coor-
dinator, we recommend taking samples when
the oil is hot and mixed from the following loca-
tions:
• Engine crankcase
• Hydraulic tank
• Main pump drive gearbox
• Final drive gearbox
• Compressor air/oil receiver tank
WIGGINS SERVICE STATION
If your machine is equipped with a Wiggins ser-
vice station it should be used whenever replen-
ishing fluids to reduce the risk of contamination
and the chance of mixing fluids.
2-2
THE DRILL MONITOR SYSTEM (DMS)
The optional DMS control panel in the opera-
tor’s cab is the Drill Monitor System. This panel
provides warning signals to the operator or
automatically shuts down the machine (for criti-
cal out-of-limit conditions) in the event that the
monitored conditions are not within safe limits.
Several of the “When Required” maintenance
checks are dictated by the signalling from the
DMS. For more information on the functions of
this system refer to section 2 of the Operator’s
Manual.
COMPRESSOR AND HYDRAULIC SYSTEMS
Cleanliness
Cleanliness is an important factor when per-
forming even the most routine service proce-
dure. You can reduce the possibility of dirt
entering a system by:
• Ensuring that all containers used for dis-
pensing oil are clean.
• Ensure that the areas around filler caps and
plugs are clean before removing them.
Never leave plugs or caps off any longer
than necessary.
• Keep disconnected hoses plugged to pre-
vent entry of dirt.
• Repair leaking cylinder rod wiper seals
immediately.
• Change filters and breathers regularly in
accordance with maintenance recommenda-
tions.
• Ensure that all gaskets, seals and protective
covers are tight and properly fitted.
Oil Contamination
Water or air in a hydraulic system can cause
pump failure. If hydraulic oil appears cloudy,
water or air is entering the system and the oil
should be drained, the system flushed and
cleaned, and refilled with new oil. Points of entry
for air or water such as suction hoses or loose
clamps, faulty seals or gaskets, and areas
where water may pool and be drawn into the
system should be checked and remedied.
Leaks
If a leak has developed in a system, it is
because there is a fault which may not be
noticeable or immediately evident. A leak is
generally a symptom of a fault such as:
• Overheating.
• Overpressure
• Excessive vibration through a mechanical
component fault.
• Incorrect operating procedure.
• Poor maintenance procedure.
When fixing a leak, try to identify the real cause.
Mixing Hydraulic Oils
The hydraulic oils used in your machine have
been selected to perform specific roles with
respect to the following properties:
• Viscosity (thickness).
• Viscosity Index (change in thickness through
temperature variation).
• Anti-wear performance.
• Heat dissipating performance.
• Compatibility with the internal materials used
in components.
Incompatibility (an adverse reaction of one or
more of the preceding properties) is to be
avoided at all costs. Never top off or fill a res-
ervoir with an incompatible fluid. Use only
the oils specified in the “COOLANT, FUEL and
LUBRICANT SPECIFICATION” table in this
manual.
Problems caused by incompatible fluids are:
• Sludging
• Oxidation
• Reduced lubrication effectiveness
• Seal damage
• Metallic erosion
• Corrosion
• Foaming/aeration
• Solidification/emulsification
• Component bearing failure
• Acid formation
• Overheating
Initial Start-Up
On the initial start-up of the machine, the
hydraulic actuators may move without notice or
without any control input signal due to air
entrapment in the circuits. Ensure that all per-
sonnel are clear prior to starting. Normally,
cycling the component several times will cause
the air to bleed off. However, if the condition
continues it will require technical assistance.
Hose Replacement
If a hose is frayed or damaged, it must be
replaced. When replacing a hose, be sure that
the correct hose type and diameter is used.
Replacing a hose with a smaller diameter hose
will increase the velocity of fluid through the
hose and result in severe overheating. Also be
sure to route and clamp the hose as originally
designed.
HEATING, CUTTING AND WELDING EQUIP-
MENT USAGE
! DANGER
Welding on a pressure vessel or near batter-
ies could cause an explosion resulting in
injury or death.
All welding should be in accordance with Ameri-
can Welding Society D1.1 ‘Structural Welding
Code’ in conjunction with AWS D14.3-82R spe-
cific for welding earth moving and construction
equipment.
Never use oxy heating or cutting equipment on
or around hydraulic components. Apart from fire
hazard the heat can damage components.
Heating or welding on hydraulic pipes or fittings
will cause a scale to develop on the inside. This
Preventive Maintenance - Page 2-3
scale may enter the system and cause severe
component damage.
Always disconnect the ground terminals from
the batteries before welding on the machine to
prevent damage to electronic controls.
The ground cable of the welding machine must
be connected to the work piece, as close as
possible to the area being welded. The ground
cable should not be connected in such a way to
allow current to flow through a bearing, joint
coupling, sealing surface, lever or control cable.
If welding is performed near pins or in places
where flexing may cause changes in the align-
ment of bushings, remove the pins and check
the alignment after welding.
AIR INTAKE SYSTEM
The engine and compressor air intake filters
should be serviced when the service indicates
to do so or the Drill Monitoring System (DMS)
indicator illuminates.
Observe the limits on the number of times the
filter elements can be cleaned and when the
safety element should be replaced.
ELECTRICAL SYSTEM
When jump-starting the machine, follow the
instructions in the Operators Manual to avoid
equipment damage or injury to personnel.
Always disconnect the batteries before welding
2-4
on the machine or alternator damage will result.
Keep all electrical compartments closed and
properly sealed during machine operation.
COOLING SYSTEM
All water is corrosive at engine operating tem-
perature. Always use coolant conditioner pre-
charge cartridges when changing the coolant,
and replace these cartridges with maintenance
cartridges at 250 hour intervals.
Use only the water and coolants specified in the
“COOLANT, FUEL and LUBRICANT SPECIFI-
CATION” topic in this manual and refer to Cater-
pillar® bulletin SEBD 0518-06.
If the engine is to be operated or stored in an
area with temperatures below 32°F (0°C), the
cooling system must be protected to the lowest
expected ambient temperature.
Clean the cooling system if scale is present or
there is evidence of oil contamination. In either
case, overheating may result.
When refilling the cooling system, add coolant
no faster than 20 qts (20 l) per minute to prevent
air pockets from developing.
After refilling the system, run the engine with the
radiator cap(s) removed until the coolant level
stabilizes. Top off the radiator if necessary.
FUEL SYSTEM
Use only the fuels specified in the “COOLANT,
FUEL and LUBRICANT SPECIFICATION” topic
in this manual.
Have your fuel supplier drain water and sedi-
ment from his fuel storage tanks at weekly inter-
vals to prevent contamination from being
pumped into the machine’s tank.
Always fill the tank at the end of the shift to drive
out moisture laden air from the tank but do not
fill the tank to the brim as fuel will expand as it warms and may overflow

Allow fuel to settle for a few minutes after filling before draining water and sediment..

After changing fuel filters, bleed the fuel circuit to remove air.

RECOMMENDED TORQUE VALUES FOR STANDARD HARDWARE - UNC

This table applies to part numbers:

001554-___ CAPSCREW, Hex hd
005486-___ CAPSCREW, Hex hd
001559-___ CAPSCREW, Socket hd
001570-___ SCREW, Flat hd socket
001577-___ NUT, Hex - regular
001575-___ NUT, Hex - heavy
001562-___ NUT, Hex - self-locking

Coarse Thread (UNC) Torque Torque

Size Grade 5 Grade 8
(Diameter in Inches) Ft.Lb. (Kg/M) 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)

1 425-460 (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.

Preventive Maintenance - Page 2-5

RECOMMENDED TORQUE VALUES FOR STANDARD HARDWARE - UNF

This table applies to part numbers:

001555-___ CAPSCREW, Hex hd
005487-___ CAPSCREW, Hex hd
001560-___ CAPSCREW, Socket hd
001571-___ SCREW, Flat hd socket
001578-___ NUT, Hex - regular
001576-___ NUT, Hex - heavy
001563-___ NUT, Hex - self-locking

Fine Thread (UNF) Torque Torque

Size Grade 5 Grade 8
(Diameter in Inches) Ft.Lb. (Kg/M) 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)

1 466-504 (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.

2-6
 WHEN REQUIRED MAINTENANCE CHECKS

Rig Model ..........................................................

Rig Serial Number.............................................

Maintenance Person ...............................................................

Date...................................

Maintenance Point Serviced By

Replace Starting Aid Cylinder

Coolant Condition

Check Cooler Cores for Obstructions

Change Air Cleaner Elements

Change Cab Air Conditioner/Heater Air Cleaner Element

Change Dust Collector Elements

Perform Crawler Brake Test

Page 2A
8 HOUR or SHIFT CHANGE MAINTENANCE CHECKS

Rig Model ..........................................................

Rig Serial Number.............................................

Maintenance Person ...............................................................

Date...................................

Maintenance Point Serviced By

Perform “Operator’s Safety Check”

Check Engine Oil Level

Drain Primary Fuel Filter Water

Check Engine Coolant Level

Check Air Compressor Oil Level

Drain Condensation from Air/Oil Receiver Tank

Check Compressor Oil Return Line Sightglass

Check Air/Oil Separator Element Indicator

Check Hydraulic Tank Oil Level

Drain Water from Hydraulic Reservoir Tank

Check Hydraulic Tank Air Pressure Regulator Gauge

Check Hydraulic Filter Service Alarm Indicators

Lubricate Pump Driveshaft

Check Oil Level in Pump Drive Gearbox

Check Undercarriage for Debris

Check Air Cleaner Element Indicators

Inspect Air Cleaner Vacuator Valves

Check Central Lubricator System Grease Level

Drain Central Lubricator Water

Check Central Lubricator Pump Oiler Level

Visually Inspect Winch Wire Rope

Check Air Lubricator Oil Level

Check Feed Chain Adjustment

Inspect the Mast Pivot Shaft Welds and Check for Proper Lubrication

Check the Condition of all Air Hose Whip Socks and Whip Checks

Page 2B
 50 HOUR or WEEKLY MAINTENANCE CHECKS

Rig Model ..........................................................

