Maintenance Manual

Original instructions
BG00471036 en-US C.001.1 2018-05-28
Maintenance Manual
DT820
Maintenance Manual DT820
WARNING
IGNORING INSTRUCTIONS HAZARD!
To avoid death or injury you MUST read, understand and follow
operator's and maintenance manuals before installing, inspecting,
operating, servicing, testing, cleaning, transporting, storing,
dismantling or disposing of the product or a part or accessory of the
product. Keep this publication for future reference.
Copyright © Sandvik
ID: BG00471036 en-US C.001.1 2018-05-28
This page is intentionally left blank
ID: BG00471036 en-US C.001.1 2018-05-28
Table of Contents
1 Introduction ................................................................... 15
1.1 The purpose of these instructions ......................................................16
1.2 Identification of the product ................................................................ 17
1.2.1 Product type and serial number .................................................. 17
1.2.2 Product manufacturer ..................................................................17
1.2.3 Manuals .......................................................................................18
1.2.4 How to identify the correct manual for the product ......................19
1.2.5 Validity of the manuals ................................................................ 19
1.3 Copyright notice ................................................................................... 19
1.4 Definitions ............................................................................................. 20
2 Safety and environmental instructions .......................23

2.1 Safety labels, safety messages and signals ...................................... 24
2.1.1 Signal words ................................................................................24
2.1.2 General hazard symbol ............................................................... 24
2.1.3 Mandatory action symbols ...........................................................25
2.1.4 Prohibited action symbols ........................................................... 26
2.1.5 Hazard symbols ...........................................................................27
2.1.6 Labels on the product ..................................................................30
2.1.7 Visual and audible signals ...........................................................55
2.2 User obligations ....................................................................................56
2.2.1 Managing work related hazards .................................................. 57
2.2.2 Scheduled safety inspections and preventive maintenance ........57
2.2.3 Personal protective equipment ....................................................58
2.3 Product limitations ............................................................................... 59
2.3.1 Intended use ................................................................................59
2.3.2 Prohibited use ............................................................................. 60
2.3.3 Center of gravity .......................................................................... 61
2.3.4 Maximum inclination angles ........................................................ 62
2.3.5 Operator visibility .........................................................................63
2.3.6 Modifications ............................................................................... 64
2.4 Hazard zones .........................................................................................65
2.5 Safeguarding .........................................................................................68
2.5.1 Guards .........................................................................................68
2.5.2 Location of the guards .................................................................69
2.5.3 Protective devices ....................................................................... 72
2.6 Complementary protective measures .................................................77
2.6.1 Use of emergency stop function ..................................................77
2.6.2 Emergency exit ............................................................................78
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2.6.3 Safe access to machine and three-point support ........................ 79

2.6.4 Isolation and energy dissipation .................................................. 80
2.7 Fire risk control measures ...................................................................83
2.7.1 In case of fire ...............................................................................84
2.7.2 Fire prevention ............................................................................ 85
2.7.3 Fire retardant and flammable materials .......................................85
2.7.4 Fire suppression ..........................................................................86
2.7.5 After a fire ....................................................................................94
2.8 Protection against emission hazards ................................................. 95
2.8.1 Noise ........................................................................................... 95
2.8.2 Vibration ...................................................................................... 95
2.8.3 Dust ............................................................................................. 96
2.8.4 Diesel emissions ......................................................................... 97
2.9 Emergency procedures ........................................................................97
2.10 Safety considerations for maintenance ..............................................99
2.10.1 Daily inspections and tasks for operators ....................................99
2.10.2 Tasks which require definite technical skills and maintenance
training .........................................................................................100
2.11 Environment ..........................................................................................100
2.11.1 Decommissioning ........................................................................ 101
2.11.2 Dismantling ..................................................................................102
2.11.3 Disposal .......................................................................................104
2.12 Potential product related hazards identified by the user ..................105
2.13 Incident reporting ................................................................................. 106
3 Machine description ..................................................... 107

3.1 Main component location .................................................................... 108
3.1.1 Drilling module .............................................................................108
3.1.2 Carrier module .............................................................................114
3.1.3 Rear module ................................................................................124
3.1.4 Safety canopy / cabin .................................................................. 138
3.1.5 Drilling components .....................................................................141
3.2 Machine orientation ..............................................................................146
3.3 Instrument panels and operating controls .........................................147
3.3.1 Tramming controls .......................................................................149
3.3.2 Tramming panel (DP) .................................................................. 149
3.3.3 Switch panel (canopy model) ...................................................... 169
3.3.4 Switch panel (cabin model) ......................................................... 170
3.3.5 Indicator panel (QN) .................................................................... 171
3.3.6 Wipers ......................................................................................... 174
3.3.7 Hydraulic oil filling (and vacuum) on/off switch ............................175
3.3.8 Remote control for reel(s) (ERCP) .............................................. 176
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3.3.9 Reversing camera monitor (optional) .......................................... 177

3.3.10 Control devices for cooling and heating (cabin model only) ........178
3.3.11 Controls of the THC 560 drilling systems .................................... 181
3.3.12 Utility boom controls .................................................................... 204
3.4 MSE - Main switchgear and circuit breakers (380-690V) ...................208
3.4.1 Switches and gauges .................................................................. 210
3.5 1000 V main switch equipment and circuit breakers (optional) ....... 211
3.5.2 Circuit breakers ........................................................................... 214
3.6 MSC / MSU main switch equipment and circuit breakers (optional)
................................................................................................................215
3.6.2 Circuit breakers ........................................................................... 218
4 Periodic maintenance ................................................... 221

4.1 Importance of scheduled maintenance .............................................. 222
4.2 General maintenance instructions ......................................................223
4.2.1 Filling the fuel tank ...................................................................... 225
4.2.2 Maintenance of the hydraulics .....................................................226
4.2.3 Pneumatic system maintenance ................................................. 227
4.2.4 Maintenance of the rock drill pressure accumulators .................. 228
4.2.5 Electric system maintenance - Safety instructions ...................... 228
4.2.6 Maintenance of the batteries ....................................................... 231
4.2.7 Tire maintenance .........................................................................234
4.3 Commissioning service advice ........................................................... 235
4.4 First maintenance ................................................................................. 236
4.4.1 Maintenance performed according to rock drill percussion hours
.................................................................................................... 236
4.4.2 Maintenance performed according to diesel engine hours ..........236
4.4.3 Maintenance performed according to compressor operating
hours ........................................................................................... 236
5 Maintenance instructions .............................................237

5.1 General .................................................................................................. 238
5.1.1 Washing the drill rig ..................................................................... 238
5.1.2 Checking the steel structures ...................................................... 238
5.2 Hydraulic rock drill HLX5 ..................................................................... 239
5.2.1 Checking the flushing housing seals and the seal housing guide
rings .............................................................................................239
5.2.2 Inspection of the front end with the rock drill on a feed rail ......... 240
5.2.3 Checking and tightening bolts and tie rods ................................. 243
5.2.4 Checking the charge gas pressure of the pressure
accumulators ............................................................................... 246
5.2.5 Rock drill overhaul .......................................................................247
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5.2.6 After rock drill service .................................................................. 247

5.3 Hydraulic rock drill HLX 5T, HFX 5T ....................................................248
5.3.1 Removing the flushing housing ................................................... 248
5.3.2 Checking the stabilizer pins .........................................................249
5.3.3 Wear limits for the flushing housing bushings ............................. 249
5.3.4 Checking the rotation bushing bearings inside the gear housing 250
5.3.5 Checking the rotation bushing .....................................................250
5.3.6 Checking the coupling ................................................................. 252
5.3.7 Checking the chuck ..................................................................... 253
5.3.8 Checking the shank .....................................................................253
5.3.9 Disassembling the flushing housing ............................................ 254
5.3.10 Changing the flushing housing bushings .....................................255
5.3.11 Assembling the flushing housing .................................................259
5.3.12 Attaching the flushing housing .................................................... 260
5.3.13 Checking the accumulator filling valve and cover plug condition 261
5.3.14 Checking the accumulator pressure ............................................262
5.3.15 Checking the bolt tightness and tightening torques .....................262
5.4 Hydraulic rock drill RD520/RD525 .......................................................268
5.4.1 Removing the flushing housing ................................................... 268
5.4.2 Checking the pistons head and chuck bearing ............................269
5.4.3 Wear limits for the flushing housing bushings ............................. 270
5.4.4 Checking the coupling ................................................................. 270
5.4.5 Checking the chuck ..................................................................... 271
5.4.6 Checking the shank .....................................................................272
5.4.7 Disassembling of the flushing housing ........................................ 273
5.4.8 Changing the flushing housing bushings .....................................274
5.4.9 Assembling the flushing housing .................................................278
5.4.10 Attaching the flushing housing to the rock drill ............................ 279
5.4.11 Checking the accumulator filling valve and cover plug condition 280
5.4.12 Checking the accumulator pressure ............................................281
5.4.13 Checking the bolt tightness and tightening torques .....................281
5.5 Boom TB/SB ..........................................................................................287
5.5.1 Greasing points of the TB/SB boom ............................................288
5.5.2 Checking bearing bushings and axle pins ...................................289
5.5.3 Checking the tightness of bolts and nuts .....................................290
5.5.4 Checking the slide pieces of the cradle .......................................291
5.5.5 Checking the slide plates and slide pieces ..................................293
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5.5.6 Checking boom clearances ......................................................... 293

5.5.7 Checking the cylinder pins .......................................................... 294
5.5.8 Checking the sensor boxes ......................................................... 295
5.5.9 Lubricating the electric box connections ..................................... 295
5.5.10 Checking of the angle restriction function ................................... 296
5.5.11 Testing the lift/swing cylinder seals ............................................. 297
5.5.12 Lift/swing cylinders overhaul ....................................................... 298
5.6 SUB utility boom ...................................................................................299
5.6.1 Lubricating the pins and bearings of the utility boom .................. 299
5.6.2 Inspecting the cylinder joint pins, pin lockings and bearings .......300
5.6.3 Adjusting the boom extension clearance .....................................301
5.6.4 Checking hydraulic pressures ..................................................... 302
5.6.5 Inspecting the turning joint lug welding and the basket tilt
cylinder fixing lug welding ............................................................303
5.6.6 Inspecting the condition of the boom beams ...............................303
5.6.7 Changing the tilting cylinder joint pin and bearing .......................303
5.7 Feed TF/TFX .......................................................................................... 303
5.7.1 Checking the tightness of bolts and nuts .....................................303
5.7.2 Checking the condition and mounting of the impulse cylinders /
inductive sensors .........................................................................303
5.7.3 Checking the front centralizer ......................................................304
5.7.4 Lubricating the hose reel ............................................................. 304
5.7.5 Adjusting the slide pieces (TF500) .............................................. 305
5.7.6 Adjusting the slide pieces (TFX500) ............................................306
5.7.7 Checking the tightness and condition of the feed wires .............. 306
5.7.8 Checking the tension of the hoses .............................................. 308
5.7.9 Checking the condition of the steel strips ....................................309
5.7.10 Checking the condition of the hose reel components ..................310
5.8 Carrier .................................................................................................... 311
5.8.1 Machine greasing points ............................................................. 311
5.8.2 Checking the planetary gear oil level .......................................... 312
5.8.3 Checking the differential oil level .................................................312
5.8.4 Checking the battery electrolyte level ..........................................313
5.8.5 Checking the pressure of the brake accumulators ...................... 313
5.8.6 Releasing the pressure from the brake accumulators .................314
5.8.7 Filling the brake accumulators .....................................................315
5.8.8 Bleeding the brakes .....................................................................317
5.8.9 Checking the steering wheel and control arm ............................. 320
5.8.10 Checking the tightness of boom support bolts ............................ 321
5.8.11 Replacing the transmission oil filter .............................................324
5.8.12 Changing the differential oil .........................................................325
5.8.13 Spicer axle types 37R, 43R .........................................................326
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5.8.14 Spicer axle types 113, 114, 123, 213 .......................................... 327
5.8.15 Checking the middle-joint bearings ............................................. 328
5.8.16 Checking the oscillation axle bearings ........................................ 328
5.8.17 Replacing the safety cartridge of the air filter .............................. 328
5.8.18 Changing the transmission oil ..................................................... 329
5.8.19 Changing the planetary gear oil .................................................. 330
5.8.20 Checking the specific gravity of the electrolyte and cleaning the
battery terminals ..........................................................................331
5.8.21 Servicing the Ansul fire suppression system (optional) ...............331
5.8.22 Maintenance procedures done as required .................................332
5.8.23 Filling the gas pre-charge pressure for the brake accumulators . 334
5.9 Diesel engine MB .................................................................................. 336
5.9.1 Replacing the engine oil and filter ............................................... 336
5.9.2 Replacing the fuel filter ................................................................339
5.9.3 Replacing the fuel water separator filter ......................................340
5.9.4 Checking the condition of poly V-belt .......................................... 341
5.9.5 Checking the engine for leaks and general condition ..................345
5.9.6 Checking the lines and hoses of the engine ................................345
5.9.7 Checking the intake pipe between air cleaner and engine ..........345
5.9.8 Checking the engine cooling system ...........................................346
5.9.9 Replacing the intake air cleaner filter .......................................... 347
5.9.10 Adjusting the valve clearances ....................................................348
5.9.11 Cleaning the fuel pre-filter ........................................................... 352
5.9.12 Checking the general condition of cooling and heating system .. 353
5.9.13 Renewing the coolant ..................................................................354
5.9.14 Replacing the poly V-belt .............................................................355
5.10 Cable and water hose reel ................................................................... 355
5.10.1 Lubricating the cable spooling system ........................................ 355
5.10.2 Checking the guide rollers of the cable reel ................................ 356
5.10.3 Checking the guide rollers of the water hose reel ....................... 356
5.10.4 Lubricating the chain of the cable reel .........................................356
5.10.5 Lubricating the chain of the water hose reel ................................357
5.10.6 Checking the tightness of the chain of the cable reel ..................357
5.10.7 Checking the tightness of the chain of the water hose reel .........358
5.10.8 Checking the cable fastening to the reel ..................................... 358
5.10.9 Checking the operation of the cable reel limit switch .................. 358
5.10.10 Changing the gear box oil of the cable reel .................................359
5.10.11 Checking the cable reel slip rings and carbon brushes ...............360
5.11 Drilling hydraulics ................................................................................ 361
5.11.1 Replacing the breather filter of the hydraulic oil receiver ............ 361
5.11.2 Replacing the pressure filter ........................................................362
5.11.3 Replacing the return oil filter ........................................................363
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5.11.4 Changing the hydraulic oil ........................................................... 364

5.12 Water circuit .......................................................................................... 365
5.12.1 Checking the operation of the water valve FV-70 ........................365
5.12.2 Checking the operation of the water valve FV-100 ......................365
5.12.3 Checking the operation of the pressure switch ........................... 366
5.12.4 Cleaning the oil cooler .................................................................367
5.12.5 Changing the mud separator strainer and O-ring ........................368
5.13 Air circuit ............................................................................................... 369
5.13.1 Checking the condition of the air receiver (optional) ................... 369
5.14 Compressor CTN .................................................................................. 370
5.14.1 Procedures prior to compressor maintenance ............................ 370
5.14.2 Changing the compressor oil .......................................................371
5.14.3 Replacing the compressor oil filter .............................................. 372
5.14.4 Checking and retightening main motor cables ............................ 372
5.14.5 Cleaning the compressor externally with a cloth ......................... 372
5.14.6 Replacing the compressor air filters ............................................ 373
5.14.7 Replacing the compressor belts .................................................. 373
5.14.8 Cleaning the cooler externally ..................................................... 373
5.14.9 Replacing the compressor oil separator cartridge, discharge
valve, valve nest, wing nut and O-rings .......................................374
5.14.10 Cleaning the oil return line ...........................................................375
5.14.11 Replacing the screen for oil return, fittings and gasket ............... 375
5.14.12 Checking the operation of the compressor relief valve ............... 375
5.14.13 Lubricating the electric motor bearings ....................................... 375
5.14.14 Replacing the seal kits of the inlet and the discharge valve ........376
5.14.15 Checking the function of the thermometer safety limits ...............384
5.14.16 Checking the condition of the compressor hoses ........................384
5.14.17 Replacing the blow-down valve ...................................................384
5.14.18 Replacing the seal kit of the pilot valve ....................................... 385
5.14.19 Replacing the oil thermostat ........................................................385
5.14.20 Replacing the motor bearings ..................................................... 385
5.14.21 Replacing the shaft seal kit ......................................................... 385
5.14.22 Replacing the air end .................................................................. 386
5.15 Compressor CT .....................................................................................386
5.15.1 Procedures prior to compressor maintenance ............................ 386
5.15.2 Changing the compressor oil .......................................................387
5.15.3 Replacing the compressor oil filter .............................................. 388
5.15.4 Checking and retightening main motor cables ............................ 388
5.15.5 Cleaning the compressor externally with a cloth ......................... 388
5.15.6 Replacing the compressor air filters ............................................ 389
5.15.7 Replacing the compressor belts .................................................. 389
5.15.8 Cleaning the cooler externally ..................................................... 389
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5.15.9 Replacing the compressor oil separator cartridge, wing nut and
discharge valve seals .................................................................. 390
5.15.10 Cleaning the oil return line ...........................................................391
5.15.11 Replacing the screen for oil return, fittings and gasket ............... 391
5.15.12 Checking the operation of the compressor relief valve ............... 391
5.15.13 Lubricating the electric motor bearings ....................................... 391
5.15.14 Replacing the seal kit of the inlet valve ....................................... 392
5.15.15 Checking the function of the thermometer safety limits ...............392
5.15.16 Checking the condition of the compressor hoses ........................392
5.15.17 Replacing the blow-down valve ...................................................393
5.15.18 Replacing the oil thermostat ........................................................393
5.15.19 Replacing the motor bearings ..................................................... 394
5.15.20 Replacing the shaft seal kit ......................................................... 394
5.15.21 Replacing the air end .................................................................. 394
5.16 SLU .........................................................................................................394
5.16.1 Draining the condensed water .....................................................394
5.16.2 Checking the condition of the water separator ............................ 395
5.16.3 Changing the water separator filter element ............................... 396
5.16.4 Cleaning the tank ........................................................................ 397
5.16.5 Replacing the breather ................................................................ 397
5.16.6 Checking the function of the monitoring system ..........................398
5.17 Electric system ..................................................................................... 398
5.17.1 Electric system maintenance - Safety instructions ...................... 398
5.17.2 Checking the operation of the fault current protector switch ....... 400
5.17.3 Checking the condition of the power supply cable ...................... 400
5.17.4 Checking the water drainage holes ............................................. 401
5.17.5 Checking the seal bushings ........................................................ 401
5.17.6 Checking connections and contacts (110 VAC - 1000 VAC) ....... 401
5.17.7 Checking connections and contacts (24 VDC, battery system) .. 401
5.17.8 Checking control system ............................................................. 402
5.17.9 Cleaning electric devices .............................................................403
5.17.10 Checking the motor terminals ......................................................403
5.18 Safety cabin ...........................................................................................404
5.18.1 Cleaning or replacing the filters ...................................................404
5.18.2 Checking the operation of the heating and air conditioning ........ 405
5.18.3 Lubricating the cabin door hinges ............................................... 405
5.19 Other components ................................................................................405
5.19.1 Checking the grease unit .............................................................405
6 Lubricants and capacities ............................................ 407

6.1 General .................................................................................................. 408
6.2 Hydraulic system .................................................................................. 413
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6.3 Rock drill shank lubrication .................................................................418

6.4 Diesel engine .........................................................................................419
6.5 Compressor ...........................................................................................420
6.6 Transmission and driveline oils .......................................................... 422
6.7 Drill steel thread grease ....................................................................... 424
6.8 Lubrication grease ................................................................................424
6.9 Engine coolant ...................................................................................... 425
6.10 Filling capacities ...................................................................................425
7 Additional instructions ................................................. 435

7.1 Towing ................................................................................................... 436
7.1.1 Towing with the engine in operating condition .............................436
7.1.2 Towing with a faulty engine ......................................................... 437
7.1.3 Releasing the parking brakes ......................................................438
7.1.4 After towing ................................................................................. 440
7.2 Transport ............................................................................................... 441
7.3 Lifting .....................................................................................................442
7.3.1 Lowering and raising equipment through a mine shaft ................445
7.4 Storage .................................................................................................. 446
7.5 Washing .................................................................................................448
8 Maintenance cards ........................................................451

8.1 Maintenance program .......................................................................... 452
8.2 Instructions for reading maintenance cards ......................................453
8.3 Maintenance performed according to rock drill percussion hours . 454
8.3.1 Every 50 hours ............................................................................ 455
8.3.2 Every 250 hours .......................................................................... 458
8.3.3 Every 500 hours .......................................................................... 459
8.3.4 Every 1000 hours ........................................................................ 461
8.3.5 Every 2000 hours ........................................................................ 462
8.4 Maintenance performed according to diesel engine hours ..............462
8.4.1 Every 50 hours ............................................................................ 463
8.4.2 Every 250 hours .......................................................................... 464
8.4.3 Every 500 hours .......................................................................... 466
8.4.4 Every 1000 hours ........................................................................ 467
8.4.5 Every 2000 hours ........................................................................ 468
8.5 Maintenance performed according to compressor operating hours
................................................................................................................468
8.5.1 Every 500 hours .......................................................................... 469
8.5.2 Every 1000 hours ........................................................................ 470
8.5.3 Every 2000 hours ........................................................................ 472
8.5.4 Every 4000 hours ........................................................................ 473
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1 Introduction
Copyright © Sandvik 15 (476)

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1.1 The purpose of these instructions

The purpose of these instructions is to promote intended safe, proper and
optimal use of Sandvik products and to help the user to identify, avoid and
prevent hazardous situations, and related consequences.
These instructions must be followed along with any instructions given in
local laws and regulations, any orders given by local authorities, and all
protective measures specific for the site.
Read and understand the complete manual carefully and follow given
instructions strictly. If there is anything you do not understand, ask your
employer or your local Sandvik representative to explain it. All sections of
this manual contain information which is vital for your safety. The manual
must be replaced immediately if lost, damaged or unreadable. For
replacement copies, please contact your local Sandvik representative.
When ordering replacement copies you must provide your Sandvik
representative with the following information of the product:
• Product model and serial number
• Manual types
• Number of paper copies or Toolman electronic manuals
• Language version of the manuals
• Delivery address
The instructions set forth in the operator’s and other manuals are to be
used as a part of the training material during orientation. By following these
instructions, safe practices will result, maintenance cost and downtime will
be minimized, and the reliability and lifetime of the equipment will be
optimized.
16 (476) Copyright © Sandvik

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1.2 Identification of the product

1.2.1 Product type and serial number
Product name: Drill rig

Product type: Sandvik DT820
The model and serial number of the product are shown on the identification
plate.
European Economic Area (EEA) Eurasian Economic Union

Other countries
countries (EAEU) countries
Identification plate location
1.2.2 Product manufacturer

Sandvik Mining and Construction Oy
P.O. box 100
33311 TAMPERE
FINLAND
www.sandvik.com

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1.2.3 Manuals
Product documentation includes the following manuals:
• The operator’s manual includes operating instructions, operator’s safety
considerations, and maintenance tasks for which an operator would be
responsible. It does not include maintenance procedures that should be
performed with less than daily frequency.
• The maintenance manual includes the preventative maintenance
schedule and a description of all scheduled maintenance tasks. It also
includes fluid and lubricant specifications and capacities. It does not
include occasional service, breakdown, or repair procedures.
• The parts manual includes part lists and illustrations for spare parts.
The model and serial number are shown on the identification plate (see the
section, "Product type and serial number"). Make sure that the model
corresponds to the one given on the cover of this manual.
Location of manuals on the product

The machine is equipped with document box(es) for the machine
documentation. The document boxes are located in the operator station.
1 2

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1 Document box for the tramming instructions

2 Document box for the manuals
1.2.4 How to identify the correct manual for the product

• Operator’s manual
The model for which product the manual is intended for is given on the
cover of the operator's manual.
• Maintenance manual
The model for which product the manual is intended for is given on the
cover of the maintenance manual.
• Parts manual
The model and serial number for which product the manual is intended
for are given on the cover of the parts manual.
1.2.5 Validity of the manuals
This manual, and especially the safety information, is valid only if no
unauthorized changes to the product are made.
Continuing improvement and advancement of product design might have
caused changes to your product which are not included in this publication.
Note also that if a third party has made changes to the product after
delivery from the manufacturer, this publication does not include information
on these changes or their influences on the product.
Whenever a question arises regarding your product, or this manual, please
consult your local Sandvik representative for the latest available
information.
1.3 Copyright notice

This publication is copyright of Sandvik Mining and Construction Oy - ©
Sandvik Mining and Construction Oy. It must not be copied, reproduced, or
otherwise made available in full or in part to any third party without Sandvik
Mining and Construction Oy´s prior written consent.
All Rights Reserved.

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1.4 Definitions
• Product: Machine, machinery, partly completed machinery, component
or tool, including related services
• User: The owner, operator or authorized and trained person involved in
the transportation, installation, operation, maintenance and disposal of
the product
• Information for use: The information in this manual, the safety labels
and signals on the product, and other related information used separately
or in combination to convey information to the user
• Harm: Physical injury or damage to health. This is always in relation to
people, not to equipment or property
• Hazard: Potential source of harm
• Risk: Combination of a probability of occurrence of harm and the severity
of that harm.
• Risk of property damage: Combination of a probability of occurrence of
property damage and the severity of that property damage
• Environmental risk: Combination of a probability of occurrence of
environmental damage and the severity of that environmental damage.
• Hazard zone: Any space within and/or around the product in which a
person is exposed to a hazard.
• Intended use of a product: Use of a product in accordance with the
information provided in the instructions for use.
• Prohibited use: Any use which is not intended use, especially use that is
specifically prohibited in the information for use or use which is plainly
dangerous.
• Safe working procedures: Practices and methods developed for users
by their employer for work to be performed. These detail how specific
risks in the workplace will be managed, taking into account information
for use supplied with the product as well as local acts, laws and
regulations.
• Safeguard: Guard or protective device.
• Guard: Physical barrier, designed as part of the product, to provide
protection.
• Protective device: Safeguard other than a guard, which reduces the risk
either alone or in conjunction with a guard; e.g., interlocking device, hold-
to-run control, limiting device.
• Emergency stop: Function which is intended to 1) avoid dangerous
situations or to reduce existing hazards to persons and damage to
product or work in progress 2) To be initiated by a single human action
• Emission value: Numerical value quantifying an emission generated by
a product (e.g., noise, vibration, hazardous substances, radiation).
• Exposure value: Quantifies the exposure of persons to emissions when
the product is in use. Exposure values can be estimated using the
emission values.
• Respirator: Approved respiratory protective device

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• ROPS: Roll-Over Protective Structure. Structure that has been designed

and constructed to reduce the possibility of a seat-belted operator being
injured should the machine rollover.
• FOPS: Falling Object Protective Structure. Structure that has been
designed and constructed to provide operators with reasonable
protection from falling objects.

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2 Safety and environmental instructions

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2.1 Safety labels, safety messages and signals

This section includes explanations of the safety symbols, signs, signals and
labels used on the product and in the information for use.
2.1.1 Signal words
The following signal words and symbols are used to identify safety
messages in these instructions:
The signal word, "DANGER", indicates a hazardous situation which, if not

avoided, will result in death or severe injury.
The signal word, “WARNING”, indicates a hazardous situation which, if not

avoided, could result in death or severe injury.
The signal word, “NOTICE”, indicates a situation which, if not avoided,

could result in damage to property or environment.
2.1.2 General hazard symbol
This general hazard symbol identifies important safety messages in this

manual.
When you see this symbol, be alert; your safety is involved. Carefully read
and understand the message that follows, and inform other users.

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2.1.3 Mandatory action symbols

Mandatory action symbols specify actions to be taken to avoid a hazard.
Mandatory actions are indicated by white symbols on a blue background.
All personnel working on or near the machine must understand and comply
with information given in all mandatory action symbols.
Wear protective gloves Wear eye-protector Wear safety helmet
Wear safety harness Wear hearing protectors Wear safety footwear
Wear protective clothing Wear high visibility Wear respirator

clothing
Disconnect from power Switch off and lockout Read the manual or in-
source equipment structions
Use cardboard for locat- Use two-point belt Use three-point belt
ing leaks in hoses
General mandatory ac-

tion symbol

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2.1.4 Prohibited action symbols

Prohibited action symbols indicate actions which are prohibited in order to
avoid a hazard. Prohibited actions are indicated by a red circle with a red
diagonal line across the circle. The action which is prohibited will always be
in black. All personnel working on or near the machine must understand
and comply with information given in all prohibited action symbols.
No climbing No smoking No open flames
Do not touch Limit or restrict access Do not weld
Do not remove safety Do not modify General prohibited ac-

guard tion symbol

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2.1.5 Hazard symbols

Hazard symbols are used to indicate the type of the hazard and the
potential consequences. Hazard symbols are indicated by a yellow triangle
with black symbols and black frames. All personnel working on or near the
machine must understand and comply with information given in all hazard
symbols.
Mechanical hazard symbols
Falling load hazard Crushing hazard Flying material hazard
Crushing hazard - feet Crushing hazard - Cutting hazard

hands
Entanglement hazard Entanglement hazard Entanglement hazard
Entanglement hazard - Slipping hazard Tripping hazard

rotating drill
Falling hazard Skin injection hazard High pressure injection

hazard
Hanging load hazard Run over hazard Sideways tipping haz-

ard

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Mechanical hazard symbols
Forward/backward tip- Sideways tipping haz- Sideways tipping haz-

ping hazard ard, from level position ard
Forward/backward tip- Sideways tipping haz- Remote controlled ma-

ping hazard ard, from level position chinery hazard
Electrical hazard symbols
Electrical hazard Dangerous electrical Electrical shock / Elec-

voltage trocution hazard
Thermal hazard symbols
Hot surface hazard Hot coolant splashing

hazard
Noise hazard symbols
Noise hazard
Radiation hazard symbols
Laser hazard Radioactive hazard

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Material/substance hazard symbols
Explosion hazard Fire hazard Hazardous/poisonous

material hazard
Chemical burn hazard Dust hazard Environment pollution

hazard
Ergonomic hazard symbols
Lifting hazard

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2.1.6 Labels on the product

The safety labels communicate the following:
• The severity level of the risk (i.e., signal word, "DANGER" or
"WARNING")
• The nature of the hazard (i.e., the type of hazard - cutting parts, high
pressure, falling objects, dust, live parts, etc.)
• The consequence of interaction with the hazard (i.e., cut, injection,
crushing, explosion, electrocution etc.)
• How to avoid the hazard
IMPORTANT! Keep the safety labels clean and visible at all times.
Check the condition of safety labels daily. Safety labels and
instructions, which have faded, been damaged, been painted over,
come loose or that do not meet the legibility requirements for safe
viewing distance must be replaced before operating the product.
Installing the safety label

1. Make sure that the temperature of the surface on the area where the
safety label is to be installed is more than +5°C.
Note! Sandvik recommends using Easywork Sprayclean degreasing agent
or equivalent for cleaning the dirty surface. It is important that the
agent does not leave any agent layer on the surface.
2. Clean the surface carefully of grease, oil, silicone and such dirt when
installing the labels and shields.
Note! Do not install the safety label on a hole. The stability and life cycle of
the safety label decrease significantly when dirt goes through the
holes on the back side of the label.
3. Put a masking tape as a corner on the upper edge and left side on the
surface for marking the position of the safety label.
4. Remove the cover paper carefully from the safety label to not get dirt on
the sticking surface.
5. Remove only the upper part of the cover paper if the cover paper is a
two-piece.
6. Fold the cover paper for one centimeter from the upper edge if the cover
paper is a one-piece.
7. Set the safety label carefully to its position on the marked corner and
press its upper edge tightly to the surface so that the safety label cannot
move.
8. Lift the lower edge of the safety label carefully so that the safety label
does not come loose from the sticking surface and remove the rest of the
cover paper (or the other part of the two-piece).
9. Pull the cover paper downwards to remove it.
Note! The safety label must be installed at once to its correct position to
make sure its stability.

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10. Make sure that the safety label is in the planned position.
Note! Make sure the spatula is clean that the safety label does not get
scratched.
11. Press the safety label to the surface from up to down with a spatula or
piece of carton.
12. Remove the masking tapes.
Note! The glue on the safety label gets full adhesion (sticking time) in 48
hours from installing.
Note! Do not wash the machine with a pressure washer during the sticking
time (48 hours).
13. Make sure that the machine is in the temperature of at least +5°C for
two to three hours after installing the safety labels.
Removing the old safety labels

1. Warm the surface of the safety label with a warm-air heater so that the
glue of the safety label warms.
2. Remove the safety label carefully with a metallic spatula.
3. Clean the machine surface, refer to step 2 in "Installing the safety label".
Note! Keep the safety labels clean and visible at all times. Check the
condition of safety labels daily. Safety labels and instructions, which
have faded, been damaged, been painted over, come loose, worn-out
to be as unreadable or that do not meet the legibility requirements
for safe viewing distance must be replaced before operating the
product.
4. Install a new safety label, refer to steps in "Installing the safety label".

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Safety, information and symbol labels

The diagram(s) below indicates the location of the machine's safety,
information and symbol labels.
* Optional label
** Only if the machine is equipped with TIER4 engine
Articulation area - left side, cabin
321 305
438 *
109
417 313
105
418
Articulation area - left side, canopy
321 305
438 *
109
417 313
105
418

ID: BG00471036 en-US C.001.1 2018-05-28
Articulation area - right side, cabin
325
313 109
322
105
305
108
Articulation area - right side, canopy
325
313 109
322
105
305

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Drilling module - left side
126 121
126 121
Drilling module - right side
121
126
121 126

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Front frame - left side, cabin
123 60
145 500
310 33
0
102 336
*
401
109
129
309 417
108
125
60
314
Front frame - left side, canopy
123
60
60 310
500
102
417
109 33
145
125
108
129
309
314
60

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Front frame - right side, cabin
60 123
128 500 310 145
0
33 102
109
129
309
60
108
125
*
406
*
407
Front frame - right side, canopy
60 123
310
60
500
102
109
33
128 129 145
309
125
108 60

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Front frame - front, cabin
*
137
60
303 303
Front frame - front, canopy
60
303

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Operator station - cabin
119
*
101 141 144 142 113
419 120 402.1 402.2

307
400
*
* 159
401
107
Operator station - canopy
307 130 107 316
101 141 142 113
120
402.2
119
400
402.1

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Rear frame - left side
*
* 132
179
*
174 * *
309 132 409
*
159
104
309
* * * *
167 411 308 502 179 111 179
304
129
324 40 303 311 314 110 60

ID: BG00471036 en-US C.001.1 2018-05-28
Rear frame - right side
*
502 124
* * * *
179 111 111 179 133 174
*
309 179
129
*
401
104
303
106
60 110 306 420 * 413 *
Rear frame - rear
60
* 103
127
* 112
412
416
60 60

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Rear frame - top
310
310
Utility boom (optional)
461 173 173
461
460 460
471
470 150
472 472
170
34 144
61 458 457 470

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455 455
456 456
Utility boom (optional) - cabin
252
470
458

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Utility boom (optional) - canopy
101 141 144 113
252
400 458 470
119

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Safety and information label descriptions
101 102 103
104
105 106
174
107 108 109

ID: BG00471036 en-US C.001.1 2018-05-28
112
110 111
127
113 119 120
121 123 124

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126
125 128
170
129 130 132
133 137 141

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145
142 144
173
150 159 167
179 252 400

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+ +
Extinguishing
Extinguishing + +
+ system
system release + FIRE
FIRE
400 401 402 EXTINGUISHER
+ + EXTINGUISHER
AT FIRE
AT FIRE
Stop
Stop engine
engine + +
Activate
Activatesystem
system
Turn off
Turn off master
masterswitch
switch
Cut off
Cut off fuel
fuel
If fire
If fire not
notout,
out,
use hand extinguisher
+ use hand extinguisher +
Only CAN/USA
S ≤ 15 mg/kg
S ≤ 10 mg/kg ULTRA LOW SULFUR FUEL ONLY
ULTRA LOW SULFUR FUEL ONLY
403 403
EN ID = 55194064
EN ID = 55207589
Only CAN/USA

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Symbol label descriptions
Ref. Description Symbol label
303 Tie down point
BG00394347
304 Battery isolation switch
305 Rotation direction
306 Fuel tank / filling the tank
307 Stopping diesel engine
BG00407280
308 Venting of water pump
309 Tire pressure
310
Lifting point
461

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Open the battery isolation switch and discon-

nect the both battery cables (+ and -) and
311
disconnect connectors from the ECM before
welding the rig.
313 Additional cooling
314
411 Oiler drainage
413
316 Hydraulic oil temperature
321 Powerpack left
322 Powerpack right
324 Battery
ID=BG00962700
325 Hydraulic oil receiver

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336 Windshield washing liquid
406 Valve handle operation positions
407 Grease unit
409 Water tap
412 Air inlet
416 Water inlet
417 Central greasing
418 Identification plate

55055051- B

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418 Identification plate, CE
418 Identification plate, EAC
55055051- B
419 Hazardous voltage
419 Hazardous voltage
420 Antifreeze agent valve
438 Hydraulic oil return pressure
Air pressure
Water pressure

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Compressor air filter
Percussion pressure
Rotation pressure
Feed pressure
Stabilizer pressure
The following symbol labels are valid only if the machine is equipped
with a utility boom:
Jack monitoring, right front jack
Jack monitoring, left front jack
Jack monitoring, right rear jack
Jack monitoring, left rear jack
455 Max. surface force front jacks

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456 Max. surface force rear jacks
457 Max. horizontal force
458 Utility boom min. operating temperature
460 Anchorage point

ID = 55202281
Max. 510 kg=

+310 kg
470 Basket max. load without safety canopy
ID=55099041
470 Basket max. load with safety canopy
Max. 330 kg=

+130 kg
470 Basket max. load with sliding safety canopy
ID=BG00520206

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471 FOPS label (with safety canopy)
472 Safety canopy locking
2.1.7 Visual and audible signals

The machine is equipped with the following visual and audible safety
signals:
• Reverse alarm: The reverse alarm switches on when the drive selector
is set to reverse position. The alarm sound is frequent beeping.
• Warning and function signals: The warning and function signals give
important information on the machine operating status, functions,
warnings and alarms. Warning and function signals inform the operator,
for example, of oil levels, brake pressures and engine functions. For
more information, see the section, "Description of controls and functions"
in the operator's or maintenance manual.
• Horn: The horn releases a loud sound and can be used to warn others in
dangerous situations. The horn push button is located in the tramming
panel. For more information, see the section, "Description of controls and
functions" in the operator's or maintenance manual.
• Beacon (optional): The beacon is located at the top of the safety cabin/
canopy. The beacon flashes a yellow light when the machine is on gear.
The beacon can also be activated manually.
• Fire suppression system signals (with fire suppression system
option): The alarm will sound and release a loud siren when the fire
suppression system is activated. Depending on the type of the fire
suppression system, there can also be visual alarms. For more
information, see the section, "Fire risk control measures".

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2.2 User obligations
WARNING
IGNORING INSTRUCTIONS HAZARD!
If you do not understand any information related to your duties in the
operator's or maintenance manual you MUST make sure that you get
clarification from a person who is well trained with regard to the task
you want to do. When necessary, you or your representative must
contact a Sandvik representative to seek clarification as to how you
should do the task.
The safe use of a product depends on, among other things, a combination
of the design and construction measures taken by the manufacturer, the
skills of the operators, and protective measures taken by the user.
Instructions are an essential and integral part of the product and they must
be always available for the users. It is important to pass on the information
for use to any subsequent user of this product.
Sandvik prohibits the consumption of drugs and/or alcohol or any other
substance likely to impair judgement while using, being in the hazard zone
of, or supervising the use of a Sandvik product.
Safety information covers the following: transport, commissioning, use,
operation, cleaning, troubleshooting, maintenance and disposal of
machinery. If you need more detailed instructions, you must contact your
local Sandvik representative.
As part of ensuring the safe use of the product, you as the user are
responsible for the following:
• Use of Personal Protective Equipment (PPE)
• Scheduled testing and maintenance of safeguards and protective devices
• Provision and use of additional safeguards
• Regular training regarding site safety and safe working procedures
In addition, you must always be familiar with the following:
• Site organization and supervision
• Workplace safety, including safe working procedures
• Permit-to-work systems
All near-miss incidents and accidents where a Sandvik product has been
involved must be reported to your local Sandvik representative without
delay. See also the section, "Incident reporting".
The following safety guidelines apply to each person working with the
product or in the vicinity of the product. Every single person is responsible
for his or her own safety and for the safety of his or her colleagues. In case
of violation of any safety guidelines or regulations, everyone has a duty to
warn others and report near misses or any safety violation to the
responsible supervisor.

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2.2.1 Managing work related hazards

The user must always perform a local risk assessment before every new
task, e.g., work phase or shift. This assessment, also known as a Real
Time Hazard Analysis, ensures that the user stops and thinks about what
he or she is going to do before starting to work:
• Identify potential hazards that could impact you, your colleagues, the
environment, your product and/or work method while you are performing
the task.
• Assess the risks and implement the actions needed to eliminate or
reduce the risks.
Only competent persons may carry out operation and other tasks. The
employer must:
• Provide training and orientation
• Validate training methods
• Verify competence and skills
• Monitor and evaluate user performance regularly
2.2.2 Scheduled safety inspections and preventive maintenance
It is important to thoroughly inspect the product before use to make sure it
is safe to operate. Look for defects and damage before any operations.
Report any defects. Do not operate the machine if critical defects are
present. For more information, see the section "Operating Instructions" in
the operator's manual.
Scheduled maintenance is an essential procedure to ensure and maintain
safety and performance of the product. Follow the specified instructions for
the maintenance and inspection of product. For more information, see the
section "Periodic Maintenance" in the maintenance manual.
WARNING!
The use of unauthorized parts presents an uncontrolled risk and
could cause death or severe injury. The use of unauthorized parts
will also invalidate warranty.
It is the user's responsibility to use only authorized parts as listed in
the parts manual!