Rig Serial Number.............................................

Maintenance Person ...............................................................

Date...................................

Maintenance Point Serviced By

Perform the 8 Hour Maintenance Checks

Lubricate Air Swivel

* Replace Hydraulic Feed Circuit Filter Elements

* Replace Compressor Main Oil Filter Elements

* Replace Hydraulic Return Filter Elements

* Replace Servo Replenshing Filter Elements

* Change Winch Oil

* Initial 50 Hours or Operation Only

Page 2C
 250 HOUR or MONTHLY MAINTENANCE CHECKS

Rig Model ..........................................................

Rig Serial Number.............................................

Maintenance Person ...............................................................

Date...................................

Maintenance Point Serviced By

Perform the 50 Hour Maintenance Checks

Check Engine Mounts for Tightness

Change Engine Oil and Replace Filter

Inspect Alternator and Air Conditioner Compressor V-Belts

Check Battery Condition and Electrolyte Level

Replace Secondary Fuel Filters

Replace Coolant Conditioner Cartridge

Check Fan Mountings, Blade, Guards and Hose Condition

Replace Compressor Main Oil Filter Elements

Clean Compressor Oil Scavenge Line Strainer

Sample Compressor Oil

Add Oil to Compressor Poppet Inlet Valve (Low Pressure Compres-

sors Only)

Replace Hydraulic Servo Replenishing Filter Elements

Replace Hydraulic Feed Circuit Filter Elements

Clean Hydraulic Tank In-Line Air Strainer

Clean Hydraulic Tank Water Trap Filter

Replace Hydraulic Tank Breather

Check Hydraulic Tank Mounting Bolts

Clean Pump Drive Breather

Check Water Injection Pump V-Belt Tension

Page 2D
 250 HOUR or MONTHLY MAINTENANCE CHECKS
CONTINUED

Rig Model ..........................................................

Rig Serial Number.............................................

Maintenance Person ...............................................................

Date...................................

Maintenance Point Serviced By

Change Water Injection Pump Oil

Check Rotary Head Oil Level

Check Feed Chain Tension

Lubricate Feed Chains

Inspect and Lubricate Chain Sprockets

Check Oil Level - Crawler Final Drives

Replace Engine & Compressor Primary Air Cleaner Elements

Clean Central Lubrication Water Trap Filter

Check Central Lubrication Operation

Check Electrical Wiring Condition

Check Air Intake and Exhaust System

Check Dust Collector Hoses and Components

Check Decals and Nameplates

* Adjust Engine Valve Lash

* Change Oil - Crawler Final Drives

* Initial 250 Hours or Operation Only

Page 2D (cont’d)
 500 HOUR or 3 MONTH MAINTENANCE CHECKS

Rig Model ..........................................................

Rig Serial Number.............................................

Maintenance Person ...............................................................

Date...................................

Maintenance Point Serviced By

Perform the 250 Hour Maintenance Checks

Clean Engine Crankcase Breather

Change Primary Fuel Filter Element

Change Pump Drive Gearbox Oil

Replace Hydraulic Return Filter Elements

Change Rotary Head Gearbox Oil

Clean Water Injection Suction Strainer

Check Winch Oil Level

Replace Engine & Compressor Safety Air Cleaner Elements

Inspect Drill Pipe Safety Hoop

Inspect Mast Pedestal Welds

Page 2E
 1000 HOUR or 6 MONTH MAINTENANCE CHECKS

Rig Model ..........................................................

Rig Serial Number.............................................

Maintenance Person ...............................................................

Date...................................

Maintenance Point Serviced By

Perform the 500 Hour Maintenance Checks

Change Hydraulic Oil

Check Compressor Mounting Hardware Torque

Change Compressor Oil

Change Air/Oil Separator Filter Element

Change Winch Oil and Clean Breather

Replace Rotary Head Gearbox Breather

Check Torque of Mast Pivot Block Bolts

Page 2F
 2000 HOUR or 1 YEAR MAINTENANCE CHECKS

Rig Model ..........................................................

Rig Serial Number.............................................

Maintenance Person ...............................................................

Date...................................

Maintenance Point Serviced By

Perform the 1000 Hour Maintenance Checks

Change Engine Coolant

Check Cooler Mounting Hardware Torque

Change Crawler Final Drive Oil

Test Mast Pedestal Welds

Replace Mast Pivot Block Hardware and Dowel Pins (4000 Hours)

Page 2G
 WHEN REQUIRED

FUEL SYSTEM
c40-53
Replace Ether Starting Aid Cylinder

! DANGER
ETHER IS POISONOUS !!
Avoid breathing vapors and repeated skin
STRAP
contact, keep out of the reach of children,
use only in well-ventilated areas, and do not
store cylinders in living areas or operator’s
compartment.

! DANGER
ETHER IS FLAMMABLE !! COOLING SYSTEM
Observe the following precautions while
handling ether cylinders:
• Do not smoke while changing cylinders. Check Cooling System
• Do not store cylinders at temperatures
above 49°C (120°F).
• Do not store cylinders in direct sunlight ! WARNING
• Do not puncture or burn cylinders.
Steam can burn. Allow the coolant to cool.
• Discard cylinders in a safe place.
Open the radiator filler cap slowly.
Replace an ether cylinder as follows:
If the cooling system is contaminated, the
engine overheats or if foaming is observed in
5. Loosen the clamp and unscrew the empty
the radiator, follow the “Change Engine Cool-
ether cylinder.
ant” procedure in the “2000 Hour or 1 Year”
maintenance check.
6. Remove the used gasket and install the new
gasket supplied with each cylinder.
Check the Cooler Core
7. Install the new cylinder. Tighten the cylinder
hand tight. Fasten the clamp securely.
Dusty working conditions may require you to
clean the cooler fins more often than a normal
operating maintenance schedule.

When Required Maintenance Checks - Page 2A-1

AIR CLEANERS - ENGINE & COMPRESSOR
Changing Elements
General
Proper air cleaner servicing will result in maxi-
mum protection against dust. Proper servicing
can also save time and money by increasing fil-
ter life and dust cleaning efficiency. Two of the
most common servicing problems are: Over
Servicing and Improper Servicing. Replace or
clean elements only when the restriction indica-
tor on the filter or the warning light on the instru-
ment panel indicate to do so. Don’t be fooled by
filter appearance, the filter should look dirty.
Careless servicing procedures can cause con-
tamination. Use the following procedures as a
guide to air cleaner maintenance.
SAFETY
ELEMENT
PRIMARY
ELEMENT
SERVICE
INDICATOR/NUT
VACUATOR
VALVE
Primary Element
1. Loosen the wing nut and gently slide the pri-
mary element out of the air cleaner assembly.
2. Inspect the service indicator for the safety
element. Remove and replace the element if
the indicator is in the red zone.
3. Inspect the inside of the filter housing and if
cleaning is required remove the safety element.
Be careful not to allow dust to enter the intake
duct.
Page 2A-2
4. If the filter is dented or bunched it must be
replaced. Never rap or hit the element to
remove dirt. The primary element can be
cleaned with compressed air, pressurized water
or washed with detergent. If cleaning the pri-
mary element with proceed as follows:
COMPRESSED AIR
! WARNING
Always use a face shield and protective
clothing when using compressed air. Fail-
ure to do so can cause eye damage or
blindness.
NOTICE
Using compressed air above 30 psi (205
kPa) can damage the filter element.
A. Blow air ALONG (not across) the pleats
inside and outside of the element as shown.
COMPRESSED AIR
B. After cleaning, inspect the element with a
light bulb as shown. Replace the element if
necessary.
PRESSURIZED WATER
NOTICE
Using compressed water above 40 psi (with-
out nozzle) (280 kPa) can damage the filter
element.
A. Direct water ALONG (not across) the pleats
inside and outside the element.
B. Air dry the element Do Not dry with a light
bulb.
C. After drying, inspect the element with a light
bulb as shown. Replace the element if neces-
sary.
PRESSURIZED WATER
WASHING WITH DETERGENT
A. Remove excess dust with compressed air
or water as described earlier.
B. Wash the element in warm water with a
non-sudsing household detergent or Donaldson
D-1400 Washing Compound.
C. Rise the element with clean water from both
sides if necessary.
D. Let dry in warm circulating air of less than
160°F (71°C).
E. After drying, inspect the element with a light
bulb as shown. Replace the element if neces-
sary.
INSPECTION
5. Before installing the cleaned or new element
press the element gasket to ensure that it has
not gotten brittle.
6. Slide the primary element over the safety
element and tighten the wingnut.
7. Inspect all air cleaner and air duct connec-
tions for leakage before starting the engine.
Safety Element
The safety element should be replaced every
third time the primary element is cleaned or
replaced or as indicated by the service indicator
in the safety filter hold down nut as shown.
1. Remove the primary element as described
earlier.
2. Remove the split pin and nut that hold the
safety element in place.
3. Remove and discard the safety element.
The safety element should not be cleaned.
4. Clean the inside of the filter housing espe-
cially around the areas of the element sealing
surfaces.
5. Install a new safety element.
6. Install the primary element.
‘T’ STYLE AIR CLEANER
Primary Element
1. Unlatch the filter cover and remove the
cover and gasket.
2. Loosen the wing nut and gently slide the pri-
mary element out of the housing.
3. Inspect the service indicator/nut for the
safety element. Remove and replace the ele-
ment if the indicator is in the red zone.
4. Inspect the inside of the filter housing and if
cleaning is required remove the safety element.
When Required Maintenance Checks - Page 2A-3
Be careful not to allow dust to enter the intake
duct.
COVER
LATCHES