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2.2.3 Personal protective equipment

Operators and anyone in the vicinity of the product MUST wear approved
personal protective equipment, which includes but is not limited to:
• Safety helmet
• Eye-protector
• Hearing protectors
• Safety footwear
• Respirator
• Protective gloves
• Protective clothing
• Safety harness when working at heights
• High visibility clothing
Do not wear loose clothing or jewelry that can get caught on controls or
pulled into moving parts of the product.
Tie back long hair. Long hair can get entangled, which could cause death or
severe injury.
Beware of the cap lamp cable. The cable can get caught or entangled on
the control devices which could cause death or severe injury.

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2.3 Product limitations

2.3.1 Intended use
The drill rig has been designed for:

• Drifting in underground mines and tunneling
• Face drilling
• Cross cut drilling
• Bolt hole drilling
In addition, the drill rig is intended to be used in following conditions:
• Ambient temperature limits: 0 °C to +40 °C (if ambient temperature is not
within these limits, contact your Sandvik representative)
• Altitude limits: max. +3000 m, min. -2000 m (if altitude is not within these
limits, contact your Sandvik representative)
• Sufficiently ventilated area
• Non-explosive atmosphere
• The power supply (voltage, frequency) marked on main switchgear type
plate. The voltage does not vary more than ±10% of the rated voltage in
any operating situation.
Power supply to the drill rig must include the following:
• Overload protection
• Short-circuit protection
• Earth fault protection
• Other protection, such as control cable and screened cable, if required by
the national standard
The above mentioned protections must be adjusted according to the
machine trailing cable size.

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2.3.2 Prohibited use

The following uses are prohibited:
• Use which is not in accordance with the intended use as described
above.
• Use of product for any other purposes than those instructed in the
operator's and maintenance manuals.
• Use of product for towing.
• Use of product for personnel transport.
• Use of product for transporting unsecured items (for example drill rods/
bits).
• Use of utility boom (if equipped) for transporting items.
• Use of drilling boom(s) for lifting purposes.
• Use of product for moving objects (for example loose boulders).
• Bypassing or overriding machine safeguards for any reason.
• Use of product without required and approved personal protective
equipment.
• Use of product without required and approved training.
• Use of product when unauthorized personnel are in the working area.
• Use of product when a fault is detected.
• Use of product when the power supply voltage varies more than ±10% of
the rated voltage in any operating situation.
• Use of product on insufficiently scaled and/or unsupported drilling area.
• Use of product when lighting conditions are insufficient.
• Welding of product
• Tramming or otherwise moving the product when personnel, who are not
seated nor using a seatbelt, are on board the product.

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2.3.3 Center of gravity

Location of the center of gravity varies depending on the optional devices.
Location of the center of gravity when the drill rig is in tramming position is
represented in the figure(s) below.
7°

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2.3.4 Maximum inclination angles
WARNING
TIPPING HAZARD!
Incorrect tramming or parking procedures could result in death or
severe injury.
Do not tram, park or operate the machine on a slope that exceeds the
maximum inclination angles.
The machine's inclination angle indicators are located in the operator

station.
During tramming and parking

During tramming and parking, the maximum inclination angles are allowed
only when the booms are in tramming position.
The maximum front tilt angle during tramming and parking is 15°.
The maximum side tilt angle during tramming and parking is 5°.

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During drilling operation
The front tilt angle during drilling operation shall be approx. 0° (The drill rig
must be as horizontal as possible.).
The side tilt angle during drilling operation shall be 0°.
When the machine has been leveled with the jacks to correct working
position, the boom(s) can be moved to drilling position.
2.3.5 Operator visibility
When operating the machine, always remember that visibility is limited.
Ensure that unauthorized persons are not present in the vicinity of the
machine.

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2.3.6 Modifications
WARNING
MODIFICATION HAZARD!
Unauthorized modifications could lead to death, severe injury or
property damage.
Always contact a Sandvik representative in order to get advance
written approval for any modification.
All modifications and corrections not authorized in the product manuals 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 or environment.
Unauthorized modifications will also void the warranty.
If modifications and alterations 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.
If a modification or correction as described above has been implemented
without the manufacturing organization’s permission, its effect on warranty
liability will be considered case-by-case. Thus, the warranty application
may be rejected altogether.
Should you consider a modification or alteration necessary, you must
contact the organization that manufactured and designed the product. No
modification is permitted unless you first obtain the written approval of the
manufacturer.
In order to plan and implement the modification you must deliver adequate
documentation:
• Product model/type
• Serial number of product
• Description of the modification or correction
• Related blueprints
• Related photos
• And other material, if necessary

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Installing supplementary systems on the machine

In some operating conditions it may be required to install supplementary
systems on the machine. These might be systems that are required in order
to comply with the industrial safety requirements valid for enterprises
operating dangerous industrial facilities. In case the customer decides to
add to the machine any specific systems, the customer solely takes the full
responsibility for such a system. The customer shall also perform a risk
assessment, as well as train the operating and maintenance personnel to
the correct use and service of the system. Any such modification must be
done in a way that it does not compromise the machine safety and integrity.
Prior to installation, the system interface to the machine has to be approved
by Sandvik.
2.4 Hazard zones
WARNING
MOBILE MACHINERY HAZARD!
The moving machine and its moving parts could cause death or
severe injury.
Ensure there is nobody in the hazard zone during operation.
During tramming without reeling the hose or cable

The hazard zone, when tramming in a tunnel without reeling the hose or
cable, extends 5 meters on both sides of the rig and 5 meters on the front
and rear. Ensure that there are no persons in the hazard zone during
tramming.

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During tramming while reeling the hose or cable

The hazard zone, when tramming in a tunnel while reeling the hose or
cable, extends 5 meters on both sides of the rig, 5 meters on both sides of
the outreeled hose and cable and 5 meters on the front and rear. Ensure
that there are no persons in the hazard zone during tramming.

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During drilling operation

The hazard zone during drilling operation begins at the front axle and
extends forward.
If access to the hazard zone is necessary, ensure that accidental actuation

of drilling and boom controls have been prevented. For a work of short
duration in the hazard zone, the drilling module movement prevention
switch can be used to prevent drilling and boom movements. Tasks which
may require short term access to hazard zone could include e.g. changing
a drill bit. If a longer working time is required, shut down the power pack(s)
before entering the hazard zone. Refer to operator's manual for
instructions.
Ensure that there is no risk of falling rocks or other hazards before entering
the hazard zone.

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2.5 Safeguarding
2.5.1 Guards
WARNING
DO NOT REMOVE OR MODIFY GUARDS!
Operation without the guards in place is dangerous and could cause
death or severe injury.
Removing or modifying the guards is strictly prohibited! Before
operation, always make sure that the guards are undamaged and in
place.
FOPS/ROPS (Falling Object Protective Structure / Roll-Over Protective

Structure)
The machine is equipped with a safety canopy/cabin. The canopy has been
granted FOPS approval according to EN ISO 3449. The cabin has been
granted FOPS and ROPS approvals according to EN ISO 3449 and EN
ISO 3471. However, cabins made of acid-proof steel are only granted
FOPS approval. Never make any alterations to FOPS/ROPS structures.
Making any alterations will void the machine's FOPS/ROPS approval. No
welding, drilling, cutting or other form of alteration of any kind is permitted
on a certified FOPS/ROPS structure. In the event of an accident, a modified
FOPS/ROPS can fail to protect the operator and result in death or severe
injury. All damaged structures must be replaced before using the machine.
Never attempt to repair a protective structure.

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2.5.2 Location of the guards

The diagram below indicates the location of the machine's guards.
3 15 14 17 6 12 10 19 16 18 1 20
8 7 11 9 13 19 2 18 4 20 5
Safety cabin and optional Safety canopy and option-

Protection cover and
1 safety grate (only in cabin 1 al safety grate (only in 2
sleeve for hydraulic hoses
model) canopy model)
Protection plates under oper-

ator station to protect against Control system covers un-
3 Machine covers 4 5
pin hole leaks (only in cano- der drilling control panel
py model)

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Thermal insulation for tur-

Trailing cable junction box
6 bo and exhaust manifold 7 Slip ring unit cover 8
cover
and piping (optional)
Drive shaft protection cov- Guards on rotating diesel Guards on rotating com-
9 10 11
ers engine fans pressor fans
Guard on diesel engine al- Power pack coupling cov- Battery compartment cov-
12 13 14
ternator belt er er
Protection plate on canopy

Main switchgear cabinet Water pump coupling cov-
15 16 tube (only in canopy mod- 17
door er
el)

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Step box cover on both Side box cover on both Boom taper pin hole
18 19 20
sides sides cover

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2.5.3 Protective devices
WARNING
TAMPERING HAZARD!
Bypassing or overriding of a safeguard or a protective device could
cause death or severe injury.
Do not make any alterations to protective devices. Make sure that
they are in place and work properly before operating the machine.
The machine is equipped with several protective devices which are

designed to reduce risks to the users. Do not modify the protective devices;
they must always be operable and in place. Remember that regular
preventive maintenance is required. Follow all the instructions for
scheduled maintenance provided in the maintenance manual. In addition to
the maintenance manual, section "Description of controls and functions" in
the operator's manual, as well as these safety and environmental
instructions give information on the protective devices.
The protective devices in the machine include but are not limited to the
following:
• seat belt
• cable reel limit switch
• battery isolation switch
• main switchgear cabinet interlock
• carrier frame joint locking bar
• drilling module movement prevention switches
• basket's safety gate (only with utility boom)
• safety wire on the feed (only with rod retainer)
In addition, the machine has hold-to-run controls, such as boom controls,
throttle pedal, safety canopy controls, hydraulic oil electric filling pump
control, rattling control and optionally buttons on the remote control for
reel(s).
Note that some of the protective devices are delivered as optional
equipment and must be ordered by the purchaser.

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Seat belt
The seat belt is a two-point lap belt with an adjustable strap. Its purpose is
to secure the operator of a machine against harmful movement that may
result from a collision, loss of balance or a sudden stop.
The seat belt must always be fastened during tramming.
Carrier frame joint locking bar

WARNING! CRUSHING HAZARD!
Unexpected movement of machine can cause severe crushing
injuries.
Never enter the center articulation area when the engine is running.
The carrier frame joint locking bar is located between the front and the rear
frame of the machine.

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The locking bar is provided to prevent unplanned movement of the carrier

frame joint and its main purpose is to protect personnel during
maintenance. The locking bar has been constructed from solid steel bar
and secured with pegs and locking pins.
The locking bar must be installed before starting any maintenance work,
before transportation or before lifting the machine.
To install the locking bar, proceed as follows:

1. Ensure the machine is in a straight position.
2. Shut down the engine and remove the ignition key.
3. Remove the frame locking bar from its bracket.
4. Remove the front and rear frame pins from the frame lugs and insert the
locking bar into the middle of the frame lugs.
5. Insert the front pin into the lug holes on the front frame and lock it.
6. Insert the rear frame pin into the upper lug hole.
7. Climb into the operator station and start the engine.
8. Slowly move the steering a bit from left to right until the rear frame pin
drops down into the lower lug hole.
• Note! To avoid damaging the machine the locking pin must be
carefully observed during installation. When the pin drops down to its
lug hole, stop turning the machine.
• It is necessary to have a second person assist the operator because
it is difficult to observe the locking pin from the operator station. The
assistant should stand at a safe distance from the machine, watch
the bar's movement and use hand signs to notify the operator of the
bar's movement.
10. Climb out from the operator station and ensure the bar is properly fixed
and lock the rear frame pin.
To remove the locking bar, proceed as follows:
2. Remove the pins and the locking bar.
If the pins are stuck:
• Climb into the operator station and start the engine.
• Slowly move the steering a bit from left or right to release pressure
against the pins.
• Climb out from the operator station and remove the pins and the
locking bar.
• Never attempt to remove the pins and locking bar while the
engine is powered on.
3. Install the locking bar back to its bracket and place the pins back to the
frame lugs.

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Basket's safety gate

WARNING! FALLING HAZARD!
Falling from the basket could cause death or severe injury.
Ensure that the safety gate is closed and locked whenever working
in the basket.
Safety wire on the feed (only with rod retainer)
There is a safety wire (1) at the front side of the feed. Pulling this wire will
stop all ongoing functions. Restarting the machine is not possible until the
safety wire switch has been manually reset from the reset button (2). The

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reset button is located at the side of the feed. Resetting can only be
performed when the pointer is visible on the range (A). When the safety
wire switch has been reset, the yellow pointer (B) will change to green. This
manual resetting does not restart the machine. It only permits restarting the
machine.
There is also a bypass button (3) in the operator station. With this button,
restarting can be permitted when and only when all ongoing functions were
stopped due to safety wire. Bypass button may be pushed down only in
order to get the boom down for resetting the safety wire switch. Make sure
there is nobody in a hazardous situation when using the bypass button.
When the button is released, all ongoing functions will stop again.

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2.6 Complementary protective measures

2.6.1 Use of emergency stop function
The machine is equipped with several emergency stop devices. To stop the
machine immediately in an emergency, use the nearest emergency stop
device.
When one of the emergency stop devices is activated, all ongoing functions
are stopped. The emergency stop remains engaged until it is manually
reset. This manual resetting does not restart the machine. It only permits
restarting the machine.
Note! Check the functioning of the emergency stop devices daily. Make
sure that the emergency stop devices can be accessed at all times.
Emergency stop button(s)

The machine emergency stop buttons are red push buttons on a yellow
background. The emergency stop function is activated by pressing down
one of these buttons. The emergency stop is reset by releasing the same
button that activated the emergency stop. The emergency stop button can
be released by turning the button.
Locations of the emergency stop buttons are represented in the figure(s)
below.

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3 2
1
1 1
1
2.6.2 Emergency exit

The machine operator station has two natural exits, which can be used also
as emergency exits. In an emergency situation, use the safest escape way.

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2.6.3 Safe access to machine and three-point support

Three-point support means keeping simultaneously two hands and one foot
or two feet and one hand in contact with the machine while ascending,
descending or moving about on the machine.
Use grab handles and steps provided to maintain 3 or 4 points of body
contact (three-point support) with the machine and keep your face towards
the machine while ascending or descending on the machine.
Keep all stairs, rails, anti-slip surfaces, steps, etc. clean of oil, grease,
snow, ice, debris, unnecessary items, and dirt to prevent accidents. Never
use the components of the machine as steps. If the work is carried out at
heights, or in an otherwise dangerous position, use proper working
platforms and safety harness, when required, to prevent falling. Never climb
on the machine's covers. Do not step aboard or hop out of a moving
machine.
Always consider the shape of the ground when stepping out of the
machine. If needed to ensure safe passage out of the machine, move the
machine to a better location.
WARNING! SLIPPING, TRIPPING AND FALLING HAZARD!
Slipping, tripping or falling could cause death or severe injury.
Use the access ways and maintain a three-point support. Keep all
access ways clean.
Safety coloring
The access ways are marked with a yellow safety coloring. If the safety
coloring wears off or its visibility otherwise is weakened, the coloring needs
to be fixed. The coloring is fixed by painting or by adhesive tape, see the
spare part number of the adhesive tape in the parts manual. The paint can
not be purchased as a spare part. To purchase the paint, contact your local
paint store. The color code of the paint is RAL 1016.

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2.6.4 Isolation and energy dissipation
WARNING
HAZARDOUS STORED ENERGY!
This machine contains stored energy in various forms. The energy
could cause unexpected consequences, death or severe injuries, if
not dealt with properly.
Before any maintenance or service work, make sure the machine is
isolated and stored energy is released.
Leave maintenance work to professionals. Follow applicable
instructions.
The machine should be isolated before performing any maintenance work.

The purpose of isolating machinery is to allow work to be undertaken safely
with no danger to life, or injury to people, or possibility of property damage.
Any instructions given in laws and regulations, any orders given by local
authorities, and all protective measures must be strictly adhered to. Check
the isolation requirements and ensure compliance before starting the job.
Maintenance and repair work on the pressurized systems may only be
carried out by persons who have received the training required for the work.
Do not start work that is not fully familiar to you.
Hydraulic system isolation

WARNING! HAZARDOUS STORED ENERGY!
There may still be pressure remaining in the system even when the
gauges show 0 bar.
Proceed with caution when working with hydraulic systems. Use
approved personal protective equipment.
When the machine is switched off, be aware that there is still stored
pressure in the hydraulic system. Hydraulic system can store pressure in
the brake circuit accumulators and rock drill accumulators, as well as in
machine components which are supported by the hydraulic system. All
major machine assemblies should be lowered to the ground or supported to
isolate any hydraulic energy.
Release pressure from the brake accumulators as follows:
• Shut down the engine.
• Turn the ignition switch to the middle position.
• Press the brake pedal several times.
• Review the pressure gauges in the tramming panel to verify that the
brake system has released pressure. Gauges should show 0 bar.

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Release any stored rock drill accumulator pressure by opening the filling
valve of accumulator and verifying zero pressure on adjacent pressure
gauge. Never direct the discharge opening at anyone. Always direct the
discharge opening to an empty area to protect those in the immediate
vicinity.
In spite of these precautionary measures, some of the hydraulic system's
subsystems may still be pressurized (e.g. boom circuit, rod handler circuit,
rod retainer circuit). Always use approved personal protective equipment
and proceed with caution.
Air system isolation

If the air system is equipped with an open-type 2/2- directional valve, it
automatically releases the pressure from the air system when the
compressor and power pack are switched off. If the air system is equipped
with air receivers (optional), it will take longer to depressurize the system.
In spite of these precautionary measures, the system may include some
subsystems, from which pressure has not been released. When performing
any maintenance or repair work, always use approved personal protective
equipment. Proceed with caution and comply with all safety requirements.
Fuel system isolation

If the fuel filter is equipped with a shutting tap, isolate the fuel system by
using the tap. This will prevent any environmental contamination during
maintenance.
Electrical system isolation

Before performing any maintenance work, always ensure that the machine
is disconnected from the power supply. Make sure that the machine cannot
be started accidentally.
Isolate the machine as follows:
• Turn off and lock the main switch and remove the power plug from the
electrical network.
• Turn off and lock the battery isolation switch.
• Place DANGER - DO NOT START warning signs on every switch. Do not
remove the warning signs unless you are fully aware of the current status
of the work and have verified that all maintenance work is complete.
Follow all the instructions and protective measures specific for the site.
• Remove the ignition key.
• Ensure that the machine is not live.
• Ensure that nobody turns the power on by accident.

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Location of the main switch(es)
1 2

2 Main switch
Battery isolation switch (S1)
The battery isolation switch turns on/off the current from the carrier's battery
to the drill rig's electric circuit.
• The battery isolation switch (S1) has to be in the ON position when the
drill rig is being used.
• On the tramming panel, there is a remote button (S10) that controls the
battery circuit's main fuse (F1). this same button (S10) is used to cut off
the power to the carrier.
• The battery isolation switch (S1) does not stop voltage from flowing to all
devices in the carrier. Voltage remains in the beacon control (optional)
and Secondary Power System [SPS] (optional). Even if the battery
isolation switch (S1) has been opened, if the main switch (Q100) is ON,
the main electric system continues to feed voltage to the carrier's
systems.
If the drill rig is equipped with an optional pilot circuit (pilot = continuity of
the protective bonding circuit):
• The remote button (S10) cuts off power flowing to the carrier and the pilot
circuit, which immediately causes the main power to be turned off.

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• The diesel engine power switch must be in the OFF position when the
remote button (S10) is pressed. If it is in ON position, the diesel engine
power switch will cut the pilot circuit off, which causes the main power to
be turned off.
Main switch (Q100)
The main switch turns power supply to the drill rig on/off.
Note! The main switch does not turn off the voltage at the cable reel or the
slip ring unit.
The main switch can be locked in the 0-position. When the main switch is
set to position 1 (ON), the electrical cabinet door cannot be opened.
2.7 Fire risk control measures
WARNING
FIRE AND EXPLOSION HAZARD!
An explosion hazard could exist in addition to the fire hazard.
Ignition sources like smoking, open flames, welding work and sparks
together with combustible materials like fuel, can cause fire and if
not avoided, could lead to death or severe injury.
Ignition sources are prohibited in the vicinity of the machine ready
for operation or in operation.
During maintenance appropriate fire prevention and protection
measures must be followed including but not limited to trained
personnel, proper fire extinguishing equipment and agents. Before
any maintenance or repairs requiring ignition sources like welding or
flame cutting, a proper risk assessment must be carried out prior to
the start of the work to control the risk.

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Smoking and open fire are prohibited in the vicinity of the product. Access
to all fire-fighting equipment must be granted at all times, especially during
maintenance and repair works.
All fire-fighting equipment must be inspected and serviced regularly,
according to local regulations. Damaged fire-fighting equipment and used
fire extinguishers must be replaced immediately.
Know the various types of fires and the appropriate fire-fighting methods.
Be aware that various fires must not be extinguished with water. In most
cases special extinguishing agents, dry powders or deoxygenating are
required.
All personnel must be trained regularly in fire-fighting methods, in
cooperation with local authorities and rescue organizations. In case of fire,
the fire alarm must be activated and all available personnel must contribute
in the fire-fighting according to the predetermined fire plan of the workplace.
2.7.1 In case of fire
Fight the fire as follows:
1. Stop the machine safely.
2. Press the emergency stop button.
3. Use a hand-held fire extinguisher, if possible.
4. Turn the battery isolation switch and main switch into the OFF-position.
5. Actuate the fire suppression system (optional) and use a hand-held fire
extinguisher, if possible. Note! Actuation of the fire suppression system
releases immediately a notable amount of foam/powder which may
obscure vision.
6. Be prepared with a hand-held fire extinguisher to fight any new fire
pockets.

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2.7.2 Fire prevention

Fires in any environment are extremely dangerous and can quickly get out
of control if not properly dealt with.
The following recommendations will help prevent the likelihood of a fire on
the machine:
• Always keep the machine and general area clean of flammable materials
such as fluids and lubricants, dirt and debris, and any material that could
cause or amplify fire. Clean all fuel or oil spills as quickly as possible.
• Report all electrical wiring and electrical component malfunctions to a
service personnel immediately.
• Ensure that the engine air intake, fuel and exhaust systems are
maintained properly.
• Inspect the machine regularly for hydraulic and oil leaks.
• Ensure that you are aware of and are familiar with all fire fighting
equipment on the machine. Also ensure that all fire fighting equipment is
inspected regularly and kept in working order. If the machine does not
have any fire fighting equipment, ensure that required fire fighting
equipment is available.
2.7.3 Fire retardant and flammable materials
The machine fire safety has been taken into consideration during product
engineering and manufacturing. When possible, fire retardant materials
have been chosen to improve fire safety. Examples of these measures and
material choices to prevent and control fires are the following:
• Cables used are in compliance with the IEC 60332-1 standard (Test on
electric and optical fibre cables under fire conditions).
• Surface materials of the hydraulic hoses, cable protective hoses and fire
suppression system (Ansul) hoses are MSHA approved and their inner
tubes are made of nitrile-rubber.
• Switchgears and slip ring unit are mainly made of metal.
• Fire area with fire wall has been made for the diesel engine.
• Roof panels in the cabin are made of fire retardant material.
• Cables in the engine compartment are inside a fireproof sleeve.
In spite of engineering and use of fire retardant materials, there are also
flammable materials in the machine e.g. inside switchgears, in valves,
plastic components, batteries and tires. Also oils, greases and paints used
in the machine are flammable materials. Keep the machine clean at all
times; dirt in the machine increases fire risk.

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2.7.4 Fire suppression
Fire extinguisher(s) (optional)

A fire extinguisher is an active fire protection device which is used to
extinguish or control small fires, often in emergency situations.
Location of the fire extinguishers
A B
A Cabin
B Canopy
Using a fire extinguisher

All workers must know how to operate a fire extinguisher. Fire extinguishers
are different and that is why the user has to know how to use that specific
extinguisher which is available in case of fire.
The instructions below are indicative. Familiarize yourself with the
instructions printed on your extinguisher in advance.
1. Take the extinguisher from bracket.

2. Pull out the locking pin.
3. Take out the extinguishing gun from the holder and press down the
release lever.
4. Extinguish the fire source from the bottom at a distance of 4 m.
5. Press the extinguishing gun, fan out the extinguishing agent.
6. Send the fire extinguisher immediately for refilling after use.
Maintenance shall be performed annually by an authorized manufacturer
distributor.

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ANSUL Fire suppression system (optional)

The ANSUL fire suppression system is installed in the machine for fire
suppression. The system is a cartridge operated dry chemical system with
fixed nozzle distribution network. The system can be either manual or
automatic.
Note! The system is not designed or intended to extinguish all fires. It
extinguishes mainly fires in the engine compartment. It is extremely
important that alternative fire fighting equipment is available in case
the system does not totally extinguish a fire.
The location of the fire suppression nozzles and manual actuators are

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Manual ANSUL fire suppression system

The manual fire suppression system is actuated manually by push buttons.
When a push button is pushed down, fire extinguishing chemicals are
released through the system nozzles.
Actuate the system as follows:
1 2
1. Remove the ring pin (1) on the actuator.

2. Strike the red button (2).

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Automatic ANSUL fire suppression system

Note! Automatic fire suppression system is disconnected during machine
transport and must be reconnected before machine is taken into use.
While disconnected, the automatic fire suppression system can be
manually operated from the manual actuator.
WARNING! FIRE HAZARD!

Fire could lead to death or severe injury.
Reconnect the automatic fire suppression system before taking the
machine into use.
The automatic fire suppression system includes an alarm, automatic fire

detection system and automatic fire extinguishing.
When fire breaks out, the system actuates automatically and releases fire
extinguishing chemicals through the nozzles.
The system is controlled by the control unit. The control unit is represented
below.
2
1
3
4 5 6
1 Detection indicator LED 2 Power LED

3 Guard door 4 Delay/Reset/Silence button
5 Release indicator LED 6 Manual activation button and
alarm LED

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Reconnecting the automatic ANSUL fire suppression system
2
6
1
1. Remove electric-pneumatic actuator's dust cap (4). Store the cap for later
maintenance.
2. Attach PAD (3) to release circuit drop cable (5).
3. Verify O-ring (2) on PAD is in place.
4. Attach release circuit drop cable (5) to electric-pneumatic actuator (1),
hand tighten, do NOT use tools when tightening.
5. (For CF210) Ensure that the isolation switch (6) in the interface control
module is disabled.
Engine switch-off system with ANSUL (optional)

The engine switches off automatically 5 seconds after the fire extinguishing
system has been actuated. To avoid automatic switch-off, immediately
press and release the delay button on the control unit. Pushing the delay
button will postpone the automatic engine switch-off by 5 seconds. If
necessary, use the button until you have found a suitable parking place.
Sandvik fire suppression system (optional)

The Sandvik fire suppression system is a fixed foam fire suppression
system. The primary function of the system is to protect the operator. It
greatly reduces risk to people, property and environment by providing
effective fire protection and, therefore, safer operating conditions. The
system has been specifically designed to suppress hydrocarbon fuel and oil
fires by application of liquid extinguishing agent. The agent will cut the fire's
oxygen supply off and act as a vapor seal over the fuel.
Sandvik Eclipse™ Sustain is suitable for ambient temperature above 0 °C
due to the water content in the fluorine free liquid extinguishing agent.
Sandvik Eclipse™ Extreme is suitable for ambient temperature below 0 °C
or 32 °F.
The discharge circuit nozzles are arranged in the form of a ring. It consists
of fire rated hose with a series of nozzles aimed at the risk areas.

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The location of the fire suppression nozzles and manual actuators are
1 2
1 2
Activating the Sandvik fire suppression system

The system can be actuated both manually and automatically. After
activation, the nozzles spray a full cone pattern of extinguishing agent.
Various sizes of tanks are available to provide adequate area coverage and
cooling for post fire security.

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Manual activation of the Sandvik fire suppression system
1 2
Actuate the system by turning the activation module valve handle (1) 90
degrees in direction of arrows (counterclockwise).
The safety tie (2) breaks itself. The safety tie must always be replaced after
activation.
Automatic activation of the Sandvik fire suppression system

The system is activated automatically by the fire detection and system
activation tubing when the heat caused by the fire reaches approximately
150 °C.
Note! The system may activate automatically, but if you observe fire on the
machine, always activate the system manually.
Engine shutdown kit with Sandvik fire suppression system

The engine shutdown kit's primary function is to detect when the fire
suppression system is activated and to provide the operator with an
audiovisual alarm. After a delay period, the engine will shut down.
The kit contains a double pressure switch (3) and an electronic alarm/timer
box (4).
3 4
Double pressure switch

The double pressure switch is factory set to 900 kPa falling and will switch
contacts if and when the system pressure falls below the setting of the
switch. Such a drop of pressure can be due to system activation or
pressure loss from a leak.

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Electronic alarm/timer box
5 4
1
2
6
3
1 Green indicator light for tank 2 Yellow warning light for low
pressure OK tank pressure
3 Red warning light for system 4 Engine shutdown delay timer
fault or discharge of 6 seconds with 20 seconds
time extension button
5 Engine shutdown test button 6 Key operated engine shut-
(simulating system dis- down override (for authorized
charge) personnel only)
The double pressure switch is wired into the electronic alarm/timer box. If
turned on, the double pressure switch will trigger an audiovisual alarm
(warning light (2) or (3) will turn on and an audible alarm will sound). When
the pressure starts to drop, the 6 second delay timer will begin.
Timers are factory set to an automatic 6 seconds, with a 20 second manual
timer reset. If there is no operator intervention, the automatic engine
shutdown will occur 6 seconds after the fire suppression system is
activated. If the shutdown button (4) is pressed during the 6 seconds
countdown, the timer will reset to extend the delay by an additional 20
seconds delay. The additional time allows the operator to have both hands
free to drive the machine for another 20 seconds before the engine
automatically shuts down.
The alarm/timer box is also fitted with a manual override button (6) to allow
the machine to be moved, if necessary. However, to reduce the risk of the
machine being operated with the fire suppression system discharged, the
override button must be pushed inward and held (it is a spring return
button) to maintain override. As soon as the button is released, the
machine will return to the shutdown mode.

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2.7.5 After a fire

Once the fire is out and the machine has cooled down, open the ventilation
hatches to clear the machine of smoke and gases. Avoid breathing in the
combustion gases. Keep a hand-held fire extinguisher close and ready to
use during ventilation.
Wash the machine with plenty of water as soon as possible after
extinguishing, because the powder used can cause corrosion, especially to
the cables.
Empty tanks and gas cartridges must be replaced before using the
machine. Only authorized service personnel may remove and fit powder
tanks and gas cartridges.
Do not start the machine again until the cause of the fire has been
established and the fault has been repaired.
Report all fires to the supervisor.

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2.8 Protection against emission hazards

2.8.1 Noise
DANGER
NOISE HAZARD!
Noise level emitted by the machine exceeds 80 dB(A). Continuous
exposure to noise will cause hearing impairment.
Always wear approved hearing protection.
Measured sound levels

The sound pressure level and volume measurements in the operator
station have been performed according to the European Standard EN 791
Drill Rigs - Safety.
The A-weighted sound pressure level at the operator sta-

LpA 72.5 dB
tion (during drilling) (cabin model)
LpA 100 dB
tion (during drilling) (canopy model)
LpA 79.5 dB
tion (during tramming) (cabin model)
LpA 93 dB
tion (during tramming) (canopy model)
The A-weighted continuous sound power level emitted by
LpA 125 dB
the drill rig
The estimated uncertainty for determination of A-weighted sound pressure

levels and sound power levels (standard deviation of the reproducibility of
the measurements) is 4 dB. (ISO 4871)
2.8.2 Vibration
The whole-body vibration during drilling does not exceed 0.5 m/s² *, when
tested according to the European Standard EN 791 Drill Rigs - Safety.
* the highest root mean square value of weighted acceleration

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2.8.3 Dust
DANGER
DUST HAZARD!
Breathing dust will cause death or severe injury.
In dusty conditions always wear approved respirator.
Breathing or inhaling dust particles will cause death or severe injury. Always
work with a respirator approved by the respirator manufacturer for the job
you are doing. It is essential that the respirator that you use protects you
from the tiny dust particles which cause silicosis and which may cause
other serious lung diseases. You should not use the product until you are
sure your respirator is working properly. This means the respirator must be
checked to make sure that it is clean, that its filter has been changed, and
to otherwise make sure the respirator will protect you in the way it is meant
to.
In any workplace where respirators are necessary to protect the health of
the employee, the employer must establish and implement a written
respiratory protection program with work site specific procedures and
elements including but not limited to the selection of respirators, proper
usage, maintenance and care, cleaning and disinfecting and training.
Regularly clean your working environment properly to minimize the dust
level in the air. Always make sure dust has been cleaned off your boots and
clothes when you leave your shift.
Respiratory silica dust is a hazard, which requires special attention. The
smallest particles of dust are the most harmful. They may be so fine that
you cannot see them. Remember, you must protect yourself from the
danger of breathing or inhaling dust.

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2.8.4 Diesel emissions
DANGER
DIESEL EMISSION HAZARD!
Prolonged exposure to diesel emissions will increase the risk of
death or severe health effects.
Only operate and maintain the equipment according to all applicable
instructions, procedures, laws and regulations.
Always wear approved personal protective equipment and utilize
effective controls.
International Agency for Research on Cancer has classified diesel exhaust

as a carcinogen to humans. Diesel exhaust includes gases, vapors and
particles made up primarily of carbon, ash, metallic abrasion particles,
sulfates and silicates. In addition to severe long term health effects, diesel
emissions cause short term effects such as eye and respiratory irritation.
All mines and construction sites with diesel powered equipment must have
documented diesel emission control plans and monitoring programs to
ensure that human exposure is reduced as low as practicable. Risks must
be assessed and control measures implemented according to the hierarchy
of controls. All areas where people may be exposed must be considered;
work force and incidental exposure included.
All mines and construction sites with diesel powered equipment must follow
and comply with all applicable legislation and industry requirements relating
to controlling and limiting worker exposure to diesel emissions. Locally
applicable information is available from various sources, including but not
limited to legislation, standards, guidelines, rules, safety bulletins,
strategies, best practices, instructions and position papers.
2.9 Emergency procedures

It is the employer’s responsibility to plan and prepare site specific
instructions to be followed in case of an emergency or an accident. The
machine manufacturer can also give certain general guidelines which can
be used as help in establishing the required procedures. The following
information should be considered when devising a site specific emergency
plan. This list is not meant to be comprehensive.
• Emergency stop: If the machine has to be stopped immediately, use the
emergency stop functions. Emergency stopping stops all the ongoing
functions. For more information, see the section, ”Use of emergency stop
function”.
• Emergency exit: In an emergency situation, use the safest escape way
or emergency exit. Also rescue personnel can use these exits to reach a
user in the operator station. For more information, see the
section, ”Emergency exit”.

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• Loss of stability: If there is sudden loss of stability during tramming, the

safest place for the user is usually inside operator station, seated on the
operator seat and seat belt fastened.
• Falling objects: In case of falling objects, the operator should stay inside
operator station until it is safe to leave the machine. The operator may
also, when possible, move the machine away from the hazard zone,
without leaving the operator station.
• Fire: In mining conditions, it is extremely important to avoid fires. If an
accident does happen and there is a fire, it has to be extinguished as
soon as possible. For more information, see the section, “Fire risk control
measures”.
• Accidents with chemicals: In an emergency situation or accident where
chemicals are involved, see the required first aid measures and
instructions in the material safety data sheets which have been delivered
with the machine manuals.
• Electric accidents: If the machine touches an electric power line, the
following instructions may prevent injuries or death.
- If you are standing outside the machine, do not touch any part of the
machine or try to get onto the machine. Keep everybody away from
the machine.
- If you are on the machine, do not try to get off it. If the machine is
touching a power line, the machine can catch on fire. If the machine
has rubber tires, leave the machine as soon as the tires start
smoking. JUMP OUT! Do not make yourself a conductor for the
electric current to flow from the machine to the ground. Move away
from the machine by jumping, or by leaping so that only one foot at a
time touches the ground. The electric field in the ground can cause a
dangerously high voltage between your legs. You will not be in safety
until you are about 20 meters away from the machine.
- If the boom or some other component of the machine touches an
electric power line, the whole machine becomes live. Although the
insulating rubber tires may make the situation seem safe, a person
standing on the ground and touching the machine can get a fatal
electric shock.
- If you come to a place where an electric accident has taken place, do
not risk your own life by acting incautiously to save others. Try to find
out whether a high or a low voltage is involved. Where high voltage is
involved, do not start any rescuing attempts until the power company
has cut off the voltage. It can be dangerous even to approach a
person in contact with the electric conductor, or with the machine that
touches the conductor. Remember that high voltage power lines
have no fuses that blow; the conductors are always dangerous, until
a qualified electrician has made them dead.

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- If a person is in contact with a low voltage line or with a machine that

is touching a low voltage line, rescuing can be attempted by using a
dry and clean rope, or a dry and unpainted piece of wood. Anyone
who is attempting the rescue must keep as far away from the victim
as possible. The victim must not be touched until he is completely
disconnected from the live components. If the victim is unconscious,
first aid measures must be started immediately.
• Emergency situation with utility boom (only if the drill rig is
equipped with a utility boom): In an emergency situation, when the
control place has to be changed from the basket to the operator station,
use the spare key located in the operator station. For more information,
see the section, "Using utility boom controls" in the operator's manual.
After an accident or emergency situation: Being on site where an
incident has occurred, do not take any actions with the equipment involved.
Do not speculate or give opinions on the cause. Contact your Sandvik
representative to get more information.
2.10 Safety considerations for maintenance

Before carrying out any maintenance, read and understand the
maintenance instructions. Make sure that you have all the required training,
skills and authorization before starting any maintenance work. The
maintenance instructions support the maintenance personnel to perform
the preventive maintenance for the product. The maintenance instructions
also provide information for the maintenance and operating personnel on
scheduled mechanical inspections of components and installed equipment.
Ensure that all necessary machinery isolations (see the section "Isolation
and energy dissipation") have been carried out prior to commencing any
maintenance work. Before carrying out any maintenance work, ensure that
necessary original spare parts or materials are available, or can be ordered
and supplied in time to meet the work schedule. You should only use parts
recommended by Sandvik. Failure to do so can cause death or injury or
damage to equipment. Note all completed maintenance activities in a
maintenance log or maintenance program.
2.10.1 Daily inspections and tasks for operators
Daily inspections and tasks, that are allowed for the operators, can be
found in the operator's manual section "Operator's maintenance
instructions". Operators are required to perform the inspections and tasks
described in the operator's manual. Note that in addition to the instructions
given in the operator's manual, the employer must provide operator
training.
All other inspections and tasks are allowed only for personnel with specific
maintenance training.

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2.10.2 Tasks which require definite technical skills and maintenance training
WARNING
SPECIAL SKILLS REQUIRED!
Incorrect maintenance procedures could cause death or severe
injuries.
Maintenance procedures require professional knowledge and
thorough training regarding the tasks and working methods.
Do not do any maintenance tasks without proper training. Always
follow the instructions. Use appropriate personal protective
equipment, depending on the task.
To avoid hazardous situations and severe consequences, leave all

maintenance work to professionals. Tasks mentioned here below are
examples of tasks which are allowed only for trained personnel. More
details on the risks related to the tasks and instructions for carrying out
these tasks safely can be found in the maintenance manual. Read the
instructions.
Tasks that require definite technical skills and training include, but are not
limited to:
• Hydraulic system maintenance
• Pneumatic system maintenance
• Electric system maintenance
• Battery maintenance
• Tire/Track maintenance
• Brake system maintenance
2.11 Environment
WARNING
ENVIRONMENTAL HAZARD!
The machine contains substances that could cause harm to the
environment.
Handle the chemicals and machine components according to
instructions and local regulations.

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WARNING
CHEMICAL HAZARD!
The machine contains substances that could cause harm to your
health.
Wear approved personal protective equipment. Follow the
instructions given in material safety data sheets and other
instructional material.
This section of the chapter gives general information on how to

decommission, dismantle and dispose of the product and how to handle
harmful waste, hazardous substances and liquids without causing harm to
people or environment. These instructions give general knowledge of what
needs to be considered when decommissioning and recycling the product.
Always take into account that disassembly, disposal and recycling
operations must be conducted in accordance with all applicable local, state
and federal rules and regulations, in addition to complying with all
environmental, health and worker safety instructions.
2.11.1 Decommissioning
When the machine is decommissioned or put out of service for a longer
period of time, it has to be prepared and stored properly. Correct
preparations and storage conditions are essential to maintain the machine
in an operating condition and reach the expected lifetime. Appropriate
decommissioning procedures also facilitate work when the machine is put
back into service again.
Prior to storing, wash the machine, drain the water circuits and empty the
pressure accumulators. Change the fluids that may have deteriorated
during use. Protect the machine components with appropriate protective
substances. After all the preparations are complete, store the machine in a
location that is protected from direct sunlight and rain. The ambient
temperature shall be +0 - 35 ⁰C and the relative humidity shall be below
90 %. Refer to the operator’s and maintenance instructions for further
details.