SAFETY
ELEMENT
21237s1 SPLIT PIN

PRIMARY
ELEMENT

SERVICE
INDICATOR/NUT

BODY & TUBE

ASSEMBLY GASKET

COVER
COVER
GASKET

CUP CLAMP

DUST CUP ‘T’ Style Air Cleaner

5. If the element is dented or bunched it must
be replaced. Never rap or hit the element to
remove dirt.
Safety Element
The safety element should be replaced every
third time the primary element is replaced or as
indicated by the service indicator in the safety
filter hold down nut as shown.
1. Remove the primary element as described
earlier.
2. Remove the split pin and nut that hold the
safety element in place.
3. Remove and discard the safety element.
The safety element should not be cleaned.
4. Clean the inside of the filter housing espe-
cially around the areas of the element sealing
surfaces.
5. Install a new safety element.
6. Install the primary element.
Body & Tube Assembly
Remove the dust cup and check the tubes. If
the tubes have become plugged, remove the
dust with a bottlebrush. If heavy plugging is evi-
dent, clean the tubes with compressed air (the
primary and secondary filters must be installed),
or with water no hotter than 160°F (72°C). Do

Page 2A-4
not steam clean! DUST COLLECTOR

Inspect Dust Cup Change the Filter Elements

The dust cup at the base of each air cleaner
should be removed and emptied. Turn the
thumb screw and loosen the cup clamp.When
installing the cup, be sure the cup is fully sealed
by the gasket.
Routine inspection of door gaskets, suction
hose, dump hoses, dusthood seals and other
wear items is necessary to ensure that there are
no leaks to the system.

FILTER ELEMENT

THUMB SCREW

OPERATOR’S CAB WING NUT

Change Air Conditioner/Heater Filter Ele-
ment
Remove and replace the filter element as
described in the previous topic.
Inspect the filter elements through the access
doors provided. Remove the elements by
unthreading the wingnuts. Be sure to tighten the
wingnuts after the elements have been replaced
or cleaned.

AIR CONDITIONER/
Compressed air must be clean and filtered to
HEATER AIR CLEANER ensure that there is no contamination of the
PRE-CLEANER
ELEMENT valve seats.

Filters can be ruined by operating under wet

conditions. Occasionally the filters can be
c245-2 removed, blown out and inspected for tears.

NOTICE
Do not run the dust collector fan if drill dust
is venting from the fan exhaust. Severe dam-
age to the fan, the fan shaft and it’s bearings
will occur.

When Required Maintenance Checks - Page 2A-5

UNDERCARRIAGE Both operator and technician’s must be present during
the brake test process. Failure to comply can lead to
machine or property damage.
Brake Test
Risk Assessment
The following procedure applies to Sandvik undercar-
riages. Customer or Servicing Dealer must assure machine and
Introduction personnel safety.

Measuring the amount of drift of the machine on a set
slope will determine if there is a need to check the travel
brake.
NOTE!
• The machine configuration and ground conditions that
are used during the test can affect the results of the
test.
• If machine weight has been modified additional pre-
cautions apply.
• Do not exceed machine gradient limitations as stated
in operator manuals and on decal inside machine
cabin. The same decal will be referenced in this docu-
ment.
• Pump pressures must meet machine specifications
before performing this test.
• Prior to brake test, confirm machine tram options that
may include electric and hydraulic components or
interlocks are enabled.
Required tools
Minimal tools are required to perform this test.
Brake Test Tools Required
Perform Risk Assessment, Job Safety Analysis or Take 5
prior to performing a machine brake test.
Give specific attention to degree or percent of gradient
with relation to machine and personnel safety.
Test Procedure
1. Position mast horizontal in mast rest.
2. Place machine on a slope near the maximum allowed
for the machine. The surface of the slope must be hard
(to prevent track grouser shoes from sinking into soft
ground) and smooth (so that obstructions do not hin-
der track motion).
3. Do not exceed machine gradient references!
4. Prepare a berm, sufficient wheel chocks or wood
blocks 76 mm (3 inches) away from the track as a
means to limit track in event of unwanted movement.
5. To indicate the relative position of machine to the
slope, put a mark on both track grouser shoe and roller
rock guard or track frame.
6. Stop machine.
7. Operator can leave the cabin and machine, but do not
leave machine unattended.
8. Per the marked positions on the track, measure the
machine movement on the slope after 3 minutes

DESCRIPTION QTY

INCLINOMETER 1

STOPWATCH 1

SCALE 150 MM (6 IN) 1

D25KS

25° 10°
46% 17%

Page 2A-6
 D245S

25° 19°
46% 34%

Drift Limits mm - inches Actual

0 mm - 0 inches
0 mm - 0 inches
0 mm - 0 inches

Machine should maintain zero movement over the 3 min-

ute time.

If there is any track motion on the maximum slope limit,

the track brakes assemblies need service.
Do not operate machines with faulty brakes or machines
that cannot withstand the designed slope.

When Required Maintenance Checks - Page 2A-7

Page 2A-8
 EVERY 8 SERVICE HOURS 2. Open the drain valve to allow the accumu-
lated water to drain.
OR DAILY
3. Close the drain.

ENGINE
PRIMARY
FUEL
Measure Crankcase Oil Level FILTER

1. Measure engine oil level. Maintain oil level

to FULL mark on the ENGINE STOPPED side
of dipstick.

2. Add oil if necessary through fill point.

WATER
DRAIN
VALVE

COOLING SYSTEM

Check Coolant Level

FILLER
Check that the coolant is visible in the sight-
glass. Add coolant if necessary.

FILLER
CAP

DIPSTICK
COOLANT
SIGHT
GAUGE

Adding Coolant
Drain Fuel Water Separator Bowl

1. Locate the water separator bowl at the base ! WARNING

of the primary fuel filter. Steam can burn. At operating temperature,

8 Hour Maintenance Checks - Page 2B-1

engine coolant is hot and under pressure.
Remove the filler cap only when the engine
is stopped. Open the filler cap slowly only
when cap is cool to the touch.
NOTICE
If filling the radiator via the Wiggins station,
leave the radiator cap off to prevent pres-
sure from building up during filling.
1. Remove the radiator filler cap slowly.
! WARNING
Cooling System Conditioner contains alkali.
Avoid contact with skin and eyes to prevent
personal injury.
2. Inspect the condition of the cap gasket.
Replace if necessary.
3. Maintain the coolant level to the bottom of
the filler tube.
4. Replace the cap and tighten.
NOTE !
• Inspect for coolant leaks, damaged or deteri-
orated hoses and obstructed radiator cores.
• Any of these may cause damage to the
engine through overheating.
COMPRESSOR
! WARNING
• Do not remove caps, plugs, or other com-
ponents while the compressor system is
running or 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.
Page 2B-2
Check Oil Level
Check the oil level at least 10 minutes after
shutdown, with the unit level and separator
pressure zero.
1. Observe the oil level in the air/oil receiver
tank sightglasses.
1
2
OIL LEVEL
SIGHTGLASS
The oil level should be maintained so that it
is visible in the center sightglass.
NOTICE
Do not mix compressor oils. Incompatible
fluids may cause compressor damage or
reduced oil change intervals.
2. Add oil if necessary, through the fill point (1)
or Wiggins station. Do not overfill; the oil level
must not rise above the upper sightglass (2).
Drain Condensate From Air/Oil Receiver
Tank
Remove the plug from the valve and open the
valve and drain off water until oil appears.
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, then drain, flush and refill the system.
 .

ELEMENT
INDICATOR

RECEIVER
TANK

RECEIVER TANK
DRAIN

Check Air Hose Whipchecks

Check Oil Return Line Sightglass
Check the condition of the cables and their posi-
When the engine is running, inspect the sight- tioning.
glass (1) to ensure that oil is visibly flowing. If oil
is not visible, clean the in line strainer (2).

Check Air/Oil Separator Element Indicator

When the engine is running, ensure the indica-

tor is not showing its red band. If the red band is
fully visible, change the separator element.
Some models do not have a dirt alarm indicator
on the filter housing. In this case the filter condi-
tion is monitored by a warning lamp on the
instrument panel.

8 Hour Maintenance Checks - Page 2B-3

HYDRAULIC SYSTEM damage and reduce oil change intervals.

Check Oil Level in Reservoir Tank

1. Fully retract all hydraulic cylinders and shut-

down the engine.
REGULATOR
GAUGE
2. Look at the sight gauge. The oil level must
be maintained to the decal line. Add oil if
necessary. HAND
PUMP

HYDRAULIC
OIL
SIGHT
GAUGE Drain Water From Reservoir Tank

Open the valve and drain off 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, then
drain, flush and refill the system.

Adding Oil
HYDRAULIC
TANK
DRAIN

! WARNING
• Before filling, shutdown the engine and
relieve all pressure from the tank by
opening the tank vent ball valve.

• Double check that all hydraulic cylinders

are retracted, or the tank may be over-
filled and rupture.

Add oil only via the Wiggins station or the hand

pump.
Check Hydraulic Tank Air Pressure Regula-
tor Gauge
NOTICE The tank is pressurized to prevent entry of con-
• Do not mix hydraulic oils. tamination and to prime the hydraulic pumps.

• Incompatible fluids may cause pump Inspect the air pressure gauge while the engine

Page 2B-4
is running. It should read between 3 and 5 p.s.i.

Check Servo Replenishing Filters Dirt WINGNUT

Alarms

The indicators should be checked to ensure that

they are not seized and for oil bypassing the fil-
ACCESS
ter. DOOR

1. With the engine stopped, turn the indicator

(1) through its range of movement. It should
turn freely.

2. With the engine and pumps running,

observe the position of the indicator. It should
point to the green sector. If it points to either the
yellow or red sectors, the filter element should
be changed, as it is clogged and oil is bypassing
the element.
2. Clean the grease fitting in each universal
joint and lubricate with two strokes from a hand
grease gun.
NOTICE
• Do not overlubricate the universal joints.