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2.11.2 Dismantling
WARNING
SPECIAL SKILLS REQUIRED!
Incorrect dismantling procedures could cause death or severe injury.
Dismantling shall only be done by persons with professional
knowledge and training.
When the product has reached the end of its life-cycle, it has to be
disposed of in a proper way. The end user of the product is responsible for
the product disposal. If the end user does not have the ability or the
resources to disassemble and dispose of the product, the work must be
performed by someone who does possess the necessary knowledge and
skills.
When dismantling the product, the following shall be considered:
• There are certain tasks which require special professional skills to ensure
the work is done in a safe and proper manner. Follow the local
regulations and guidelines set by your employer and the authorities.
• Carry out the work in a well ventilated space in a safe area that will not
be a traffic hazard for other machinery or personnel.
• Use appropriate personal protective equipment.
• Prior to beginning, ensure there are proper waste collection and recycling
points for spare parts and materials. Fluids and chemicals shall be
handled, separated and stored in compliance with all local, state and
federal rules and regulations.
• Note that during dismantling some special tools are needed. These can
be e.g., equipment for draining refrigerant, cutting torches, welding or
similar equipment, lifting gear, stands, crowbars, adjustable wrenches,
hammers, screw drivers etc. Ensure that correctly rated lifting equipment
is used to disassemble heavy components.
• Clean the machine before dismantling for better visibility and empty out
all loose parts from the cabin.
• Keep equipment for fire extinguishing, first aid and eye-washing closely
available.
• Before any dismantling operations, prevent accidental start-up of the
machine and make sure that the machine will not move.
• Note that there can be stored energy in various forms in the machine;
follow the procedures for isolation and energy dissipation. Ensure that all
energy sources are isolated and depressurized.
Before the actual disassembly of the machine, drainage must be
completed. Drainage means the removal of chemicals, fluids and materials
that are harmful to the environment. When carrying out the drainage
operations, avoid spilling fluids and liquids on the ground. Use a sink or a
container to avoid leakage. Any oil that is spilled onto the ground, including
biodegradable oil, must be collected as quickly and as carefully as possible.

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Refer to the maintenance manual for further information concerning the

lubricants and filling capacities of your machine.
Information on chemical safety can be found in material safety data sheets
and chemical technical data sheets. These data sheets are included in the
maintenance manual as an appendix and they cover all the factory filled
oils, lubricants and coolants of the machine in normal conditions. Material
safety data sheets include detailed instructions on chemical safety and give
information, for example, on identification of the substance, hazards related
to the substance, substance properties, first aid measures, fire fighting
measures, personal protection measures, toxicological information,
environmental information and information on storage, transportation and
disposal.
After the drainage is completed, the recyclable parts can be separated from
the machine.

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2.11.3 Disposal
This section gives useful advice to identify which parts of the product are
recoverable, with a view to recycling or reusing the materials or
components for new applications. To ensure environmentally sound
treatment of a product and all of its components, the recovery issues are
already taken into account during the design phase of the product. Correct
handling of waste materials reduces costs and promotes the best use of the
components and materials.
• Machine 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.
• Plastic: 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.
• Rubber parts and tires: Tires can be recycled, and used as recovered
material. Worn-out tires can be returned to the dealer from whom they
were originally bought. Rubber tubes and hoses must be cleaned before
they are disposed of.
• Glass: Glass can be recycled, as well as laminated glass such as
windshields and windows. Various types of glasses shall be sorted
according to local rules and regulations.
• Electrical and electronic waste: Electrical and electronic components
contain valuable and recyclable materials, and in addition a set of
chemicals and heavy metals. 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. Never dump
hazardous electrical or electronic waste.
• Gas discharge / xenon lamps: Gas discharge lamps contain mercury
and are hazardous waste. They must not be dumped. Lamps must be
taken care of by an authorized hazardous waste disposal company.
• Air conditioning units: Air conditioning units, which contain CFC and
HCFC compounds, must always be delivered for treatment to a licensed
waste disposal facility.

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• Batteries: Batteries are classified as environmentally hazardous material

and require special handling and storing in accordance with applicable
ordinances, rules and regulations. Batteries can cause serious harm to
the ecosystem; lead in the batteries is highly toxic and it accumulates in
the body over time. The disposal shall be taken care of by an authorized
waste disposal company. According to producer responsibility, producers
of batteries and accumulators are also responsible to accomplish the
waste management of batteries that they have placed on the market.
Batteries also contain diluted sulphuric acid. The acid is extremely
corrosive and it burns skin, eats holes in clothing, and can cause
blindness if it gets in the eyes. If you get battery acid on your skin, or
clothes, rinse them immediately with water. Use sodium bicarbonate to
neutralize the acid. If it gets in the eyes, flush the eyes with water, and
call a doctor.
• Oils and fluids: Oil waste must not be disposed of by burning, and
under no circumstances must oil be poured down the drain or into water
systems. Waste oil shall be collected in appropriate containers. The best
containers for collecting oil waste are the original containers for the oils.
The original containers already have the necessary warning labels, are
easy to close, and can be moved around fairly easily. Always strike out
the product name on the label and clearly label the container “oil waste”.
Empty oil containers must not be dumped in landfills without having been
cleaned. Cleaned plastic containers can be disposed of as regular waste.
Most countries have arranged a recycling system for metal barrels.
Greases, fuels, solvents, and other substances must not be mixed with
oil waste.
• Solid waste containing oil: Oil filters, oil rags, fuel filters, and oil
absorbents must be collected in a separate container.
• Solvents and oil trap sludge: Solvents and sludge that has collected on
the surface of the oil traps can both be collected in a same container. The
surface layer in the oil traps must be removed regularly, and the entire
trap must be drained at least once a year, including the sludge at the
bottom. Do not mix the oil trap sludge with oil waste.
• Fuel oil: Fuel oil is hazardous waste that must in all cases be processed
by an authorized waste treatment plant.
• Radiator, brake, and clutch fluids: Used radiator, brake, and clutch
fluids contain traces of heavy metals, zinc, and copper, for which reason
they must not be poured down the drain or mixed with oil waste. They are
to be collected in a separate, labeled container and delivered to the same
plants as the oil waste.
2.12 Potential product related hazards identified by the user

Sandvik has taken all necessary precautions to design a safe machine. If,
in spite of these efforts, you observe a hazard for which you believe there
are insufficient safety measures, immediately inform your supervisor. If
necessary, also inform the other employees working with the product.
Report the hazard to your local Sandvik representative. Do not perform a
task if you are unable to perform the task in a safe manner.

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2.13 Incident reporting

Product safety issues to be reported are events where a product
manufactured by Sandvik Mining and Construction has been involved in an
accident or near-miss incident. Safety-related feedback, such as
unauthorized modifications, missing manuals and safety labels, negligence
of maintenance or misuse shall be reported to your local Sandvik
representative as well.
Reporting is mandatory to ensure safe working conditions for employees, to
provide information for the risk assessment process, and to initiate product
improvements.
Contact your local Sandvik representative to report safety issues, such as
those mentioned above.

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3 Machine description

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3.1 Main component location

3.1.1 Drilling module
3 1 2
3 1 2
3 1 2
1 Rock drill
2 Feed
3 Boom
4 Utility boom (optional)

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Hydraulic rock drill (HLX5)
4
5
1 Flushing housing
2 Gear housing
3 Pressure accumulator
4 Rotation motor
5 Carriage
Hydraulic rock drill (HLX 5 T)
4
5
1 Flushing housing
2 Gear housing
3 Pressure accumulator
4 Rotation motor
5 Carriage

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Hydraulic rock drill (RD520/525)
1 2 3
7
4
5
6
1 Body cylinder 2 Percussion mechanism

3 Rotation motor 4 Gear housing
5 Stabilizer 6 Flushing housing
7 Pressure accumulator (low 8 Pressure accumulator (high
pressure) pressure)
9 Pressure accumulator (stabil-
izer)

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Cylinder feed (TF500, left feed)
7
2
1 8
6
3
TRR1
SCR 6
8
7
1 Front centralizer 2 Intermediate centralizer

3 Beam 4 Feed cylinder
5 Hose reel 6 Rod retainer TRR1 / SCR**
(optional)
7 Safety wire (optional) 8 Safety wire switch (optional)
** see more information separate TRR1 / SCR instruction.

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Cylinder feed (TF500, right feed)
8 2
7
1
5
4
3 5
6 2
3
4
6 SCR
TRR 6

5 Hose reel 6 Rod retainer TRR1 / SCR
(optional)
7 Safety wire (optional) 8 Safety wire switch (optional)
Cylinder feed (TFX500)
5
4
2 1
3
7 6

5 Hose reel 6 Safety wire (option)
7 Safety wire switch (optional)

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Boom (TB)
5 1
7 8 2
9 3
6 4
1 Feed extension cylinder 2 Feed cradle

3 Bolting cylinder 4 Rotation mechanism
5 Feed tilt cylinder 6 Feed swing cylinder
7 Boom extension cylinder 8 Boom lift cylinder
9 Boom swing cylinder
Utility boom
1
2 8 9
4 5 6
1 Utility boom stabilization 2 Utility boom swing cylinder

pump cylinder
3 Utility boom lift cylinder 4 Utility boom extension cylin-
der
5 Basket tilt cylinder 6 Basket
7 Basket safety canopy (op- 8 Safety gear fastening point
tional)
9 Utility boom controls

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3.1.2 Carrier module
5 1
3 8 9
2
3
10 11
4
6
7 12
5
12
3
3 10 11
2
8 9
1 Diesel engine 2 Transmission

3 Axles 4 Jacks control valve (front)
5 Jacks control valve (rear) 6 Pressure switch for front jack
control
7 Pressure switch for rear jack 8 TFX valves
control
9 Pressure accumulators 10 Double pressure relief valve
11 ** Extra pieces for front jack
extension

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Diesel engine (MB 904 LA)
3
16
7
11
15
9 13
12
4
1
11
17
10
5
2
14
1 Fuel filters 2 Oil drain plug

3 Engine oil filter 4 Engine oil filling cap
5 Dipstick of engine oil level 6 Contamination indicator for
air filter
7 Pumps for steering and 8 Radiator (air, oil, water)
brakes
9 Expansion vessel (cooler) 10 Air filter (dry)
11 Poly V-belts 12 Level sensor
13 Exhaust catalyzer (option) 14 Muffler
15 Charger guard 16 Warning sign, finger cover
17 MR2 Engine control unit

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Diesel engine (MB 906 LA)
8
7
10
9
3
6
1
11
5
4
1 Fuel filters 2 Oil drain plug

3 Engine oil filter 4 Engine oil filling cap
5 Dipstick of engine oil level 6 Radiator (air, oil, water)
7 Expansion vessel (cooler) 8 Poly V-belts
9 Charger guard 10 Warning sign, finger cover
11 MR2 Engine control unit

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Transmission (T20000)
2 1
1 Gear pump for steering 2 Gear pump for brakes

3 Transmission oil filter 4 Dipstick of transmission oil
level / transmission oil filling
cap
5 Transmission oil drain plug

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Transmission (HR32000)
3 1
5
2
1 Transmission oil filling cap 2 Transmission oil drain plug

3 Transmission oil filter 4 Checking mark of transmis-
sion oil level (FULL)
5 Checking mark of transmis-
sion oil level (LOW)
Diesel engine control unit MR2 (MB engine)
1 Engine control unit MR2

Note! Disconnecting the engine control unit (MR2) connectors while the
engine is running may destroy the engine MR2 and ADM units.
Note! Always turn off the engine and turn the rig main switch to position
OFF before disconnecting the connectors.

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Axles
A
2
1 1
B
2
3
A Front axle
B Rear axle
1 Planetary gears
2 Brakes
3 Bearing assembly
Control valve (front jacks)
1 Control valve (front jacks)

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Control valve (rear jacks)
1 Control valve (rear jacks)
Pressure switch (front jacks)
1 Pressure switch for front jacks control

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Pressure switch (rear jacks)
1 Pressure switch for rear jacks control
TFX valves
1 2
1 TFX valve
2 Cover plate

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Pressure accumulators
1 Pressure accumulators
Double pressure relief valve
1 Double pressure relief valve

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Brake valve connection box
1 Electrical box

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3.1.3 Rear module
8 13 20
19
16
1 15
5
18 11
3 6
11
14 7
5
12 1
17 9 10
1 Main switch gear 2 Hydraulic oil filling pump

3 Hose reel 4 Cable reel

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5 Power packs 6 Hydraulic oil receiver

7 Compressor 8 Water booster pump
9 Pressure reducing valve 10 Mud separator
11 Oil coolers 12 Battery isolation switch
13 Central lubrication (optional) 14 Greasing unit (optional)
15 Washing reel (optional) 16 Fuel tank
17 Battery (2x) 18 Rear lights
19 Cable spooling system (op- 20 Rear jacks control valve
tional)
MSE Main switchgear (380-690V)
6
Q100 4
P410 0
5 S300 1P100 P400
Option 2P100
7
X24 X41 X28
2 3 1
1 Power pack hour meters 2 Percussion hour meters

3 Compressor hour meter 4 Main switch
5 Supply voltage meter 6 Protective breakers
7 Emergency stop button (op-
tional)
MSE Main switchgear (1000V)
7 4 3 1
6 5 2 8
1 Hour meters for powerpacks 2 Percussion hour meters

5 Supply voltage meter 6 Protective breakers
7 Resetting of electronic motor 8 Cabinet for third boom elec-
protector relays (Australian trical equipment (not use with
models) utility boom)

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MSC/MSU Main switchgear, analog voltmeter
4
3
2
10 1
1 10 1
1 Powerpack hour meter 2 Percussion hour meter

5 Protective breakers 6 Supply voltage meter (ana-
log)
MSC/MSU Main switchgear, digital voltmeter
3 6
8888
8888
8888
1
4
5
1 Powerpack hour meter 2 Percussion hour meter

5 Protective breakers 6 Supply voltage meter (digital)
Hydraulic oil filling pump (electric)
1
2
JB43
1 Hydraulic oil filling pump switch

2 Oil filling pump

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Hydraulic oil filling pump (manual) (optional)
1 Oil pump
Hose reel THR 2,5E (optional)
1
2
1 Reel
2 Chain
3 Hydraulic motor
Hose reel THR 5E (optional)
1 Reel
2 Chain
3 Hydraulic motor

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Cable reel TCR4EL / TCR5E
A
6 5 2 1
2
8
8
5
3 4 3 4
10 9
9
A Cable reel with spooling B Cable reel without spooling

1 Reel 2 Hydraulic motor
3 Slip ring unit 4 Limit switch
5 Gear box 6 Cable spooling system (op-
tional)
7 Remote controller (optional) 8 Cable reel control block as-
sembly
9 Cable supply connection box 10 Cable and hose reel control
valves for reeling out (option-
al)

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Powerpacks
4
2 5
1 Electric motor
2 Pressure filter
3 Variable displacement pump for percussion / feed
4 Gear pump (rotation)
5 Gear pump (optional) (utility boom)
Hydraulic oil receiver
2 5 3
4
8
1
7
1 Oil level indicator

2 Return filter
3 Breather
4 Pressure switch
5 Oil level switch
6 Drain valve
7 Oil heater (optional) (behind the hydraulic oil tank)
8 Vacuum pump (optional)

ID: BG00471036 en-US C.001.1 2018-05-28
Compressor CTN
8 12 9 3
2
16
10 5
11
15
14 13 1 7 4
1 Compressor 2 Air filter

3 Filling hole cap 4 Oil separator filter
5 Electric motor 6 Output pressure adjusting
screw
7 Oil separator 8 Inlet valve
9 Oil cooler 10 Oil filter
11 Safety valve 12 Air filter condition indicator
13 Pressure gauge 14 Temperature gauge
15 Outlet tube 16 Air pressure releasing valve

ID: BG00471036 en-US C.001.1 2018-05-28
Compressor CT
12 5
8 7
3 2
9 13
16 14
10 11
1
15 6 4
1 Compressor 2 Air filter

3 Filling hole cap 4 Oil separator filter
5 Electric motor 6 Oil level sight glass
7 Oil separator 8 Inlet valve
9 Oil cooler 10 Oil filter
11 Oil vortex cleaner 12 Air filter condition indicator
13 Pressure gauge 14 Temperature gauge
15 Outlet tube 16 Air pressure releasing valve
Water booster pump
1 Electric motor
2 Water booster pump
3 Bleeding valve

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Pressure reducing valve and mud separator
1
4
1 Shut-off valve
2 Mud separator
3 Drain valve
4 Safety valve
5 Pressure reducing valve
Oil cooler(s)
1 Oil cooler
Battery isolation switch
2 3
1

2 Carrier main fuse (incl. remote operation)
3 Protective breakers

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Central lubricator (optional)
1 Greasing unit
Greasing unit (optional)
4
1
1 Greasing unit
2 Reel
3 Ball valve
4 Greasing pistol
Pressure cleaning system with reel (optional)
1 Reel
2 Orifice
3 Ball valve

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Fuel tank
2
1
1 Filling cap
2 Fuel level sensor
3 Drain plug
Fuel tank (fast filling system)
FUEL
NOZZLE
1 Fast filling system (wiggins)
*** Follow the wiggins separate instructions

*** Filling plug must be in its place when fuelling the tank

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Battery
1 Battery (x2)
Rear lights
2 1
1 2
1 Driving lights
2 Brake lights (red led lights)

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Control valve (rear jacks)
1 Control valve (rear jacks)

ID: BG00471036 en-US C.001.1 2018-05-28
Support bearing
Maintenance Manual
8
Manual greasing
Steering cylinder RIGHT
7
NOTICE! NOT INCLUDED IN TC 8
6
Steering cylinder LEFT
5
Rear oscillating
4
Front oscillating
Steering cylinder LEFT
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Steering cylinder RIGHT
1
CENTRALIZED LUBRICATION
FILL ALL HOSES BEFORE CONNECTION
TC 8 Lower pin centre hinge

9
137 (476)
DT820
3.1.4 Safety canopy / cabin
1 3
2
4
5
2
1
2 1 3
4
1 Control panels
2 Safety canopy / cabin
3 TFX control panel
4 Safety chains
5 Reverse camera (optional)
Control panel THC
A 1
B
1 Operator’s control panel

A Canopy model
B Cabin model

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TFX control panel assembly
1 TFX control panel
Safety chains
1 Safety chains
** The safety chains must be fastened when working on the working

platform.

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Reverse camera
2
4
3
1
1 Rear camera
2 Front camera (only in cabin models)
3 Extra light
4 Display
A Canopy model

ID: BG00471036 en-US C.001.1 2018-05-28
3.1.5 Drilling components
3 4
1 2 5
2 1
3 4
3 4
1 2 5
1 Water separator
2 Shank lubrication unit
3 Drilling valves
4 Boom valves
5 Flushing valves

ID: BG00471036 en-US C.001.1 2018-05-28
Water separator (side box left)
A B C D E F
1
3
1 Sight glass
2 Indicator
3 Drain valve
4 Pressure measurement points
A Service brake / front 80 bar
B Service brake / rear 80 bar
C Parking brake front 30 bar
D Parking brake rear 30 bar
E Charging of accumulators 135-160 bar
F Clark clutch 17-19 bar

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Shank lubrication unit - SLU
6
1 2
7
1 Filling cap
2 Oil container
3 Booster switch
4 Pump unit
5 Drain valve
6 Level switch
7 Dipstick

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Drilling valves (Cabin model)
3
4
5
2
5
4 3
1 Percussion and feed control block

2 Antijamming and return automatics control block
3 Return automatics control block
4 Control valve of rotation
5 Pressure switches for percussion hour meter

ID: BG00471036 en-US C.001.1 2018-05-28
Drilling valves (Canopy model)
2
3
1 Percussion and feed control block

2 Antijamming and return automatics control block
3 Impulse cylinders control block
4 Rotation control block
5 Pressure switch for percussion hour meter
6 Pressure switch for stabilizer pressure (optional)
Boom valves
1 Boom control block

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Flushing valves
1 Flushing valve (flow control option)

2 Flow switch
3.2 Machine orientation

Left
Rear Front
Right

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3.3 Instrument panels and operating controls

Canopy model
10 2 3 5
7 1
8
4
1 Switches 2 Instruments
3 Indicator lights 4 Driving controls
5 SW-panel 6 QN-indicator light panel
7 Boom(s)/drilling control panel 8 Pressure gauges panel (for
right boom)
9 Pressure gauge panel (for 10 Signal (pulse)/red flashing
left boom) light- engine go into over-
drive( > 2500 rpm)
WARNING! SHEARING HAZARD!

Sliding canopy tubes could cause severe injury.
Ensure that no one is near the canopy tubes when lowering and
lifting the canopy. Do not place fingers in the canopy tube holes.
WARNING! FLYING MATERIAL AND NOISE HAZARD!

Falling rocks and noise could cause death or severe injury.
Always wear approved eye-protector, safety helmet and hearing
protectors.