• Seal rupture can occur and allow ingress

of dirt.
1

• Do not use a pressurized grease gun.

PUMP DRIVE GEARBOX

Check Oil Level

SERVO
FILTERS 1. Locate the dipstick on the pump drive gear-
box.

FILL PLUG
DRIVESHAFT

Lubricate Pump Driveshaft

PUMP DRIVE
Ensure the fittings and grease gun are clean GEARBOX
before servicing.
DIPSTICK
1. Remove the wingnut and open the access
door.

8 Hour Maintenance Checks - Page 2B-5

2. The oil level should be between the LOW
and FULL marks on the dipstick. If necessary
add oil of the type specified in the “Coolant, SAFETY
ELEMENT
Fuel and Lubricant Specification” section of this
manual through the fill opening. PRIMARY
ELEMENT

UNDERCARRIAGE

Check for Debris SERVICE

INDICATOR/NUT

VACUATOR
Visually inspect the undercarriage for rocks, VALVE
debris and built-up dirt. Clean idlers and sprock-
ets as necessary.

AIR INLET CENTRAL LUBE SYSTEM

Check Air Cleaner Element Indicator Check Central Lubricator Grease Level

Check the indicator located on the air inlet pipes Remove the clips securing the lid to the tank.
as shown. Service the elements as needed as Replace the canister if necessary.
explained in the “When Required” maintenance
checks.

CLIP

ELEMENT INDICATOR

Drain Water and Check Pump Oiler Level

Inspect Vacuator Valves
Vacuator valves should be inspected very 8
hours of machine service. Check to see that the
valve is not inverted, damaged or plugged.
Replace as needed.
1. Unscrew tap (1) under the bowl to drain the
water. Close the tap after draining.
2. Check the oil level through sightglass (2). If
oil is needed, unscrew the bowl and add Engine
Oil (CG) as required.

Page 2B-6

1 2
MISCEALLANEOUS
Inspect Winch Wire Rope
Visually inspect the winch wire rope for kinking,
twisting and general wear, lubricate if required.
Replace as necessary and discard in accor-
dance with 3.5 of ISO 4309:1990.
Check Bit/Hammer Lubricator Oil
Locate the lubricator tank sight gauge and fill as
required through the filler port.
FILLER
CAP
LEVEL
SIGHTGAUGE
Check Feed Chain Adjustment
With the mast lowered and the rotary head at
the top of it’s travel, check the sag of the chain
as shown.
NOTICE
A chain that has too much slack can cause it to
jump a sprocket and jam.
If a chain jumps sprocket teeth it will cause mis-
alignment of the rotary head travel resulting in
premature failure of components.
Inspections to the feed system chains is accom-
plished as follows:
1. Raise the rotary head to the top of the mast.
2. Unlock and lower the mast to the mast rest (hori-
zontal position).
3. Tag-out the cab to inform others of the servicing
in progress.
4. Measurements of the feed chain sag must be
made midway between mast table and rotary head,
and from the bottom edge of the mast chord to the
top of the feed chain as shown.
5. If the chain tension is not set to proper specifica-
tions, perform chain adjustments as per O&M man-
ual instructions.
The general rule for chain sag measurement is as
follows. The chain sag should be adjusted to within
1% of the distance from the sprocket to the rotary
head. Example: If the distance from the sprocket to
rotary head (at the top of the mast) is 13.7 meters (45
feet), then the sag measurement distance calculation
is as follows.
13.7 meters (45 feet) x 0.01 = 13.7 cm (5.4 in.)
A = 13.7 cm (5.4 in.) sag at center of mast when not
equipped with a drill pipe stabilizer assembly.
B = 6.85 mm (2.7") sag at 1/3 length from table and
1/3 length from crown of mast when equipped with a
drill pipe stabilizer assembly.
8 Hour Maintenance Checks - Page 2B-7
 ROTARY HEAD AT
MAST MAST TOP OF STROKE
TABLE CHORD ‘B’ ‘A’ ‘B’

MEASURING FEED CHAIN SAG

MAST PIVOT SHAFT

Inspect Welds and Check for Proper Lubri-

cation

If drilling conditions require that the mast be

lowered between holes, the mast pivot shaft
welds should be inspected in the areas shown
and the shaft checked for proper lubrication.

If cracks, broken welds or signs of improper

lubrication are visible, do not lower the mast
and immediately lockout the machine’s starting
system. Notify the proper maintenance person-
nel to arrange for repair or replacement.

Page 2B-8
 EVERY 50 HOURS OR INITIAL 50 HOURS OF OPERATION

WEEKLY Replace Air Compressor Main Oil Filter Ele-

ments
Refer to the “250 Hour Maintenance Checks”.
AIR SWIVEL
Replace Hydraulic Return Filter Elements
Refer to the “250 Hour Maintenance Checks”.
Grease Air Swivel

Replace Feed Circuit Filter Element

NOTICE Refer to the “250 Hour Maintenance Checks.”
• Do not over-lubricate.

• Do not use a pressure grease gun, as this
can cause damage to the seals.
1. Remove the protective cap to expose the
lubrication fitting.
2. Lubricate the air swivel with two strokes of a
hand grease gun.
Replace Hydraulic Servo Replenishing Filter
Elements
Refer to the “500 Hour Maintenance Checks.”
Change Winch Oil
Refer to the “1000 Hour Maintenance Checks”.

3. Replace the protective cap.

LUBRICATION
FITTING

245-46 AIR SWIVEL

50 Hour Maintenance Checks - Page 2C-1

Page 2C-2
 EVERY 250 HOURS OR Change Crankcase Oil and Filters

MONTHLY
! WARNING
Hot oil or components can cause burns if
ENGINE they contact skin.

1. With the oil warm and the engine stopped,

Check Engine Mount Torque
Remove the belt cover and inspect the front and
rear engine mounts for cracks or signs of move-
ment and the bolts for tightness.
drain the crankcase by removing the plug from
the oil pan and allowing the oil to drain into a
suitable container.

PLUG OIL PAN

2. Install the plug when draining is completed.

ENGINE 3. Use a strap wrench to remove the oil filter.

MOUNTS
(REAR)

c25-11 REMOVE
TO ACCESS OIL FILTERS
FRONT MOUNTS

4. Clean the filter base to ensure that all traces

of the old seal are removed.

5. Coat the seal on the new filter cartridge with

clean engine oil.

250 Hour Maintenance Checks - Page 2D-1

6. Install the new filters by hand. When the fil-
ter seal contacts the base, tighten the filter 3/4
turn more.
NOTE !
Do not overtighten the filter.
7. Refill the crankcase. See the “Refill Capaci-
ties” and “Fuel, Coolant and Lubricant Specifi-
cations” tables.
8. Start the engine and run long enough to
ensure that the lube system cavities and filter
have oil.
FILLER
DIPSTICK
9. Stop the engine and allow the oil to drain
back to the sump for a minimum of five minutes.
The oil level reading should indicate FULL on
the ENGINE STOPPED side of the dipstick.
Page 2D-2
Engine Valve Lash (Initial)
ADJUST
Adjust valve lash (clearance) at the first oil
change. All subsequent adjustments are to be
performed at the “Every 3000 Service Hour”
interval.
Refer to Engine Valve Lash in the Caterpillar®
Maintenance Manual for the procedure.
ALTERNATOR and AIR CONDITIONER COM-
PRESSOR V-BELTS
Inspect
Inspect the belts for wear. Replace the belts if
worn, cracked or frayed.
Check Belt Adjustment
1. Remove the capscrews securing the belt
cover and remove the cover to access the
belts..
BELT
COVER
C25-11
REMOVE
TO ACCESS
BELTS
2. Apply a 12 kg (25 lb.) force perpendicular to
the belt, midway between the driving and driven
pulley. Measure the belt deflection. Proper belt
deflection is 15 to 20 mm (9/16 to 7/8 inch).
Adjust the belt tension as required.
Adjust Belt • Battery electrolyte contains sulfuric acid.
It will cause severe personal injury if it
1. Loosen the alternator pivot bolt and the lock- contacts skin or eyes.
nut on the belt tensioner rod.
• Always wear protective glasses when
working with batteries.

1. Open the battery box access door.

LOCKNUT

2. Turn the adjustment bolt until correct belt BATTERY

ACCESS
deflection is obtained. DOOR

3. Tighten the locknut.

2. Clean the tops of the batteries with a clean
4. If new belts are installed, check the belt cloth. Check for corrosion or looseness of the
adjustment after 30 minutes of engine opera- terminals and cable clamps. If necessary,
tion. replace, clean or tighten cable clamps.

5. Secure the belt cover. 3. Clean the cable clamps and terminals with a
wire brush, then coat them with petroleum jelly.

BATTERIES
! WARNING
DO NOT top off batteries with acid.

Check Battery Electrolyte Level and Clean 4. Remove the battery fill caps. Maintain the
Batteries electrolyte level to the bottom of the filler tube.
If the level is low, top up with distilled or demin-
Locate the battery box located at the left front of eralized water.
the machine.
5. Replace the fill caps and close the cover.

! DANGER
FUEL SYSTEM
• Batteries give off explosive hydrogen
gas.