ID: BG00471036 en-US C.001.1 2018-05-28
Cabin model
9 5 7 6
3
10 2
11
1 Switches 2 Instruments
3 Indicator lights 4 Driving controls
5 SW-panel 6 QN-indicator light panel
7 Wipers 8 Boom(s)/drilling panel
9 Pressure gauge panel (for 10 Pressure gauge panel (for
right boom) left boom)
11 Signal (pulse)/red flashing
light - engine go into over-
drive( > 2500 rpm)

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3.3.1 Tramming controls
2 3
1 Steering wheel
2 Brake pedal
3 Accelerator pedal
4 Drive selector
Optional: Parking lights are on, when the battery isolation switch is
switched on.
When tramming the rig, the parking and brake lights are lit towards the
tramming direction.
3.3.2 Tramming panel (DP)
1 3
1 Left panel
2 Middle panel
3 Right panel
4 Front panel

ID: BG00471036 en-US C.001.1 2018-05-28
Left panel
1 4
A
3 A A
6
B B
B
3a
3b 5
2 A
B
A A
7
B B
Diesel engine overspeed warning The light flashes and beeps if the diesel engine speed
1
siren (H24) exceeds 2500 rpm.
Key switch for utility boom control A) Control from the basket
position selection (S3) (if the drill B) Control from the operator station Note! The jacks
2
rig is equipped with a utility operate only when the key switch is turned to this
boom) position.
A) Extending the front jack beam
The indicator lights (3a and 3b [SH40a and SH40b]) go
Button for extending/retracting on when the jack beam has been extended almost fully
the front jack beam (SH40) (if the (if the drill rig is equipped with a utility boom).
3
drill rig is equipped with an ex- B) Retracting the front jack beam
tendable front jack beam) The indicator lights (3a and 3b [SH40a and SH40b]) go
off when the jack beam is retracted (if the drill rig is
equipped with a utility boom).
A) Jack up
The indicator light on the button goes off when the jack
is lifted (if the drill rig is equipped with a utility boom).
Button for lifting/lowering the drill
4 B) Jack down
right front jack (SH41) (optional)
The light on the button comes on when the jack touch-
es the ground (if the drill rig is equipped with a utility
boom).

ID: BG00471036 en-US C.001.1 2018-05-28
A) Jack up
Button for lifting/lowering the left
5 B) Jack down
front jack (SH42) (optional)
boom).
A) Jack up
Button for lifting/lowering the drill
6 B) Jack down
right rear jack (SH43)
boom).
A) Jack up
Button for lifting/lowering the left
7 B) Jack down
rear jack (SH44)
boom).

ID: BG00471036 en-US C.001.1 2018-05-28
Middle panel
1 C
2 3 4
Middle panel with MB engine
1 A B
00000 P
P1
MAX 2500 rpm
2 3 4
1/2 100 150 100 150
1/4 3/4 ba r bar
50 200 50 200
1 0 250 0 250
0
1 2
P2 P3 P4
F R
Middle panel with Tier4 engine
Tacho-, hour- and speedometer. The tachometer indicates

1 Main instrument (P1)
engine speed in hundreds of revolutions per minute (rpm).
Fuel gauge and indicator light
2 The indicator light comes on if the fuel level is too low.
(P2)

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Front brake circuit pressure The indicator light comes on if the front brake circuit pres-
3
gauge and indicator light (P3) sure falls below 100 bar.
Rear brake circuit pressure The indicator light comes on if the rear brake circuit pressure
4
gauge and indicator light (P4) falls below 100 bar.
C
19 21
10
20
18
8 22
Indicator lights with MB engine
A B
5 9 12 16
6 10 13 17
7 P 11 14 18
8 15
Indicator lights with Tier4 engine

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Illuminated Stop engine indicator light indicates that the engine must be
stopped as soon as it can be safely done. The engine must remain shut
Engine shutdown down until the engine can be repaired. See more detailed information in
5
indicator light section "Engine protection" below.
Note: Engine shutdown indicator light blinking = stop the engine within 30
seconds
Low temperature start aid. Preheat (after key On and before cranking): At
key On, the ECM checks the intake manifold air temperature. Based on
this temperature, the ECM lights Engine Preheater Indicator light and en-
Engine intake air
6 ergizes the intake air heaters. After a calibrated period of time, the ECM
preheat
turns off the intake air heaters and the Engine Preheater Indicator light
turns off. Once the indicator light is off, the operator can crank the engine.
Pre-heat time increases with colder intake manifold air temperatures.
The indicator is lit if the pressure in the front parking brake circuit falls be-
low 50 bar and in the rear parking brake circuit falls below 5 bar.
• Front brake circuit 5 bar (NC7, TC7-TC9) / 50 bar (TC11-TC12)
Parking brake in-
7 • Rear brake circuit 5 bar (NC7, TC7-TC12)
dicator light (H15)
The indicator light blinks if the brakes of one axle are left in a different
state than the other’s when the brake is engaged or released, i.e. the
pressure difference between the brake circuits becomes too high.
Charging indica- The indicator light comes on if the alternator is not working.
8
tor light (H6) Switch off the engine and identify the cause.
The Check Engine lamp comes on when the engine needs to be serviced
at the first available opportunity.
Monitored critical parameters:
• Coolant level
• Coolant temperature
• Oil pressure
• Water-in-fuel is detected
Check Engine
9 • Intake manifold temperature (charge temperature)
warning light
• EGR orifice temperature
• Crankcase pressure
• DOC out temperature
• DOC delta temperature
• DPF out over temperature
• Soot loading
Air filter indicator
10 The indicator light comes on if the air filter is clogged.
light (H5)
Brake failure;
11 brake system Inpending brake pressure 110 bar (ABA-optional)
malfunction

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The exhaust filter will require maintenance periodically. The DPF Lamp
provides an indication that the filter has not been able to regenerate under
The diesel partic-
the previous engine operating conditions and is in need of assistance in
ulate filter (DPF)
order to perform regeneration.
12 lamp (only in use
A flashing DPF lamp combined with an illuminated Check Engine lamp in-
with Tier 4i
dicates that the after treatment diesel particulate filter needs to be regen-
QSB6.7 engine)
erated immediately (refer to the engine manual). Engine power will be re-
duced automatically.
The Regen Disa-
Provides an indication to the equipment operator that Regeneration has
bled Lamp (only
13 been disabled (switch S22 is turned on) and automatic and manual (non-
in use with Tier 4i
mission) regeneration cannot occur.
QSB6.7 engine)
Indicates:
Transmission fail- • the transmission oil pressure of the transmission is too low
14
ure/malfunction
• the transmission oil temperature is too high
15 Turn signals Optional
The High Exhaust System Temperature (HEST) Lamp provides an indica-
tion to the equipment operator when exhaust system temperature is ele-
HEST Lamp (only
vated above normal levels for the operating condition. HEST Lamp comes
16 in use with Tier 4i
on when the exhaust gas temperature reaches 675 °C.
QSB6.7 engine)
In a manual regeneration the HEST lamp will come on all the time to warn
the operator of hot exhaust gases at idle.
To identify the fluid used to reduce emissions from operation of the diesel
Diesel exhaust
17 engine by means of a selective catalytic reaction.
fluid (DEF)
Option, not available yet.
Hydraulic oil level
18 indicator light The indicator light comes on if the hydraulic oil level is too low.
(H602B)
The indicator light is lit if one of the following malfunctions has been de-
tected:
• The engine speed is too high.
• The oil pressure is too low.
• The oil level is too low.
Engine stop indi- • The coolant temperature is too high.
19 Note:
cator light (H41)
Warning lights:
• Continuous red and yellow = stop the engine immediately
• Blinking yellow = stop the engine within 30 seconds
• Blinking yellow and red = stop the engine within 10 seconds
Engine stop time:
• Coolant temperature or level, engine oil level or oil pressure: 30 s
Door latch indica-
20 Park brake actuation if doors are open (Kaz-optional)
tor light

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The indicator light comes on if one of the following malfunctions has been
detected:
• The oil pressure is too low or the oil pressure signal is not available.
• The oil level is too low or too high.
• The coolant temperature is too low or the temperature signal is not
available.
Engine malfunc- • The coolant level is too low or the level signal is not available.
21 tion indicator light Note: Stop the engine immediately if the oil pressure or the oil level is too
(H42) low, if the coolant temperature is too high, or if the coolant level is too low.
The safe operation of the engine is endangered (risk of engine damage).
• No CAN connection to the engine control unit (MR2) or CAN data un-
reasonable
• Active faults of medium or high priority in the engine control unit's fault
memory
• Faults of medium or high priority in the carrier adaptation unit's (ADM2)
fault memory
Fuel filter indica-
22 The indicator light comes on if the fuel filter collects too much water.
tor light (H67)

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Main instrument
The main instrument consists of a conventional tachometer, multifunction
LCD matrix display, and the display group shift button.
In addition to the default view (operating hour meter), several other
practical display modes can be viewed in the LCD display. However, note
that the alarms, CAN fault codes, and warnings are available only when
they are active or include data that has not been reset.
5
2
4
6
1 Tachometer
2 Symbol for measured variable
3 6-digit value for the measured variable
4 4+1-digit resettable operating hour meter
5 Measurement unit for the variable
6 Display group shift button
Operating hour meter

The LCD display is an operating hour meter by default. The number after
the decimal point in the resettable operating hour meter refers to tenths of
hours. The meter can be reset by pressing the shift button for more than
two seconds.
Alarms
If an alarm is triggered, the LCD display shifts automatically to the alarm
screen. The general alarm symbol starts to blink alternately with the symbol
indicating the alarm type. If several alarms are triggered at the same time,
the most critical alarm will be displayed. The alarm list in the alarm display
can be browsed by pressing the shift button briefly.
The alarm can be reset by pressing the shift button for more than two
seconds. The value displayed last will return to the LCD display. If the
problem causing the alarm remains, the general alarm symbol remains
displayed on the left-hand side of the screen. The vertical line to the right of
the alarm symbol indicates that the alarm does not refer to the currently
displayed value. If the alarm is reset and the problem causing the alarm is

ID: BG00471036 en-US C.001.1 2018-05-28
cleared, the alarm will be removed from the list of active alarms. Although
the problem is cleared, the triggered alarm must be reset in order to
remove it from the alarm list.
CAN fault codes

If a new trouble code is received from the diagnostics (DTC, for ‘diagnostic
trouble code’), the LCD automatically shifts its view to the CAN fault code
screen. The code symbol (an open book) is displayed on the left side of the
screen, followed by the code name in the middle. The code number from
the buffer is displayed on the right-hand side.
Physical values
The physical value display shows the symbol of the current physical value.
In standard mode, the physical value is displayed on one line, followed by
the measurement unit. If the value is outside the defined range, the display
shows ‘------’. A probable cause for exceeding the limits is a damaged
sensor or cable.
To view the physical values in the physical value display, press the display
group shift button for more than 0.5 seconds.
Warnings
A special graphic symbol (ISO) blinks on the warning display. The warning
can be reset by pressing the shift button for more than two seconds. If there
are no other alarms and warnings to reset, the last active screen will be
displayed. If several alarms are active at the same time, the most critical
alarm will be displayed. If the problem causing the alarm is cleared, the
alarm will be removed, if it has been reset.
If you want to display different warnings on the warning screen, press the
shift button for more than 0.5 seconds.
Speedometer (optional)
Speedometer is the final view on the LCD display. Without speed
measurement option it shows 0 km/h.

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IGNITION ON
START-UP LOGO
10.9.2013 V4.0x Software update date, gauge software version
ENGINE HOURS
Total hours / trip hours
Trip reset --> hold button longer than two seconds
FAULT CODE COUNTER

FAULT CODE MEMORY
(Also shows the engine PDL-unit fault codes by the ADM2)
Engine fault code (02=count)
Inside: Counter reset --> ignition off, press button and turn ignition on
press for two seconds
FAULT CODE (BUFFER=02)
Suspect Parameter Number (SPN)
Failure Mode Identifier (FMI)
Occurrence Count (OC)

e.g., 111 (SPN) = Coolant level
1 (OC) = Occurrence: one time
01 (FMI) = Low coolant level or faulty wiring
BATTERY VOLTAGE
Start of cycle ENGINE OIL PRESSURE

At any time
ALARM/WARNING SITUATION(example)
pressing for two
seconds ENGINE OIL TEMPERATURE FRONT BRAKE PRESSURE
(pressure below 100 bar)
ENGINE COOLANT TRANSMISSION OILPRESSURE

TEMPERATURE (pressure below 13.8 bar)
TRANSMISSION OILPRESSURE
TRANSMISSION TEMPERATURE
%
ENGINE LOAD AT CURRENT
BOOST PRESSURE
INTAKE MANIFOLD TEMPERATURE
FUEL TEMPERATURE
FUEL ECONOMY
ENGINE TOTAL FUEL USED
Rotation of the meter display V 4.01 (for Mercedes Benz engine)

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IGNITION ON
START-UP LOGO
27.1.2012 en V4.03 Software update date, gauge software version
ENGINE HOURS
Total hours / trip hours
Trip reset --> hold button longer than two seconds
E ECM ON TIME
C 22
U 22.0 Total ECU run time
FAULT CODE COUNTER

Engine fault code (02=count)
FAULT CODE MEMORY Fault 02
Counter reset --> ignition off, press button and turn ignition on
Inside: press for two seconds FAULT CODE (BUFFER=02)

Suspect Parameter Number (SPN)
Failure Mode Identifier (FMI)
Occurrence Count (OC)
ATC
1 2 3 _ _ _ _ Count
ACTIVE FAULT
CODE COUNTER e.g., 111 (SPN) = Coolant level
1 (OC) = Occurrence: one time
01 (FMI) = Low coolant level or faulty wiring
BATTERY VOLTAGE
ENGINE COOLANT
TEMPERATURE ALARM/WARNING SITUATION(example)
At any time
pressing for two
FRONT BRAKE PRESSURE
seconds TRANSMISSION OILPRESSURE (pressure below 100 bar)
TRANSMISSION OILPRESSURE
TRANSMISSION TEMPERATURE (pressure below 13.8 bar)
E Torq ACTUAL ENGINE TORQUE

%
ManiP INTAKE MANIFOLD PRESSURE
ENGINE FUEL RATE
Rotation of the meter display (for Cummins engine)

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DISPLAY
GROUP FAULT CODE MEMORY
PHYSICAL VALUES ALARM/WARNING
PRESS
PUSH-BUTTON
SHOW NEXT SHOW NEXT SHOW NEXT

VALUE FAULT CODE ALARM/WARNING
> 0.5 s
* FAULT CODE COUNTER

MOVE INTO MOVE INTO INSIDE QUIT
>2 s START OF CYCLE FAULT CODE MEMORY ALARM/WARNING
ALARM/WARNING SYMBOLS:
ALARM BRAKE PRESSURE (FRONT)
WARNING BRAKE PRESSURE (REAR)
GENERAL ALARM FUEL LEVEL
ENGINE OIL PRESSURE

WARNINGS/ALARMS OF THE SENSOR
VALUE OVER THE LIMIT
: ENGINE OIL TEMPERATURE
ENGINE COOLANT TEMP.
ENGINE COOLANT LEVEL
ENGINE INTERNAL FAULT
ENGINE SPEED
BOOST PRESSURE
ENGINE CAN FAULT
INTERPRETATION OF ALARM/WARNING :
-- check fault code memory of gauge
-- see fault codes (J1939)
Alarm/warning symbols (for Mercedes Benz engine)

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DISPLAY
GROUP FAULT CODE MEMORY
PHYSICAL VALUES ALARM/WARNING
PRESS
PUSH-BUTTON
SHOW NEXT SHOW NEXT SHOW NEXT

VALUE FAULT CODE ALARM/WARNING
> 0.5 s
* FAULT CODE COUNTER

MOVE INTO MOVE INTO INSIDE QUIT
>2 s START OF CYCLE FAULT CODE MEMORY ALARM/WARNING
ALARM/WARNING SYMBOLS:
ALARM BRAKE PRESSURE (FRONT)
WARNING BRAKE PRESSURE (REAR)
GENERAL ALARM FUEL LEVEL
WARNINGS/ALARMS OF THE SENSOR ENGINE COOLANT TEMPERATURE

VALUE OVER THE LIMIT
:
WIF WATER IN FUEL INDICATOR
ENGINE OIL PRESSURE
COOLANT LEVEL
DPF fault DPF DIFFERENTIAL PRESSURE SENSOR
ManiP MANIFOLD PRESSURE
CONTROLLER (ECM INTERNAL HW FAILURE)
ENGINE SPEED
INTERPRETATION OF ALARM/WARNING :
-- check fault code memory of gauge
-- see fault codes (J1939)
Alarm/warning symbols (for Cummins engine)

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Right panel
1 12
11 10
9
A A
7
A A
B B B B
8 A
B
0
B B
B A C A C
A C 13
3 SH56
4 B
A C
A B A B
2
6 5
The indicator light is lit constantly if the pressure of both

brake circuits has fallen below the set limits:
• Front brake circuit 5 bar (NC7, TC7-TC9) / 50 bar
Parking brake engaged indicator (TC11-TC12)
1 light (H15B) (ABA-option, alterna- • Rear brake circuit 5 bar (NC7, TC7-TC12)
tive for S37) The indicator light blinks if the brakes of one axle are
left in a different state than the other’s when the brake
is engaged or released, i.e. the pressure difference be-
tween the brake circuits becomes too high.
A) Stop
Diesel engine start/stop switch
2 B) Standby/running position
(S2)
C) Start
A) Lights off
3 Front light switch (S4) B) Front driving lights
C) Front driving lights and working lights
A) Rear working lights
4 Rear light switch (S5) B) Lights off
C) Rear driving lights
Blinker switch and indicator light
A) Left blinker
5 (S22) (optional, alternative for
B) Right blinker
S29)

ID: BG00471036 en-US C.001.1 2018-05-28
Service brake test switch (S29) A) Front brake circuit test

6
(optional, alternative for S22) B) Rear brake circuit test
Button for raising/lowering the
safety canopy (canopy models) / A) Safety canopy / operator station up
7
operator station (if fitted, cabin B) Safety canopy / operator station down
models) (S45)
Button for raising/lowering the left
boom support (S47) (only in A) Support up
8
DT1200 series drill rigs, alterna- B) Support down
tive for S52)
Button for raising/lowering the
drill right boom support (S48) A) Support up
9
(only in DT1200 series drill rigs, B) Support down
alternative for S51)
Button for turning the front frame A) Front frame to the right
10
(S51) (only in DL411 drill rigs) B) Front frame to the left
Button for lifting/lowering the front
A) Front frame up
11 frame (S52) (only in DL411/
B) Front frame down
DL421 drill rigs)
Carrier emergency brake button
Engages the parking brake, shuts down the diesel en-
12 (S37) (optional, alternative for
gine, and sounds the horn.
H15B)
To start the hand throttle, the gear must be in the neu-
tral position and the parking brake must be on. The
hand throttle can't be used while driving. To start the
hand throttle, first turn the switch to the position (B) and
then turn it to the position (C) for a moment. To turn the
hand throttle off, turn the switch to the position (A).
The hand throttle is a 3-level. When the switch is turned
to the position (C) first time, the engine rpm raises to
1200 rpm. If the switch is turned to the position (C)
Hand throttle switch and indicator again, the engine rpm raises to 1400 rpm. If the switch
13
light (SH56) is turned to the position (C) again, the engine rpm rais-
es to 1600 rpm. If the switch is turned to the position
(C) fourth time, the engine rpm returns to the first level
(about 1200 rpm).
NOTE that if the hand throttle is in the position (B)
when the drill rig is started the hand throttle doesn't
start, but the indicator light is on. To restart the hand
throttle you will need to turn the switch to the position
(C) for a moment. Keep the hand throttle switch in the
position (A) when it is not in use.