• Do not smoke or allow any other ignition ! WARNING

source near the batteries. • Fuel leaked or spilled onto hot surfaces
250 Hour Maintenance Checks - Page 2D-3
 or electrical components can cause a
fire.
• Disconnect the battery when changing
fuel filters.
Change Secondary Fuel Filters
1. Stop the engine.
2. Close the fuel supply line valve (if fitted).
3. Use a strap wrench to remove the fuel filters.
SECONDARY
FUEL
FILTERS
4. Clean the filter base. Be sure to remove all
of the old seal.
5. Apply a light coat of clean fuel to the new fil-
ter seals.
6. Install the new filters by hand. When the
seal contacts the base, tighten 3/4 turn more.
NOTE !
Do not overtighten the filters.
7. Open the fuel supply valve.
8. Prime the fuel system. See the topic “Prim-
ing the Fuel System”.
9. Start the engine and inspect for leaks.
Page 2D-4
Priming the Fuel System
Priming the fuel system fills the fuel filters and
removes air from the fuel system after the filters
have been changed. Refer to the Caterpillar®
engine Operation and Maintenance manual if
the engine fuel supply has run dry.
1. Turn the priming pump plunger counter-
clockwise and pull out the plunger.
FUEL
PRIMING
PUMP
PLUNGER
2. Pump the plunger to fill the new filter ele-
ment. Continue pumping until resistance is felt,
indicating that the filter is full.
3. Turn the pump handle knob clockwise to
lock the plunger.
4. Start the engine and check for fuel leaks.
COOLING SYSTEM
Change Coolant Conditioner Cartridge
Check the cooling system only after the engine
is stopped and cool to the touch. Refer to the
engine manufacturer’s Operation and Mainte-
nance Manual for coolant testing and additional
specifications.
NOTE !
Ensure that a MAINTENANCE (not a PRE-
CHARGE) conditioner cartridge is used for this 5. Open the shutoff valves on the coolant lines
service, unless the coolant is also being
changed. 6. Check for leaks with the engine running.

1. Close the coolant inlet and outlet valves.

2. Use a strap wrench to remove the cartridge.
! WARNING
Engine coolant contains alkali - avoid con-
tact with skin and eyes.
3. Clean the filter base.
4. Install the new cartridge by hand. When the
seal contacts the base, tighten 3/4 turn more.
Check Radiator Mounting Hardware Torque
Using a torque wrench and the torque table
listed in this manual, check the radiator mount-
ing hardware.
Check Cooler Fan Finger Guards and Radia-
tor Blade Condition

STANDARD CARTRIDGE LOCATION

FINGER
SHUTOFF GUARD
HARDWARE
VALVES

COOLANT
CONDITIONER
CARTIDGE

Check the tightness of the fan guards and

inspect the fan blades for cracks. Replace if
necessary.

COOLANT COMPRESSOR
CONDITIONER
CARTIDGE

Change Main Oil Filter Elements

The filters should be changed every 250 hours

unless the DMS or service light indicates the fil-
ters are bypassing oil, in which case they should
be changed immediately.

OPTIONAL CARTRIDGE LOCATION

NOTE !
Do not overtighten the cartridge.

250 Hour Maintenance Checks - Page 2D-5

 1

6
COMPRESSOR
MAIN OIL FILTER
2

3 GROMMET

! WARNING 7

4
Ensure the engine is shutdown and the
internal pressure relieved.

1. Unscrew the filter housing cap (1).

2. Remove the cap (1), spring (2) and washer

(3).

3. Quickly remove the two filters from the hous-

ing to prevent dirty oil from the elements from BASE
dripping into the housing.

NOTICE
Be sure to inspect the inside of the filter
base to ensure that the element grommet
was removed at the time the lower element
was removed.
4. Replace the O-ring and backup rings on the
cap and base if necessary.
5. Install two new elements, ensuring they are
joined with the plastic connector.
6. Install the washer, spring and cap.
7. Check the oil level and replenish if neces-
sary.
8. Start the engine and inspect for leaks.
SHOWN
WITH MANUAL INDICATOR
NOTE !
Only Schroeder elements are authorized for use
in the compressor system. Use of any other
brand must be authorized by the Sandvik Engi-
neering Department.
Clean Oil Return (Scavenge) Line Strainer
The oil line strainer should be cleaned every
250 hours or when oil is not visible in the sight-
glass.

Page 2D-6

! WARNING
Be sure the engine is shutdown and pres-
sure relieved before proceeding.
1. Unthread the plug and remove the screen
from the housing.
PLUG
2. Wash the screen clean with a non-flamma-
ble solvent and dry with compressed air.
3. Reinstall the strainer and plug.
Change or Sample Compressor Oil
NOTE !
The oil change interval depends on the type of
oil and whether or not oil analysis is being used.
See the ‘Recommended Lubrication Viscosity
Chart’ in section 1 of this manual for details.
NOTE !
The oil should be warm when changed.
! WARNING
Avoid touching hot oil or components -
these can cause burns.
! WARNING
Ensure the engine is shutdown and internal
pressure relieved.
Locate the drain valve and take an oil sample
for analysis. If required, change the oil as
described in the 1000 Hour Maintenance Sec-
tion.
RECEIVER TANK
DRAIN
Add Oil to the Poppet Lubricant Cavity
Remove the plug on the top of the poppet and
add no more that 350 ml (12 ounces) of clean
compressor oil.
NOTICE
Do not mix compressor oils. Incompatible
fluids may cause compressor damage or
reduced oil change intervals.
PLUG
POPPET VALVE
LOW PRESSURE COMPRESSORS
250 Hour Maintenance Checks - Page 2D-7
 4

HYDRAULIC SYSTEM

Change the Servo Replenishing Filter Ele-

ments
5
The filter elements should be changed after the
first 50 hours of operation and at each 250
hours thereafter, or as indicated by the dirt
alarm indicator.

3
1
2

SERVO
3. Remove the element (2) together with grom-
REPLENISHING met (3).
FILTERS
4. Thoroughly clean the element housing and
inspect the bypass mechanism (4) on the filter
base and O-ring (5) for damage. Replace if
necessary.

5. Install a new element and replace the ele-

! WARNING ment housing. Tighten the housing firmly but do
Avoid skin contact with hot oil or compo- not overtighten.
nents - burns will result.
6. Start the engine and inspect for leaks.
1. Ensure the engine is stopped, and the
hydraulic tank pressure relieved.

2. Unthread the filter housing (1). Change Feed Cylinder Circuit Filter Element

The filter elements should be changed after the

first 50 hours of operation and at each 250
hours thereafter, or as indicated by the DMS.

! WARNING
Avoid skin contact with hot oil or compo-
nents - burns will result.

1. Relieve the hydraulic tank pressure by open-

ing the ball valve on the hydraulic tank as
shown.
Page 2D-8

BALL VALVE
2. Locate the filter assembly located between
the hydraulic tank and the mast pedestal
Unthread the bolts and remove the element
housing to expose the elements.
MOUNTING
BOLTS
3. Remove the filter from the housing and drain
the oil into an appropriate container.
4. Inspect the housing for contaminents. Clean
the housings.
5. Install a new element.
6. Replace the O-ring on the cover.
7. Check the oil level and replenish if neces-
sary.
8. Start the machine and inspect for leaks.
NOTE!
Only Schroeder elements are authorized for use
in the hydraulic system. Use of any other brand
must be authorized by the Sandvik Engineering
Department.
Clean Hydraulic Reservoir In-Line Air
Strainer
! WARNING
The air line to the hydraulic tank may be
pressurized. Vent air pressure by opening
the air vent ball valve.
1. Shut down the engine and vent air pressure
by opening ball valve (1).
2. Remove strainer (2) from the air line.
3. Clean the strainer in a non-flammable sol-
vent and dry with compressed air.
4. Replace the strainer.
Clean the Water Trap Filter
1. Unscrew the water trap filter housing (3).
2. Remove the filter element.
3. Clean the element in a non-flammable sol-
vent and dry with compressed air.
4. Replace the element and screw the housing
on hand tight.
Replace the Breather/Filter
1. Unscrew breather/filter assembly (4) and
discard.
250 Hour Maintenance Checks - Page 2D-9
 PUMP DRIVE GEARBOX
Breather/Filter
4

Check Clean Breather

Valve
5
Regulator 1. Remove the breather.
7 Ball
Valve
(Vent) 2. Clean in a non-flammable solvent and dry
1 with compressed air.
Pressure 3. Install the breather.
Relief
Valve
6

Water Trap
3

Air Strainer
2

BREATHER
NOTE !
Ensure that the check valve assembly (5) has
been retained in the fitting and not removed with
the breather/filter assembly.
WATER INJECTION PUMP
2. Clean the contact area of breather/filter (4)
ensuring all traces of the old seal are removed.
Check Belt Tension
3. Apply a thin film of clean oil to the seal sur-
face on the new breather/filter assembly. ! WARNING
NOTICE Ensure the keys are removed and the
machine has been tagged-out before
Do not overtighten the filter/breather proceeding.
assembly.
1. Undo the four bolts (1) and remove belt drive
4. Screw the new filter assembly onto the guard (2).
check valve fitting by hand.
2. Inspect the condition of drive belts. Replace
as a pair if cracked or frayed.

Check Hydraulic Tank Mounting Hardware
Inspect the mounts at the four corners of the
tank for signs of cracks or movement and re-
torque the mounting bolts.
3. Measure the belt deflection using thumb
pressure (approximately 12 kg (25 lbs) midway
between the pulleys. Deflection should be 13 to
19 mm (1/2 to 3/4 inch).

Page 2D-10
 allow the oil to drain into a suitable container.

2. Replace the drain plug.

2 3. Refill the compartment.

4. Replace fill plug (1).

1
1

2
To adjust:

1. Loosen 4 bolts (5).

2. Slide motor (6) away from pump (7) to

tighten the belts and then retighten bolts ().

3. Replace belt drive guard (2).

ROTARY HEAD

7
Check Gearbox Oil Level

1. With the mast raised, lower the rotary head

to access the fill plug.

2. Remove the fill plug and inspect the oil level.

The correct oil level should be up to the top of
the planetary gear assembly. Overfilling will
cause oil to blow out of the breather.

6 3. Add oil of the type specified in Section 1 of

BELT ADJUSTMENT
5 this manual if necessary.

4. Clean and install the fill plug when finished.

Change Oil

! WARNING
Use caution and avoid touching hot oil or
components - these can cause burns.

NOTE !
The oil should be warm when changed.

1. Remove fill plug (1) and drain plug (2) and

250 Hour Maintenance Checks - Page 2D-11

 plate.

In most roller chain drives, the chain is considered

ROTARY worn out when it has reached 3% wear elongation.
HEAD With 3% wear, the chain does not engage the
MOTOR
sprocket properly and can cause sprocket damage
245-45 or chain breakage. On drives with large sprockets
(more than 66 teeth), allowable wear is limited to
200/N (N = no. of teeth on largest sprocket) and may
be substantially less than 3%. On fixed-center, non-
adjustable drives, allowable wear elongation is lim-
ited to about one-half of one chain pitch.
FILL/LEVEL
PLUG Measure a representative section of chain and if
wear elongation exceeds 3% or the functional limit,
REPLACE THE ENTIRE CHAIN. Do not connect a
FEED SYSTEM new section of chain to a worn section.

Lubricate Feed Chain Sprocket Inspection

1. Clean the chain with 30 psi compressed air
or with a brush. Do Not Pressure Wash or
Steam Clean the Feed Chains!
2. Brush or spray a light penetrating oil (such
as WD-40) onto the chains to lubricate internal
surfaces of the chain and drive out water.
3. Brush SAE 40, or heavier, on all chain sur-
faces to provide a barrier against dirt and mois-
ture, and prevent corrosion.
Chain Wear Inspection
Inspect the chain for
cracks, broken, deformed,
or corroded parts; and for
tight joints or turned pins. If
any are found, find and
correct the cause of the
damage, and REPLACE
THE ENTIRE CHAIN.
Even though the rest of the
chain appears to be in
good condition, it has been
damaged and more failures are likely to occur. The
upper diagram to the right shows a link plate with
shaded areas indicating areas where stress occurs
and the lower diagram an example of crack in a link
Inspect sprockets for chipped, broken, or deformed
teeth. If any are found, find and correct the cause of
the damage and REPLACE THE SPROCKET.
Sprockets normally are stronger and less sensitive
to damage than chains, but running a worn chain on
new sprockets can ruin the sprockets in a short time.
This is because a worn chain rides very high on the
sprocket teeth and wears the sprocket teeth in an
abnormal pattern.
The bottom sprockets are particularly susceptible to
wear because drilling dirt can accumulate around
them. When the bottom radius between the teeth
wears and deepens, the teeth actually form a wedge
that can put tremendous force on the pins and roll-
ers as they travel over the sprocket under load.
Sprockets should be inspected and if worn, replaced
when the chain is replaced.
A worn sprocket is not nearly as well defined as a
worn chain. However, there are some sprocket char-
acteristics that indicate when a sprocket should be
replaced. Check for roughness or binding when a
new chain engages or disengages the sprocket.
Inspect for reduced tooth thickness and hooked
tooth tips. If any of these conditions are present, the
sprocket teeth are excessively worn and the
sprocket should be replaced.
As the sprocket turns and roller progress from sur-
face “A” to “B”, power is transmitted to the roller,
advancing the chain. When the roller reaches “C”,

Page 2D-12
the sprocket is no longer transmitting power, but is
guiding the chain. If the sprocket material from “A” to
“C” is worn or broken then sprocket must be
replaced.
The diagram to the right depicts a sprocket with
shaded areas indicating “wear patterns”. Wear
slightly above the tooth trough at “A” indicates normal
wear with proper chain tension. If the chain tension is
slack, wear indication will be observed at “B”.
Do not run new chain on worn out sprockets
because it can cause the chain to wear rapidly. The
pitch of the new chain is much shorter than the
effective pitch of the worn sprocket, so the total
chain load is concentrated on the final sprocket
tooth before disengagement. Then, when the chain
disengages from the sprocket, the roller is jerked out
of the hooked portion of the sprocket tooth and that
results in a shock load on the chain as the load is
transferred from one tooth to the next.
WORN SPROCKET
MATERIAL
UNDERCARRIAGE
When all the track components are in the
correct position, use a grease gun to tension the
track. Fit the grease hose connector on the
valve of the grease-operated tensioner.
Keep the grease gun under pressure during the
track tensioning.
L
F
Important! When setting the track tension,
there must be a sagging (F) in the track of 2-3
cm for a track length (L) of 1-1.5 m. This is
measured linearly for a length (L) between 1
and 1.5 meters (at least 4 track elements).
Check the sagging (F) using a straight-edge
and ruler to measuring the distance (F) from the
top edge of the pad to the straight-edge.
TOO LOOSE
TOO TIGHT
NOTE: If the track is to slack it may slip off the
roller flanges, the sprocket and the front
guide wheel and considerably increase
track wear. IF the track is too taut, the
tracks increase wear on the front guide
wheel and the bearings and results in a
high degree of wear on the track
bushings and pins. It also requires
greater motive power during driving
with consequent increased fuel
consumption
250 Hour Maintenance Checks - Page 2D-13
Detach the grease gun connector when the 6. Repeat the procedure for the other final
track tension is correct. Move the undercarriage drive.
forward and backward for one complete turn of
the sprocket and make adjustments as
required. Check the track position on the front
guide wheel and on the sprocket. AIR INLET - ENGINE & COMPRESSOR
Depending on the configuration, on some
models there might not be any sagging in the
Replace Primary Elements
upper section of the track. In this case, the track
tension can be adjusted by measuring the
1. Loosen the wing nut and gently slide the pri-
hydraulic pressure of the tensioning device or
mary element out of the air cleaner assembly.
lifting the undercarriage. The sag measurement
in the upper section in this case is the same
2. Inspect the service indicator for the safety
rules as above where the distances L and F
element. Remove and replace the element if
apply.
the indicator is in the red zone.

3. Inspect the inside of the filter housing and if

Check Final Drive Gearbox Oil Level
cleaning is required remove the safety element.
Be careful not to allow dust to enter the intake
C
duct.
h FILL/
LEVEL
e PLUG 4. If the filter is dented or bunched it must be
c
replaced. Never rap or hit the element to
k
remove dirt.
t
h
SAFETY
e ELEMENT

PRIMARY
c ELEMENT
r DRAIN PLUG
a
w
ler final drive gearbox oil level as follows:
SERVICE
1. Position the machine on a level surface. INDICATOR/NUT
VACUATOR
VALVE
2. Position one of the final drives so that the
drain plug is at the bottom.

‘T’ STYLE AIR CLEANER

3. Remove the level/fill plug. The oil should be
to the bottom of the fill plug opening.
4. Add oil, of the type specified in “Recom-
mended Lubricant Viscosity” table, through the
level/fill opening if necessary.
1. Unlatch the filter cover and remove the
cover and gasket.
2. Loosen the wing nut and gently slide the pri-
mary element out of the housing.

5. Clean and replace the plug. 3. Inspect the service indicator/nut for the
safety element. Remove and replace the ele-
Page 2D-14
ment if the indicator is in the red zone.

4. Inspect the inside of the filter housing and if

cleaning is required remove the safety element.
Be careful not to allow dust to enter the intake
duct.

COVER
LATCHES
SAFETY
ELEMENT
SPLIT PIN WATER TRAP
FILTER
PRIMARY
21237s1 ELEMENT

Check System Operation

Inspect all lubrication points serviced by the

SERVICE central lubrication system to ensure that ade-
INDICATOR/NUT
quate lubricant is being delivered. Check the
following areas:
• Undercarriage Pivot Points
GASKET
• Feed Chain Sprockets and Winch
COVER Sheaves
‘T’ Style Air Cleaner • Loader Pivots
• Mast Lock Pivots
5. If the element is dented or bunched it must
be replaced. Never rap or hit the element to
remove dirt. MISCELLANEOUS

Check Electrical Wiring

CENTRAL LUBRICATION SYSTEM
Visually inspect the electrical wiring for wear
particularly near areas of high heat.
Clean Water Trap Filter

1. Disassemble the filter and clean the parts in
a non-flammable solvent.
2. Dry with filtered compressed air and re-
assemble.
Check Intake and Exhaust Systems
Visually inspect the intake and exhaust system
pipe connections.
Inspect the engine exhaust muffler for wear.

Check Dust Collector Hoses

Visually inspect the condition of the dust collec-

tor hoses. Replace as necessary.

250 Hour Maintenance Checks - Page 2D-15

Check Decals and Nameplates

Walk around the machine and check the condi-

tion of the safety and information decals. Refer
to the parts manual for decal locations and
ordering information.

Page 2D-16
 EVERY 500 HOURS OR 3. Loosen the capscrews and remove cover
(3).
3 MONTHS
4. Wash the element in clean, non-flammable
solvent and allow to dry.
ENGINE
5. Install valve cover (3).

6. Attach hose (2) and secure it in place with

Clean Engine Crankcase Breather (TIER 2)
clamp (1).
1. Loosen hose clamp (1).

2. Detach the hose from cover (3). 3 1

3. Loosen clamp (2) and remove cover (3).

3

4. Remove the breather element from cover (3)

and wash the element in clean, non-flammable
solvent and allow to dry. Inspect the seal for 2
cracks or damage.

5. Apply clean petroleum jelly to rubber parts

and install the seal.

6. Install the element in cover (3) and secure it

in place with clamp (2).

7. Attach the hose and secure with clamp (1).

Tighten the clamp to 4.5 Nm (40 in-lbs).
FUEL SYSTEM

1 3
2 ! WARNING
• Fuel leaked or spilled onto hot surfaces
or electrical components can cause a
catbrthr.tif fire.

• Disconnect the battery when changing

fuel filters.