ID: BG00471036 en-US C.001.1 2018-05-28
Front panel
2 7 6 12 10
P STOP
P A
P
D B
R
C
8 11 5 1
4 9 3
Front panel with MB engine
7 6 12 10
A B C
P
A
P
S17
S22
D
S9
B
SH2 S10 SH3
S21 S46
R
S AF ETY
BRAKE TES T
P
8 11 5 13
Front panel with Tier4 engine

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The indicator light is lit constantly if the pressure of both

brake circuits has fallen below the set limits:
• Front brake circuit 5 bar (NC7, TC7-TC9) / 50 bar
(TC11-TC12)
Parking brake engaged indicator
1 • Rear brake circuit 5 bar (NC7, TC7-TC12)
light (H15)
The indicator light blinks if the brakes of one axle are
left in a different state than the other’s when the brake
is engaged or released, i.e. the pressure difference be-
tween the brake circuits becomes too high.
The indicator light comes on if the brake charging pres-
Descending brake pressure indi- sure drops below 110 bar. When the pressure falls be-
2 cator light (H20) (ABA-option, allow 75 bar in the front or rear service brake circuit, the
ternative for P247) brakes are automatically engaged and cannot be over-
ridden.
Water hose reel indicator light
The indicator light comes on when there are only a few
3 (H247) (optional, alternative for
turns of the hose left on the reel.
S25)
Water hose reel warning signal The warning signal sounds when there are only a few
4 (P247) (optional, alternative for turns of the hose left on the reel. Operates simultane-
H20) ously with the indicator light (H247).
5 Horn button (S9) Press the button to sound the horn.
Immediately cuts off all power to the carrier (and the
main power if the drill rig is equipped with a pilot cir-
cuit).
Remote switch for the battery iso- Note:
6
lation switch (S10) • The lights go off.
• Does not save the collected data.
• May damage the Flash memories.
The button can be used for bypassing the diesel engine
stops caused by the diesel engine's control units (for
Engine stop override button example low oil pressure, low oil level, low coolant lev-
7
(S17) el) and by the automatic fire extinguishing system.
Note! The button must be used only in emergency
situations when the drill rig must be moved.
The parking brake is engaged by pushing down the but-
ton.
Parking brake engagement but-
8 Before releasing the parking brake, the button must be
ton (S21)
released by pulling it up (after this the indicator light
[SH2] comes on).
Parking brake test switch (S25)
9
(optional, alternative for H247)

ID: BG00471036 en-US C.001.1 2018-05-28
Note! S46 is functional only when switch S45 on

ERCP is in position A.
It's only possible to reel when the diesel engine is run-
ning and after the joystick has been briefly returned in
Cable and water hose reel con- the middle position. Only after this the joystick can be
10
trol lever (S46) used.
A) Cable and water hose in
B) Water hose in
C) Cable and water hose in when reversing
D) Cable in
The indicator light comes on if the parking brake circuit
is open or has not been released.
Parking brake releasing button
11 When the parking brake engagement button (S21) has
and indicator light (SH2)
been released, the indicator light comes on and the
parking brake can be released by pressing this button.
The indicator light comes on and the parking brake is
engaged when:
1.The cable reel limits are reached.
• At the first limit, the parking brake can be over-
ridden by pressing the button. The cable can
be reeled in.
• At the second (final) limit, the parking brake
Cable reel limits indicator light, cannot be released. It may be necessary to un-
first limit override button and re- plug the cable and manually reel the cable in
12
mote control for reels indicator until the final limit is deactivated again.
light (SH3)
2.Control place selection switch S45 on ERCP is
turned to position B (control from remote control).
• The indicator light goes off when switch S45 is
turned back to position A (control from tram-
ming panel).
• Parking brake release is enabled from the op-
erator station.
The diagnostic/manual regenera-
tion switch S22 May be used by the operator to prevent regeneration
• A: Regeneration disabled when the machine is operating in a hazardous environ-
ment and the OEM is concerned about high tempera-
• B: Regeneration enabled
ture. If the regeneration is disabled, the Regen Disa-
13 • C: Manual Regeneration / en- bled Lamp provides an indication to the equipment op-
gine diagnostic* (spring-return erator that Regeneration has been disabled and auto-
switch) matic and manual (non-mission) regeneration cannot
*Refer to the manual: Engine occur. NOTE! Refer to the engine manual.
fault codes.

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Engine diagnostics socket (for Tier4 engine)
Socket location.

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3.3.3 Switch panel (canopy model)
1.
S500 Not in use

0 - Stop
S501 Water booster pump I - Start (if powerpack is running)
S - Start (manually)
0 - Stop
S502 Compressor I - Start (if powerpack is running)
0 - Stop
S503 External pump (option) I - Start (with water booster pump)
External pump test Left - test earth fault relay.
S504
switch (option) Right - acknowledge after earth fault.
Pressure control reset button
S505
Press this after a fault to reset the fault.
Greasing system (op-
SH506
tion)
Emergency stop (op-
S507
tion)
Positioning laser switch
S508
(option)
S510 Canopy light
Warning beacon (op-
S511
tion)
Hydraulic oil tempera-
1
ture gauge

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3.3.4 Switch panel (cabin model)
S500 Not in use

0 - Stop
S501 Water booster pump I - Start (if powerpack is running)
0 - Stop
S502 Compressor I - Start (if powerpack is running)
0 - Stop
S503 External pump (option) I - Start (with water booster pump)
External pump test Left - test earth fault relay.
S504
switch (option) Right - acknowledge after earth fault
Pressure control reset button
S505
Press this after a fault to reset the fault.
Greasing system (op-
SH506
tion)
S507 Emergency stop
S508 Positioning laser switch
S510 Cabin light
Warning beacon (op-
S511
tion)

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3.3.5 Indicator panel (QN)
1 1-H613 1 2-H613 1 3-H613 2 H618 3 H619 4 H620
5 1-H612 5 2-H612 5 3-H612 6 H605 7 H606 8 H615
9 1-H611 9 2-H611 9 3-H611 10 H609 11 H601 12 H604
13 H602 14 H610 15 H614 16 H621 17 H617 18 H622
19 H608 20 H607 21 H603 22 H616 23 H623 24 H624
Powerpack of
1 boom 1 and 2
running (H613)
Compressor 1
2
running (H618)
Water booster
3 pump running
(H619)
Compressor 2
4 (optional) running
(H620)

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Overload of powerpack motor for boom 1 and 2. The indicator light

goes on if the motor’s protective switch (F100) is triggered or, if the
thermal protector alarms (motor temperature over 155°C). The pro-
Powerpack motor tective switch must be reset by turning its control switch first to 0 posi-
5
overload (H612) tion and then to 1 position. The thermistor protector is reset automati-
cally as the motor temperature drops. The indicator light goes on also
if the magnetic triggering of the protective switch comes activated
when the powerpack is started.
The indicator light goes on and the powerpack, the compressor and
Compressor 1
the water pumps stop when the compressor’s protective switch F240
6 motor overload
is triggered. The protective switch must be reset manually. Turn the
(H605)
main switch to the 0-position before resetting the protective switch.
Water booster
the water pumps stop when the water pump’s protective switch F230
7 pump motor
is triggered. The protective switch must be reset manually. Turn the
overload (H606)
main switch to the 0 position before resetting the protective switch.
High-pressure The indicator light goes on and the powerpack, the compressor, and
water pump mo- the water pumps stop when the high-pressure water pump’s protec-
8
tor overloaded. tive switch F280 is triggered. The protective switch must be reset
(H615) manually. (Optional)
Clogged pres- When the indicator light goes on, the pressure filter has come so dirty
sure filter of pow- that it must be replaced. The filter monitoring device does not stop
9
erpack for boom drilling functions. When the oil is cold (below 30°C), the monitoring
1 and 2 (H611) system is bypassed to avoid alarms caused by thick oil.
If the air pressure remains below 2.8 bar for more than 10 seconds
Air pressure low (default threshold), the pressure control system stops the drilling. The
10
(H609) indicator light remains on, and it can be turned off by pressing the ac-
knowledgment button (S505).
Low water pressure. If the water pressure falls below 2.8 bar for over
4 seconds (default value), the pressure control system stops the drill-
ing. The indicator light will remain on, and it can be turned off by
pressing the acknowledgment button S505. After this, drilling can be
Water pressure continued normally.
11
low (H601) If the water pressure falls below 2.8 bar for over 1 minute, the pres-
sure control system stops the drilling water pump. The indicator light
will remain on, and it can be turned off by pressing the acknowledg-
ment button S505. After this, the water pump must be started using
the manual switch S501.
When the temperature of the compressor's output air reaches 100°C
the indicator light goes on. Compressor is still functional, but the
warning light indicates either possible failure, or need for mainte-
Compressor air nance of the compressor, which should be checked as soon as possi-
12
too hot (H604) ble. Light stays on as long as temperature drops below 100°C.
When temperature reaches 115°C the power pack, compressor, and
water pumps stop. This is an indication that something has failed in
the compressor and shall be immediately investigated and fixed.

ID: BG00471036 en-US C.001.1 2018-05-28
If the oil level drops below the allowed minimum, the powerpack, the
compressor and the water pump stop and indicator light goes on. The
level monitoring system has a 3-second time delay for preventing
Hydraulic receiv-
false alarms if the oil level momentarily drops too low, for instance,
13 er oil level too
when the rig rocks.
low (H602)
The indicator light goes off when a sufficient amount of oil is added
and control system is reset by pushing button S505.
If the indicator light blinks, the oil level in the shank lubrication is low.
The indicator light goes on and the powerpack, compressor, and wa-
Hydraulic oil too ter pumps stop if the hydraulic oil temperature exceeds 75 °C. The in-
14
hot (H610) dicator light goes off automatically when the oil temperature has drop-
ped sufficiently.
When one of the emergency stop buttons is activated, this indicator
Emergency stop light goes on and all electric motors and the diesel engine stop. The
15
activated (H614) indicator light goes off when the button(s) are released, but the mo-
tors must be started separately.
16 (H621) Not in use
Main power
The indicator lights up when the main switch is turned to the ON posi-
17 switched on
tion.
(H617)
External pump
18
running (H622)
Shank lubrication
19 unit oil level low
(H608)
The indicator light goes on if the return oil filter has become so dirty
Return oil filter that it must be replaced. The filter control device does not stop the
20
clogged (H607) drilling functions. When the oil is cold (below 30 °C), the monitoring
system is bypassed to avoid alarms caused by thick oil.
When the main switch is turned on, the relay (K120) checks the three-
Phase sequence phase current for correct direction of rotation. If the direction of rota-
21
fault (H603) tion (i.e., the phase sequence) is incorrect, the indicator light comes
on and the motors are prevented from starting.
22 (H616) Not in use
Earth fault de-
23
tected (H623)
External pump
24 the water pumps stop when the protector switch F290 is triggered.
overflow (H624)
The switch must be reset manually. (Optional)

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3.3.6 Wipers
1 2 3 4 5 6 7
Windscreen washing valve (S524) (op-

1 On/off
tional)
Windscreen wiper's intermittent opera-
2 On/off
tion (S525)
3 Windscreen washer/wiper (S520) On/off
4 Right window washer/wiper (S521) On/off
5 Left window washer/wiper (S522) On/off
6 Rear window washer/wiper (S523) On/off
Fast wiping. Sprays wa-
ter on the windscreen
7 Windscreen washer/wiper (S526)
and makes a couple of
wiping movements.

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3.3.7 Hydraulic oil filling (and vacuum) on/off switch
A B
A) Vacuum pump start

B) Filling pump start
Hydraulic receiver filling pump
The switch must be held in this position for the entire
(and vacuum pump [optional])
1 duration of pumping.
start switch and indicator light
The indicator light comes on when the switch is held
(SH330)
on. The pump stops automatically when the hydraulic
receiver is full.

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3.3.8 Remote control for reel(s) (ERCP)
6
A
1 Emergency stop button (S35.1) Stops all electric motors and the diesel engine.
2 Reeling the cable out (S47.2)
3 Reeling the cable in (S47.1)
Reeling the water hose out
4
(S48.2) (if equipped)
Reeling the water hose in (S48.1)
5
(if equipped)
A) Control from tramming panel
• Selection A enables the parking brake release from
Control place selection for reel(s) the operator station.
6 B) Control from remote control (ERCP)
(S45)
• Selection B engages the parking brake and turns
the indicator lights (SH3 and SH2) on.

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3.3.9 Reversing camera monitor (optional)
1 2 3 4 5 6 8
7
Press the button to switch the monitor on/off.

There is a red light on the button when the monitor
1 Power power is switched on and it is on standby.
When the monitor is on, there is a green light on all but-
tons.
Press the button (for less than 0.5 seconds) to access
the display brightness, contrast, colour, or tone settings.
2 Menu
Press the button (for more than 2 seconds) to access
the SETUP MENU mode.
Press the button to select the camera.
3 Select Press the button to select submenus in the SETUP
MENU mode.
Press the buttons to adjust the display brightness, con-
trast, colour, or tone.
4 Dn/Up
Press the buttons to move up or down in the SETUP
MENU mode.
Press the buttons to adjust the speaker volume.
5 -/+ Press the buttons to select options in the SETUP
MENU mode.
6 Brightness sensor
7 Remote control sensor
8 Speaker
* For more information on using the monitor, refer to the sub-supplier's

documentation.

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3.3.10 Control devices for cooling and heating (cabin model only)
1 2 3 4 5 6
1. Air conditioning control knob for adjusting the cooler’s air temperature.
2. Selector switch for air intake. The blower can either take in fresh air
through the filter from outside the cabin or circulate the air in the cabin.
3. Temperature control for the warm air blown by the heater when using the
diesel engine
4. 4-position switch (0, 1, 2, 3) for adjusting the blowing speed.
5. Temperature control for the warm air blown by the heater when using an
electric heater.
6. 2-position switch (ON/OFF), power switch for the electric heater.
Note!
• Control knob (1) is not in use if there is no air conditioning in the rig.
• Control knobs (2), (3), (5) and switch (6) are not in use, if there is no
heating, but only air conditioning in the rig.
• Control knob (3) is not in use, if the rig has no heating during tramming.

ID: BG00471036 en-US C.001.1 2018-05-28
Cooling
1.Turn the air conditioning on by turning the

switch (4.) to the desired speed, and turn on
1 the cooling by turning the thermostat (1.) first
to maximum position (clockwise).
2.Choose internal air circulation from the con-
troller (2.). When using cooling, ALWAYS: -
2 keep all windows and doors closed.
3.Choose the appropriate fan speed using the
switch (4.). Adjust the blast air temperature
using the thermostat (1.) only if the cabin gets
too cold even at a lower fan speed. You can
4
also turn on the heating, and adjust the tem-
perature using the temperature controls (3. or
5.).
3 5
Note! Max. setting 3 is intended only for temporary (few minutes) use
when the vaporizer cell is in danger of freezing.
Adjust the cabin temperature so that it is pleasant for you, not according to
the temperature gauge. The human body cannot tolerate sudden extensive
temperature changes. Therefore it is recommended that the cabin
temperature not be more than 5 - 7 °C below the ambient (outside air)
temperature. Never direct the cold airflow directly at yourself.
4. Cooling can be used simultaneously with heat-

ing (over + 0°C). This way the air conditioning ef-
2 ficiently dries out the air in the cabin, which
keeps the windows from frosting. In this case, re-
member to keep the internal air circulation turned
on and the thermostat in the (1.) max. position.
1

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Heating
2
1.Turn the air conditioning on by turning the
1 switch (4.) to the desired speed, and turn on
0 the cooling by turning the thermostat (1.) first
6 to maximum position (clockwise).
2.Choose internal air circulation from the con-
troller (2.). When using cooling, ALWAYS: -
keep all windows and doors closed.
5 3.Choose the appropriate fan speed using the
switch (4.). Adjust the blast air temperature
using the thermostat (1.) only if the cabin gets
too cold even at a lower fan speed. You can
4 also turn on the heating, and adjust the tem-
perature using the temperature controls (3. or
5.).
Direct the airflow to the desired direction using the nozzles.

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3.3.11 Controls of the THC 560 drilling systems
Controls of the THC 560 drilling system in the safety canopy, SB/TB -boom
5 6 7 8 9 10 11 12
18
3 4 17
1 2 16
15
14
13 21
24
23
22
20
19
1 Water pressure gauge 2 Rotation pressure gauge

3 Percussion pressure gauge 4 Feed pressure gauge
5 Control lever of Two Rod 6 Rod handler control lever
System (optional) (optional)
7 SLU oil flow error /Stabilizer 8 Flushing control selector
pressure low (optional) switch (optional)
9 SLU/KVL oil level low (op- 10 Powerpack start / stop
tional for KVL)
11 Emergency stop button 12 Return automatics selector
switch
13 Boom lift and swing lever 14 Boom zoom and boom head
rotation lever
15 Feed tilt and swing lever 16 Feed transfer and extra tilt
lever
17 Rod retainer control lever 18 Rotation speed control knob
(optional)
19 Flushing control lever 20 Fast feed control lever

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21 Feed force regulating knob 22 Rotation control lever

23 Percussion control lever 24 Feed control lever

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Common functions of the safety canopy
1 Turn the switch into the START-position and release to start the
powerpack.
2 Powerpack running.
3 Turn the switch into the O-position to stop the powerpack.
1 Drilling without return-automatics selected.

2 Drilling with return-automatics selected.
3 Automatic return before reaching front limit. Turn the selector
switch right and release it to middle position.

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1 Water flushing flow control ON

2 Flushing flow control OFF
3 Air mist flushing flow control ON
1 Push emergency stop button to stop the powerpacks, the compres-

sor and the waterpump
1 Indicator light for SLU/KVL oil level low.
1 Indicator light for SLU oil flow error / Stabilator pressure low

ID: BG00471036 en-US C.001.1 2018-05-28
1 Push lever forward to rotating clockwise (thread opening).

2 Pull lever backwards to rotating counterclockwise (drilling).
1 Push lever for full percussion (used to loosen the bit).

2 Pull lever backwards to activate percussion in drilling.

ID: BG00471036 en-US C.001.1 2018-05-28
1 Push lever forward to activate feed backwards.

2 Pull lever backwards to activate feed forward.
1 Push lever forward to activate air flushing.

2 Pull lever backwards to activate water flushing.

ID: BG00471036 en-US C.001.1 2018-05-28
1 Push lever forward to activate fast feed backwards.

2 Pull lever backwards to activate fast feed forwards.
1 Turn clockwise to increase rotation speed.

2 Turn counterclockwise to decrease rotation speed.
1 Turn clockwise to increase feed pressure.

2 Turn counterclockwise to decrease feed pressure.

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SB/TB -boom controls in canopy model
4
3
1 Boom lowering
2 Boom lifting
3 Boom swing left
4 Boom swing right

ID: BG00471036 en-US C.001.1 2018-05-28
3 4
1 Boom zoom out

2 Boom zoom in
3 Boom head rotation counterclockwise
4 Boom head rotation clockwise
1 Feed tilt down

2 Feed tilt up
3 Feed swing left
4 Feed swing right

ID: BG00471036 en-US C.001.1 2018-05-28
3 4
1 Feed transfer forward

2 Feed transfer backwards
3 Bolting cylinder out
Divergence down
4 Bolting cylinder in
Divergence up
1 Push lever forward to close Pito jaws

2 Pull lever backwards to open Pito jaws

ID: BG00471036 en-US C.001.1 2018-05-28
1 Push lever left to rod retrieve rotation

2 Push lever right to rod supply rotation
1 Push lever forward to close clamping devise

2 Push lever left to extend rod handler
3 Push lever right to withdraw rod handler
4 Pull lever backwards to open clamping devise

ID: BG00471036 en-US C.001.1 2018-05-28
Controls of the THC 560 drilling system in the safety cabin, TB-boom
7 8 9 10 11 12
1 2 3 4 5 6
13 14
15 16
17 18 19
20
23
21 22
1 TFX control switch (optional) 2 Water mist flushing potenti-

ometer (not in use)
3 Control lever of Two Rod 4 Flushing flow control selector
System (optional) switch (optional)
5 SLU oil flow error / Stabilator 6 Emergency stop button
pressure low / SLU oil level
low indicator light (optional)
7 Power extractor push button 8 Water mist flushing selector
(not in use) switch (not in use)
9 PITO-control switch (option- 10 Powerpack start / stop
al)
11 Automatic flushing bypass 12 Return automatics selector
switch (not in use) switch
13 Boom lift and swing lever 14 Boom zoom and boom head
rotation lever
15 Feed tilt and swing lever 16 Feed transfer and extra tilt
lever
17 Rotation control lever 18 Percussion control lever
19 Feed control lever 20 Rotation speed control knob
21 Flushing control lever 22 Fast feed control lever
23 Feed force regulating knob

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Common functions of the safety cabin
1 Turn the switch into the START-position and release to start the
powerpack.
2 Powerpack running.
3 Turn the switch into the O-position to stop the powerpack.
1 Drilling without return-automatics selected.

2 Drilling with return-automatics selected.
3 Automatic return before reaching front limit. Turn the selector
switch right and release it to middle position.

ID: BG00471036 en-US C.001.1 2018-05-28
1 Water flushing flow control ON

2 Flushing flow control OFF
3 Air mist flushing flow control ON
1 Indicator light for SLU oil flow error / Stabilator pressure low
1 Push emergency stop button to stop the powerpacks, the compres-

sor and the waterpump

ID: BG00471036 en-US C.001.1 2018-05-28
1 Push lever forward to rotating clockwise (thread opening).

2 Pull lever backwards to rotating counterclockwise (drilling).
1 Push lever for full percussion (used to loosen the bit).

2 Pull lever backwards to activate percussion in drilling.

ID: BG00471036 en-US C.001.1 2018-05-28
1 Push lever forward to activate feed backwards.

2 Pull lever backwards to activate feed forward.
1 Push lever forward to activate air flushing.

2 Pull lever backwards to activate water flushing.

ID: BG00471036 en-US C.001.1 2018-05-28
1 Push lever forward to activate fast feed backwards.