Replace Primary Fuel Filter/Water Separator

1. Stop the engine.

Clean Engine Crankcase Breather (TIER 3)
2. Close the fuel supply line valve (if equipped).
1. Loosen hose clamp (1).
3. Using a strap wrench, remove the filter
2. Detach hose (2) from cover (3).
assembly.

500 Hour Maintenance Checks - Page 2E-1

 FUEL
PRIMING
PUMP
PLUNGER

c25-3
BASE

ELEMENT

BOWL
DRAIN VALVE

4. Clean the filter base of any gasket material. 2. Pump the plunger to fill the new filter ele-
ment. Continue pumping until resistance is felt,
5. Unthread the bowl from the base of the ele- indicating that the filter is full.
ment.
3. Turn the pump handle knob clockwise to
6. Clean the bowl in clean fuel before installing lock the plunger.
it onto the new element.
4. Start the engine and check for fuel leaks.
7. Thread the element onto the filter base until
until the element seal contacts the base.
Tighten the element 3/4 of a turn more.
PUMP DRIVE GEARBOX
8. Open the fuel supply line valve.

9. Prime the fuel system. See the topic “Prim- Change Oil
ing the Fuel System”.
The oil should be changed at 500 hour intervals,
or whenever the oil shows traces of dirt, water,
or the effects of overheating (discoloration or
Priming the Fuel System strong odor).

Priming the fuel system fills the fuel filters and NOTE !
removes air from the fuel system after the filters The oil should be warm when changed.
have been changed. Refer to the Caterpillar®
engine Operation and Maintenance manual if
the engine fuel supply has run dry.
! WARNING
Use caution and avoid touching hot oil or
1. Turn the priming pump plunger counter- components - these can cause burns.
clockwise and pull out the plunger.

Page 2E-2
 FILL PLUG
PUMP DRIVE
GEARBOX
DIPSTICK
Take an oil sample for analysis.
1. While the unit is still warm, remove the drain
plug located at the base of the dipstick and
allow the oil to drain into a suitable container.
Examine the oil for contamination or metal parti-
cles.
2. Inspect and clean the drain plug.
3. Install the drain plug.
4. Refill the housing through the fill port,
located on top of the housing, and replace the
fill plug. See the “Recommended Lubricant Vis-
cosities” table. Check the oil level using the dip-
stick provided.
NOTICE
Overfilling the gearbox can cause overheat-
ing and damage will result.
5. Start the engine and inspect for leaks.
HYDRAULIC SYSTEM
Change Return Filter Elements
The filter elements should be changed after the
first 50 hours of operation and at each 500
hours thereafter, or as indicated by the DMS.
! WARNING
Avoid skin contact with hot oil or compo-
nents - burns will result.
1. Relieve the hydraulic tank pressure by open-
ing the ball valve on the hydraulic tank.
COVER
SCREWS
BALL VALVE
2. Slowly unthread the filter cover screws and
remove the spring loaded filter cover to expose
the elements.
3. Quickly remove the elements from the hous-
ing and drain the oil into an appropriate con-
tainer.
4. Inspect the housing for contaminents. Clean
the housings.
5. Install two new elements, ensuring they are
joined with the plastic element connector.
6. Replace the O-ring on the cover and install
the cover.
7. Check the oil level and replenish if neces-
sary.
8. Start the engine and inspect for leaks.
500 Hour Maintenance Checks - Page 2E-3
 COVER
SCREWS DRAIN PLUGS

245-50

2. inspect, clean and replace the plugs.

3. Refill the gearbox through the fill/level port

with the type of oil specified in Section 1.

1471-S 245-45

FILL/LEVEL
PLUG

4. Replace the fill/level plug. Operate the

ELEMENT rotary head and check for leaks.
CONNECTOR

NOTE!
Only Schroeder elements are authorized for use WATER INJECTION
in the hydraulic system. Use of any other brand
must be authorized by the Sandvik Engineering
Department. Clean Suction Strainer

1. Drain the water tank by removing the drain

ROTARY HEAD plug and opening the valve.

2. Unscrew the fitting and remove the strainer

Change Gearbox Oil from the tank.

1. with the mast raised and the rotary head

lowered to a working height, remove the two
drain plugs from the gearbox and allow the oil to
drain into a suitable container.

Page 2E-4
 AIR INLET - ENGINE & COMPRESSOR

Replace Safety Elements

The safety element should be replaced every

245-31 third time the primary element is cleaned or
replaced or as indicated by the service indicator
in the safety filter hold down nut as shown.

1. Remove the primary element as described

earlier.
VALVE STRAINER PLUG
HANDLE 2. Remove the split pin and nut that hold the
safety element in place.
3. Clean the strainer with compressed air.
3. Remove and discard the safety element.
4. Replace the strainer and reconnect the The safety element should not be cleaned.
valve.
4. Clean the inside of the filter housing espe-
cially around the areas of the element sealing
surfaces.
WINCH
5. Install a new safety element.

Check Oil Level 6. Install the primary element.

1. With the mast raised, check the oil level in

winch sight gauge provided. The oil level should
SAFETY
be visible at the bottom of the gauge. ELEMENT

PRIMARY
2. If oil is needed, remove the sight gauge and ELEMENT

fill to the port opening with the type of lubricant

specified in Section 1.

SERVICE
INDICATOR/NUT
VACUATOR
SIGHT VALVE
GAUGE

‘T’ STYLE AIR CLEANER

The safety element should be replaced every

third time the primary element is replaced or as
indicated by the service indicator in the safety
filter hold down nut as shown.
500 Hour Maintenance Checks - Page 2E-5
1. Remove the primary element as described
in the 250 Hour Maintenance section.
DRILL PIPE SAFETY HOOP

2. Remove the split pin and nut that hold the

safety element in place.

3. Remove and discard the safety element.

The safety element should not be cleaned.

4. Clean the inside of the filter housing espe-

cially around the areas of the element sealing
surfaces.

5. Install a new safety element.

6. Install the primary element.

COVER
LATCHES
SAFETY
ELEMENT
SPLIT PIN
PRIMARY
21237s1 ELEMENT

SUPPORT WELDS

SERVICE
INDICATOR/NUT
MOUNTING HARDWARE

GASKET
COVER
‘T’ Style Air Cleaner Inspect the Pedestal Welds
Clean the pedestal areas to be inspected and visu-
ally inspect for cracks or signs of stress.

MAST and PEDESTAL

Inspect the Drill Pipe Safety Hoop

After each 500 hours of drilling, lower the mast
into the mast rest and inspect the hoop and sup-
porting weldments for fatigue. Check the mount-
ing hardware torque. Replace or re-weld any
items that appear to be damaged.

Page 2E-6
 EVERY 1000 HOURS OR
6 MONTHS HYDRAULIC
TANK
DRAIN

HYDRAULIC SYSTEM

Change Hydraulic Oil

NOTE!
The oil should be warm when changed.

! WARNING
Avoid touching hot oil or components -
these can cause burns.
! WARNING
Be sure that the engine is stopped, hydraulic
pressure relieved and the hydraulic tank air
pressure relieved before working on the
hydraulic tank.
1. Take an oil sample for analysis.
4. Replace the return filter elements as
described in the 500 Hour Maintenance
Checks.
5. Close the drain valve.
6. Refill the tank with the hand pump provided
or the Wiggins quick fill port to the correct level.
7. Start the engine and check for leaks.

2. Relieve the hydraulic tank pressure by open-

ing the ball valve on the tank as shown. COMPRESSOR

Re-Torque Compressor Mounts

Using a torque wrench, re-torque the compres-

sor bolts. See the “Recommended Torque Val-
ues” table.

BALL VALVE

3. Open the drain valve and drain the oil into a

suitable container.

1000 Hour Maintenance Checks - Page 2F-1

 3. Lift off the filter cover (2) and gasket (3).
Remove the nuts (4) and retaining plate (5).

4. Lift out the filter element (7) and wipe the

element seal and base areas clean.

NOTE!
Inspect the element for damage. Never install
damaged elements back into the compressor
system.

HIGH PRESSURE 1
COMPRESSOR
MOUNTING SYSTEM 2
HARDWARE

3
Change Air/Oil Separator Element
4

Refer to the 250 Hour Maintenance Checks for 5

oil sampling procedures.
6
Change the air/oil separator element when the
service indicator shows red. 7

ELEMENT
INDICATOR

! WARNING
Be sure that the engine is stopped and pres-
sure relieved before working on the receiver
tank.
HIGH PRESSURE COMPRESSOR SYSTEMS
5. Install a new element (7) in place.
6. Install retaining plate (5) and nuts (4).
Torque to 6.9 kg/m (50 ft. lb.).

1. ENSURE the engine is shut down and the 7. Inspect the condition of cover gasket (3).
internal pressure relieved. Replace if damaged.

2. Remove the bolts (1) from cover (2). 8. Replace cover (2) and torque bolts (1) to 190
- 210 FT LB (256 - 283 Nm).
Page 2F-2
LOW PRESSURE COMPRESSORS
! WARNING
Be sure that the engine is stopped and pres-
sure relieved before working on the receiver
tank.
1. Ensure the engine is shut down and the
internal pressure relieved.
2. For ease of removal, remove scavenge tube
(1) from cover (3).
and result in fire. Do not remove the staples
from the upper sealing gasket.
5. Install a new element (4) in place making
sure that gaskets (5) are in place on both sides
of the element flange and that the upper gasket
has staples (6) 180° apart to disipate static
charge.
6. Replace cover (3) and torque hardware (2)
to 270-292 ft-lbs (364-394 Nm). Install scav-
enge tube (1) in the cover.

3. Remove hardware (2) and lift off receiver

cover (3).
4. Lift out the filter element (4) and wipe the
cover and base sealing areas clean.
NOTE!
Inspect the element for damage. Never install
damaged elements back into the compressor
system.
1 The oil should be warm when changed.
Change Compressor Oil
NOTE !
The oil change interval depends on the type of
oil and whether or not oil analysis is being used.
See the ‘Recommended Lubrication Viscosity
Chart’ in section 1 of this manual for details.
NOTE !

2 3
! WARNING
4 Avoid touching hot oil or components -
these can cause burns.

6
5
! WARNING
Ensure the engine is shutdown and internal
c40-50 pressure relieved.
LOW PRESSURE
COMPRESSOR
SYSTEM

! WARNING
Installing a filter element without staples in
the upper gasket can cause a static charge

1000 Hour Maintenance Checks - Page 2F-3

 motor and the motor ports.

VENT

245-53

WINCH
MOTOR
RECEIVER TANK
DRAIN
4. Using a suitable lifting device, support the
winch. Remove the mounting hardware and
Changing the Oil lower the winch.

1. Locate the drain valve and drain the oil into a 5. Remove the sight glass and pour the oil into
suitable container. a suitable container.

2. If required, change the separator element.

Refer to the 1000 hours Maintenance Check.

3. Close the drain valve and install the plug. SIGHT

GAUGE

4. Refill the tank with oil of the type specified in

the “Recommended Lubricant Viscosities” table
in Section 1.

5. Start the engine and check for leaks.

WINCH 6. Refill the winch with the type of oil specified

in Section 1 to the bottom of the sight glass port.

Change Oil and Clean Breather
NOTE!
We recommend using an oil vacuum system to
remove the winch oil. If this system is not avail-
able proceed as follows:
7. Remove the vent and clean it in a solvent.
Install it when dry.
8. Install the winch on the mast and tighten the
mounting hardware to the torque values given.

1. Unspool all but the final wrap of wire rope

from the drum.

2. Lower the mast to the horizontal position.

3. Disconnect and plug the hoses to the winch

Page 2F-4
ROTARY HEAD
PIVOT BLOCK
BOLTS (SHOWN
Replace Gearbox Breather WITH LOCKING
TABS BENT UP)
1. With the mast raised, lower the rotary head
to access the breather.

245-51
BREATHER

2. Remove the breather and replace with a

new breather.

MAST

Check the Torque of the Pivot Block Bolts

Bend the bolt locking tabs back and check that

the torque on the bolts is 908 Nm (670 ft-lbs).
Bend the tabs up over the sides and top of the
bolts after tightening.

1000 Hour Maintenance Checks - Page 2F-5

Page 2F-6
 EVERY 2000 HOURS OR
1 YEAR

COOLING SYSTEM

Change Coolant

! WARNING RADIATOR DRAIN

VALVE
Steam can burn. Allow coolant to cool
before draining. Remove the radiator filler
cap slowly to relieve pressure.
NOTICE
1. Loosen the radiator filler cap slowly to
Cooling System Conditioner contains alkali.
release pressure before removing the cap.
Avoid contact with skin and eyes to prevent
personal injury.

FILLER 4. Replace the coolant conditioner cartridge

CAP with a precharge cartridges (refer to “250 Main-
tenance Checks” for more information on
replacing these cartridges).

STANDARD CARTRIDGE LOCATION

SHUTOFF
VALVES

COOLANT
2. Open the drain valve underneath the radia- CONDITIONER
tor. Allow the coolant to drain into a suitable CARTIDGE
container.

3. Close the radiator drain valve.

NOTICE
Add coolant only when the engine is
stopped and the radiator filler cap is cool
enough to touch with your bare hand.

5. Fill the system with a solution of approved

water and antifreeze. See “Refill Capacities” for
amount of solution needed.

2000 Hour Maintenance Checks - Page 2G-1

NOTE!
Add solution slowly at 20 litres (5 U.S. gallons)
or less per minute to avoid air locks.
6. Start the engine with the radiator filler cap
off. Operate the engine until the thermostat
opens and coolant level stabilizes. Fill the cool-
ing system to the bottom of fill tube. Install the
radiator filler cap.
Re-Torque Cooler Mounts
Check the torque of the cooler mounting hard-
ware. See “Recommended Torque Values”.
RADIATOR MOUNTS
UNDERCARRIAGE
Change Crawler Final Drive Oil
NOTE !
The oil should be warm when changed.
Use caution and avoid touching hot oil or
components - these can cause burns.
Page 2G-2
FILL/
LEVEL
PLUG
DRAIN PLUG
1. Position the final drive so that oil drain plug
is positioned at the bottom.
2. Remove fill/level plug and take an oil sample
for analysis.
3. Remove the drain plug. Allow the oil to drain
into a suitable container.
4. Clean the plugs and inspect the O-rings.
Replace the drain plug.
5. Refill the final drive with oil of the type speci-
fied in the “Recommended Lubricant Viscosi-
ties” chart.
NOTICE
Allow time for the oil to flow through the
gears and ensure that the entire quantity of
oil specified for each compartment is added.
Do not operate the machine with low final
drive oil - final drive failure will result.
6. Replace the fill/level plug.
7. Completely remove oil spilled onto surfaces.
8. Start the machine and allow the machine to
propel in both directions. Position the drives to
recheck the oil levels. Check for leaks after one
hour of operation.
MAST and PEDESTAL
PIVOT BLOCK
BOLTS (SHOWN
Change the Pivot Block Bolts and Hardware WITH LOCKING
(Every 4000 Hours) TABS BENT UP)

1. Lower the mast into the mast support.

2. Lockout and tagout the machine.

3. Bend the bolt locking tabs back.

4. Support the block cap, it weighs approxi-

mately 17 kg (40 lbs).

5. Remove the bolts, washers and locking tabs.
Discard this hardware.
6. If need, install jacking bolts into the dowel
pin holes and slowly pry the cap off the block.
Test the Pedestal Welds
Clean the pedestal areas and inspect for cracks
using a non-destructive inspection (NDT) method
such as a dye penetrate or magnetic particle testing.

7. Remove the existing dowel pins and replace

them.

8. Install the block cap over the dowels.

9. Apply ‘Anti-Seize’ to the threads of the new

bolts. Install the locking tabs, washers and bolts
on the blocks.

10. Diagonally tighten the bolts until a torque of

881 Nm (650 ft-lbs) is achived.

11. Bend the tabs up over the sides and top of

the bolts after tightening.
Kit Part Number 036837-052
Description Part# Qty in Kit
Bolts 001554-200 4
Lock Tabs 001441-002 2
Washers 010550-013 4
Dowel Pins 001584-070 4
Grease Fitting 001539-001 2
Set Screw 036796-012 4

2000 Hour Maintenance Checks - Page 2G-3

Page 2G-4
 SECTION 3 MACHINE STORAGE

GENERAL

If this machine is to be removed from service for an extended period of time, the following proce-
dures 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.

NOTICE
Before starting the machine after short or long term storage, or transporting, perform the 8
Hour Maintenance tasks to prevent damage to the machine.

SHORT TERM STORAGE

General

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

Preparation for Short Term Storage

Perform the following steps to prepare the machine proper for short term storage:

1. Clean the entire machine.

2. Touch up painted surfaces as necessary, after proper preparation and priming.

3. Lubricate all grease points on the machine.

NOTE!
Step 4 is unnecessary if the machine is stored in a building and the air will be dry for the duration of
storage.

4. With all hydraulic cylinders fully retracted, coat the exposed portions of the cylinder piston rods
with multipurpose grease.

5. Contact the engine manufacturer for engine storage procedures.

6. Clean and lubricate the feed chain or cables.

Removal from Short Term Storage

1. Lubricate all points equipped with grease fittings.

2. Remove preservative grease, if applicable, from the cylinder piston rods and other surfaces
where applied.

3-1
3. Check the oil levels in each gear housing. Add oil as necessary as specified in Section 1.

4. Check the oil level in the hydraulic reservoir. Add oil of the proper type, as specified in Section 1.

5. Install the battery if it was removed, fully charged.

6. Contact the engine manufacturer for procedures on removing the engine from storage.

7. Make a thorough visual inspection of the entire machine before operating it for the first time fol-
lowing storage. Check, especially, for damaged or deteriorated hydraulic hoses.

LONG TERM STORAGE

General

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

Preparation for Long Term Storage

To prepare the machine proper for long term storage, proceed as follows:

1. Clean the entire machine thoroughly.

2. Inspect for loose or missing attaching hardware throughout the machine. Tighten or replace as
necessary.

3. Inspect all painted surfaces for rust, bare metal chipping, or other defects. Prepare, prime, and
repaint as necessary.

4. Liberally lubricate all points equipped with grease fittings.

5. Drain all gear cases and clean the magnetic plugs and breathers. Replace the drain plugs and
refill each housing and case with the oil type specified in Section 1.

6. Contact the engine manufacturer for engine storage procedures.

7. Clean the battery compartment using a soda and water solution, if necessary, to remove corro-
sion. Wrap the cable terminals with waterproof tape, after cleaning.

8. Run the engine until the hydraulic oil is warm. Then drain the hydraulic system completely.

9. Replace the hydraulic filter elements.

10. Refill the hydraulic reservoir to the prescribed level with the proper oil type.

11. Operate all hydraulic functions to distribute the new oil throughout the systems.

12. Apply a suitable preservative grease to exposed portions of hydraulic cylinder piston rods, con-

3-2
trol valve spools, and other exposed unpainted surfaces.

13. When the machine is parked in the spot it is to be stored in, fill the hydraulic reservoir to the top
with hydraulic oil.

Removal From Long Term Storage

1. Clean the entire machine thoroughly. Then inspect the machine thoroughly, paying particular
attention to hydraulic hoses, tubes, and fittings.

2. Lubricate all points equipped with grease fittings.

3. 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 3.

4. Drain the hydraulic reservoir down to the proper level.

5. Remove the preservative grease from the cylinder rod pistons and other machined surfaces, if
applicable.

3-3
3-4