2 Pull lever backwards to activate fast feed forwards.
1 Turn clockwise to increase rotation speed.

2 Turn counterclockwise to decrease rotation speed.
1 Turn clockwise to increase feed pressure.

2 Turn counterclockwise to decrease feed pressure.

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TB-boom controls in cabin model
4
3
1 Boom lowering
2 Boom lifting
3 Boom swing left
4 Boom swing right

ID: BG00471036 en-US C.001.1 2018-05-28
3 4
1 Boom zoom out

2 Boom zoom in
3 Boom head rotation counterclockwise
4 Boom head rotation clockwise
1 Feed tilt down

2 Feed tilt up
3 Feed swing left
4 Feed swing right

ID: BG00471036 en-US C.001.1 2018-05-28
3
4
1 Feed transfer forward

2 Feed transfer backwards
3 Bolting cylinder out
4 Bolting cylinder in
1 Push lever forward to close clamping devise

2 Push lever left to extend rod handler

ID: BG00471036 en-US C.001.1 2018-05-28
3 Push lever right to withdraw rod handler

4 Pull lever backwards to open clamping devise
1 PITO control switch, PITO close

2 PITO control switch, PITO open
1 Control switch for TFX--feed.

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THC 560 drilling pressure gauges
Cabin model
1. 1.
2. A B 2.
3. 3.
4.
5.
6.
A Left boom
B Right boom
1 Percussion pressure gauge
2 Feed pressure gauge
3 Rotation pressure gauge
4 Water pressure gauge
5 Hydraulic oil temperature gauge
Fast wipe. Sprays water to the front window and

6
wipes couple of times.

ID: BG00471036 en-US C.001.1 2018-05-28
Canopy model
3
4
1
2
1 Water pressure gauge
2 Rotation pressure gauge
3 Percussion pressure gauge
4 Feed pressure gauge

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3.3.12 Utility boom controls

Preparations for moving the utility boom
The jacks function only when the key switch (S3) (C) has been moved to
the position ‘control from the drilling site’. The key switch is located on the
tramming panel.
WARNING! TIPPING HAZARD!
Faulty operation of the utility boom could result in death or severe
injury.
Before the utility boom operation ensure that the front jack beam is
extended and all jacks have been lowered to the ground. Check that
the jack extension indicator lights are illuminated.
S40 S41 S43 B
S3
S42 S44
When you start using the utility boom, make sure that all four indicator
lights (A) (B) are lit to indicate that the jacks have reached the ground.
The order of using front jack beam and jacks:
1. Extend the front jacks first. The lights in buttons (A) light up to indicate
that the jacks have reached the ground.
2. Then extend the rear jacks. The lights in buttons (B) light up to indicate
that the jacks have reached the ground.
When you stop drilling or using the utility boom, the order is reversed, i.e.
first raise the rear jacks and then raise the front jacks. The lights in the
control switches go out to indicate that the jacks are in transport position.
Before starting tramming, inspect visually that the jacks are fully retracted
and the rig is ready for transport.

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Controlling the utility boom from the operator station
1 2 3 4
1 2 3 4
1 Utility boom valve activating lever

2 Utility boom lifting and lowering lever
3 Utility boom swing left and right
4 Utility boom zoom in and out

ID: BG00471036 en-US C.001.1 2018-05-28
Controlling the utility boom from the basket
If you intend to control the utility boom from the basket, the key switch (S3)
on the tramming panel must be moved to the position ‘control from the
basket’. After this, the operator must take the key along to the basket. This
prevents use of the basket and jacks from the drilling site.
Note! In case of emergency, use spare key (A) located in the canopy
module / cabin.
Running the utility boom from the basket is selected by pressing the utility
boom control panel activation button (7).
The selection is deactivated by pressing the button (7) again.

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SUB utility boom controls
1
2
3
4
5
A Basket tilt B Canopy lift (optional)

1 Boom tilt 2 Boom swing
3 Boom zoom 4 Boom lift
5 Safety canopy control 6 Emergency stop
7 Free circulation valve button 8 Utility boom over center
(locks boom movements and valves
control valves)

ID: BG00471036 en-US C.001.1 2018-05-28
S3
1 2 3 4 5
Control lever Forwards Backwards

1. Boom tilt Tilt up Tilt down
2. Boom swing Boom right Boom left
3. Boom zoom Zoom in Zoom out
4. Boom lift Boom down Boom up
5. Safety canopy (optional) Canopy down Canopy up
3.4 MSE - Main switchgear and circuit breakers (380-690V)

PERSONAL INJURY HAZARD!
Take the safety equipment seriously. If the safety system prevents
the use of a device, call an electrician to solve the problem
immediately.
WARNING! ELECTRICAL HAZARD!

Electric shock could cause death or severe injury.
The product main switch does not switch off the voltage from the
cable reel or from the slip rings.

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Q1 0 0
1
F451.1
F451.2
F451.4
F451.5
F451.6
F452.1
F452.2
F452.3
F452.4
F452.5
F453.1
F453.2
F453.3
F453.4
F453.5
F454.1
F454.2
F454.3
F454.4
F450
P4 1 0
0
F312
F252
F253
F333
OPTION
OPTION
OPTION
OPTION
OPTION
OPTION
OPTION
OPTION 1 P1 0 1 2 P1 0 1 F2 9 1 F31 1 F2 5 1
( 1 P1 2 8 ) ( 2 P1 2 8 )
S3 0 0 1 P1 0 0 2 P1 0 0 P4 0 0 3P100 3P101
OP T I O N OP T I O N
OPT.
3 - P H EF S P H OR C A B I N
O P T I ON O P T I ON OP T I ON OP T I O N OPTION
X2 4 X4 1 X2 8
X6 3
A Third boom cabinet. Not used with utility boom

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3.4.1 Switches and gauges
Q100 Main switch, cuts off power supply

S300 Emergency stop button (optional)
Gauges:
1P100 Rock drill percussion hour meter for boom 1

Hour meter for power pack 1 / 1P128 Hour meter for power ex-
1P101
tractor, boom 1
2P101
tractor, boom 2
3P101
tractor, boom 3 (optional)
P400 Compressor hour meter
P410 Supply voltage meter
F253
F333
F251
F312
F291
F252
F311
Q100
1
F454.4
F453.2
F453.3
F453.4
F454.1
F453.1
F454.2
F454.3
F453.5
F451.1
F451.6
F452.3
F451.2
F451.4
F452.2
F451.5
F452.4
F452.1
F452.5
F450
P410 0
OPTION
F252
F253
F333
F312
OPTION
OPTION
OPTION
OPTION
OPTION
OPTION
1P101 2P101
OPTION
F291 F311 F251

( 1P128) ( 2P128)
S300 1P100 2P100 P400
OPTION OPTION
3-PH EFS PHOR CABI N
OPTION OPTI ON OPTI ON OPTI ON
OPT.
X24 X41 X28

X 63
F451.1
F451.2
F451.4
F451.5
F451.6
F452.1
F452.2
F452.3
F452.4
F452.5
F453.1
F453.2
F453.3
F453.4
F453.5
F454.1
F454.2
F454.3
F454.4
F450
Includes 220 VAC and 24 VDC power supply devices and the control
circuits.
Circuit breakers
F251 Fault current circuit breaker for sockets.
F252 1-phase circuit breaker for sockets X430 and X431.

ID: BG00471036 en-US C.001.1 2018-05-28
F253 Circuit breaker for cabin heater (optional).

F333 Circuit breaker for PLC A100 (optional).
F291 Fault current circuit breaker for 3-phase socket (optional).
F311 Fault current circuit breaker for internal 220 V control voltage in main switch gear.
F312 Circuit breaker for internal 220V control voltage in main switch gear.
F450 Circuit breaker for internal 24V control voltage in main switch gear
F451.1 -
Circuit breakers for control system and instruments.
F451.6
F452.1 -
Circuit breakers for lights, jacks control and hydraulic oil filling pump control.
F452.5
F453.1 -
Circuit breakers for cabin wiring harness. (optional).
F453.5
F454.1 -
Circuit breakers for A100 outputs, SUB (optional) and hydraulic oil filling pump.
F454.4
3.5 1000 V main switch equipment and circuit breakers (optional)

immediately.

A Third boom cabinet. Not used with utility boom

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Voltage is over 50 VAC in the electrical circuits of the electric motors,

working lights, cabin heater, and socket outlets. Sensors, switches,
indicators, and the electric control of hydraulics use a reduced voltage (24
VDC).
Water must never be sprayed directly at the rig’s electric boxes or
cabinets!

ID: BG00471036 en-US C.001.1 2018-05-28
Cuts off the power feed. Does not cut off the voltage to the
cable reel and the slip rings, nor the carrier battery voltage.
The switch can be locked in the 0 position. The main switch
also cuts off power to the pilot conductor that monitors the
Q100 Main switch.
supply cable and the protective conductor. The pilot conduc-
tor is an optional piece of equipment. When the main switch is
turned to position 1 (ON), the switchgear cabinet door is
locked.
Resetting of electronic motor protector relays (optional, lighted when hydraulic oil cool-
SH300
er motor protector contactor trips).
S301 Emergency stop button (optional).
Gauges
Rock drill percussion hour meter for Rock drill percussion hour meter for
1P100 2P100
boom 1. boom 2.
Hour meter for powerpack 1 / 1P128
Rock drill percussion hour meter for
3P100 1P101 Hour meter for power extractor,
boom 3 (optional).
boom 1 (optional).
Hour meter for powerpack 2 / 2P128 Hour meter for powerpack 3 / 3P128
2P101 Hour meter for power extractor, 3P101 Hour meter for power extractor,
boom 2 (optional). boom 3 (optional).
Supply voltage meter with digital
P400 Compressor hour meter. P410
scale (100 % = 1000 V).

ID: BG00471036 en-US C.001.1 2018-05-28
3.5.2 Circuit breakers
F251 Fault current circuit breaker for sockets (optional).

F252 1-phase circuit breaker for socket X430 and X431 (optional).
F311 Fault current circuit breaker for internal 220 V control voltage in main switchgear.
F312 Circuit breaker for internal 220 V control voltage in main switchgear.
F313 Circuit breaker for cabin heater. (optional).
F317 Circuit breaker for options (optional).
F333 Circuit breaker for A100.
F450 Circuit breaker for internal 24 V control voltage in main switchgear.
F451.1 -
Circuit breakers for control system and instruments.
F451.6
F452.1 -
Circuit breakers for lights and jacks control.
F452.5
F453.1 -
Circuit breakers for cabin wiring harness (optional).
F453.4
F453.5 Circuit breaker for options (optional).
F454.1 - Circuit breakers for A100 outputs, SUB (optional), and hydraulic oil filling pump con-
F454.3 trol.
F454.4 Circuit breakers for fuel filter supply (optional).
F470 Protective switch for phase sequence monitoring relay and hydraulic oil coolers.

ID: BG00471036 en-US C.001.1 2018-05-28
3.6 MSC / MSU main switch equipment and circuit breakers (optional)
immediately.

2P100 P410
1P100 OPTION P400
8888
8888
8888
1P101 2P101
OPTION
F312
F313
F314
F315
F316
F317
F318
F311
OPTION
F451.1
F451.2
F451.3
F451.4
F451.5
F451.6
F452.1
F452.2
F452.3
F452.4
F452.5
F450
X300
Q100
F453.1
F453.2
F453.3
F453.4
F453.5
F454.1
F454.2
F454.3
1H295 2H296 H106 S301S302

OPTION
OPTION
CABIN OPTION
CABIN OPTION
CABIN OPTION
CABIN OPTION
CABIN OPTION
TBB OPTION
X24 X41 X28

X63
Water must never be sprayed directly at the rig’s electric boxes or

cabinets!

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Analog voltmeter -version
P410
F311
F312
F313
F314
F315
F316
F317
F318
OPTION
F451.1
F451.2
F451.3
F451.4
F451.5
F451.6
F452.1
F452.2
F452.3
F452.4
F452.5
F450
X300
F453.1
F453.2
F453.4
F453.5
F454.1
F454.2
F454.3
F454.4
F454.5
F454.6
F453.3
Q100
Axera6 OPTION
Axera6 OPTION
Axera6 OPTION
CABIN OPTION
CABIN OPTION
CABIN OPTION
CABIN OPTION
CABIN OPTION
TBB OPTION
2P100 P400 1H295 2H296 H106 S301S302

1 1
1P100 10
OPTION
OPTION
OPTION
1P101 1
10 1
2P101
OPTION
X24 X41 X28

X63
Digital voltmeter -version

Voltage is over 50VAC in the electrical circuits of the electric motors,
working lights, cabin heater, and socket outlets. Sensors, switches,
indicators, and the electric control of hydraulics use a reduced voltage
(24VDC).

ID: BG00471036 en-US C.001.1 2018-05-28

Main switch has thermal and magnetic tripping. They protect the main
panel internal wiring. The settings must be done to meet the machine total
power.
Main switch; cuts off the power Q100 is equipped with undervoltage relay which
Q100
supply cuts off the power supply if K106 is activated.
1-phase socket outlet is equipped

X300 S301 for pilot and ground control
with 5mA ground fault sensing unit
S302 for pilot and ground control K300 for pilot and ground control
overload for oil / air cooler 1 (option- overload for oil / air cooler 2 (option-
1H295 2H296
al) al)
H106 ground fault of main switchgear 1P100
boom 1
2P100 1P101 Hour meter for powerpack 1
boom 2 (optional)
2P101 Hour meter for powerpack 2 P400 Compressor hour meter
Supply digital voltage meter + supply
P410 A-meter or alternatively supply ana-
log voltage meter

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3.6.2 Circuit breakers

If the device is connected to a power supply, set the circuit breaker
to position I only when the main switch is in position O.
F312
F313
F314
F315
F316
F317
F318
F311
OPTION
F451.1
F451.4
F452.1
F452.2
F452.4
F451.2
F451.3
F451.5
F451.6
F452.5
F452.3
F450
F453.1
F454.3
F454.1
F453.2
F453.3
F453.4
F453.5
F454.2
TBB OPTION
CABIN OPTION
CABIN OPTION
CABIN OPTION
CABIN OPTION
CABIN OPTION
F310 Fuses for external control transformer

F311 Ground fault sensing braker for cabin heater
F313 -
Circuit breakers for 110 V working lights (optional)
F314
F315 Circuit breaker for 1-phase socket
F316 Circuit breaker for cabin heater (optional)
F317 Circuit breaker for control voltage
F318 Circuit breaker for power source of 24VDC
F320 Fuses for voltage meter and phase sequence relay
F450 Circuit breaker for internal 24V control voltage in main switch gear
F451.1 -
Circuit breakers for control system and instruments
F451.4
F451.5 -
Circuit breakers for carrier
F451.6
F452.1 - Circuit breakers for hydraulic oil filling pump control, working lights, utility boom con-
F452.5 trol and beacon (optional)
F453.1 -
Circuit breakers for 24 V supply of cabin
F453.5
F454.1 Circuit breaker for MTU

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F454.2 Circuit breaker for hydraulic oil filling pump

F454.4 Circuit breaker for carrier

ID: BG00471036 en-US C.001.1 2018-05-28

ID: BG00471036 en-US C.001.1 2018-05-28
4 Periodic maintenance

ID: BG00471036 en-US C.001.1 2018-05-28
4.1 Importance of scheduled maintenance

The continued operation of the rig is ensured by regular maintenance
carried out correctly at the proper intervals. The purpose of regular
maintenance is to check the rig at regular intervals, ensuring a high uptime
for the rig. This prevents high repair costs and lost productivity. Neglecting
maintenance leads to high extra costs.
It is important to carry out daily maintenance routines carefully. All possible
faults must be repaired immediately or reported to the person in charge.
Daily maintenance includes general lubrication, inspections, and
adjustments. Each new operator must be familiarized with the daily
maintenance routines.
Note! Intervals listed for scheduled maintenance are usually based on
diesel engine hours or rock drill percussion hours.
It is recommended to keep a record of the use of maintenance and wear
parts. This way, the need for preventive maintenance can be predicted
more easily, resulting in the rig’s improved usability, service life, efficiency
and safety.
Failure to take necessary precautions increases the safety risk for the
service personnel. All maintenance personnel working with the rig must be
fully aware of possible hazards and must apply safe working methods.
Before any maintenance or repair work, the manufacturer’s instructions
must be read carefully, and they must be followed exactly.
The person responsible for maintenance and repair work must be clearly
specified.
Pay attention to the following:
• Never attempt to carry out tasks for which you have not received the
relevant training or authorisation.
• Inform the rig operator about the start of maintenance and repair work.
• Before starting the work, ensure that all unnecessary items are cleared
from the vicinity of the site and that the area is safe to work in.
• If maintenance or repair work is to be carried out on the rig, always
ensure that the rig cannot be accidentally started:
- Turn the main switch off.
- Remove the ignition key.
• Place a DANGER - DO NOT START warning sign on the main switch.
The sign may only be removed by a person who is fully aware of the
current status of the work.
• Clean and wash the rig regularly, and always before starting
maintenance or repair work.
• Before washing the rig with water, a high-pressure cleaner, a steam
cleaner, or any other method, protect any components that are
susceptible to damage from the cleaning method or due to exposure to
water. Pay special attention to the protection of electric motors, boxes,
and cabinets.

ID: BG00471036 en-US C.001.1 2018-05-28
• If necessary, equip the work site with appropriate steps or working

platforms.
• Never use the components of the rig as steps. If the work is carried out at
height, or in an otherwise dangerous position, use proper working
platforms to prevent falling. Never climb on the rig's covers.
• Keep all stairs, rails, anti-slip devices, steps, etc. clean of oil, grease,
snow, ice, unnecessary items, and dirt to prevent accidents caused by
slipping.
• Use only undamaged, high-quality tools that are appropriate for the work
in question.
• Before starting the work, ensure that the rig is on a level surface and the
park brake is engaged and that all tracks/wheels are wedged or that the
jacks are lowered to prevent movement.
• Observe the operation and condition of the exhaust pipe and exhaust
cleaner in particular, and ensure sufficient ventilation.
• Diesel engine overheating indicates a fault. Stop the engine and address
the cause of the overheating in order to prevent damage to the engine.
Ensure that air can flow freely through the engine's radiator. If necessary,
clean the radiator and remove any obstructions.
• Stop the engine and allow it and the coolant to cool down before
checking the coolant level. If this is not possible, use protective gloves
and other protective clothing when opening the radiator cap, in order to
prevent burns and related injuries. Stand as far to the side as possible,
turn your face away, and carefully open the cap slightly. Before opening
the cap fully and removing it, wait until the pressure or coolant stops
discharging from the cooling system.
• Use appropriate hoists and lifting methods when moving heavy parts and
equipment. Follow the hoist manufacturer's instructions.
4.2 General maintenance instructions

WARNING! ENVIRONMENTAL HAZARD!
Incorrect disposal of used parts and fluids could cause damage to
the environment.
Dispose of used parts and fluids in accordance with the local
environmental regulations.
See the general safety instructions for maintenance-related
environmental protection measures.
1. Park the rig on a steady and level surface.

2. Ensure that the rig cannot move by itself. (If necessary, lift the rig onto
the jacks, or use the parking brake and tire wedges.)
3. Always stop the rig before commencing maintenance procedures.
Prevent accidental starting of the rig by turning the product main switch
off or by removing the ignition key.

ID: BG00471036 en-US C.001.1 2018-05-28
4. Wash the rig before maintenance.

Do not use solvents that contain aromatic or chlorinated hydrocarbons.
Using mineral-oil-based fuels, such as gasoline, diesel oil, or petroleum,
as detergent is also forbidden. These substances can cause
deterioration, cracking, or softening of rubber and plastic parts.
5. Ensure that all necessary tools, spare parts, and accessories (oils,
lubricants, etc.) are on hand.
6. Clean the area around the filling cap thoroughly before adding fuel or oil.
7. When replacing the filters or changing oils, ensure that the oil added is
pure.
8. A high particle content in the oil (e.g., the filter becomes clogged rapidly)
can indicate some kind of fault. Find out the reason for this situation
before more serious damage is done.
9. Beware of hot surfaces and oils. Dispose of waste oil and used filters
according to local regulations.
10. Reinstall protective rails, covers and insulation materials after
maintenance.
11. Ensure that the hoses and cables cannot get entangled or tightened
during use of the rig.
If necessary, contact Sandvik's service for further information.

ID: BG00471036 en-US C.001.1 2018-05-28
4.2.1 Filling the fuel tank

Handle fuel with care: it is highly flammable.
WARNING
FIRE HAZARD!
Smoking, open flames, and sparks during refueling or handling of
the fuel tank could cause death or severe injury.
Do not refuel the machine while smoking or when near open flame or
sparks.
WARNING! FUEL SPLASHING HAZARD!

The fuel splashing into the eyes could cause severe injury.
Wear eye protectors when refueling the machine.
When filling the fuel tank, follow these instructions:

• Always stop the engine before refueling the machine.
• In addition, switch the cabin heater / air conditioning off.
• Keep the fuel gun in contact with the filling tube.
If this is not possible, arrange for the gun to be earthed in some other
way.
This eliminates possible sparks caused by static electricity.
• Ensure that no fuel is spilled onto hot surfaces.
• Never lock the nozzle lever in motion without looking after it.
• Wipe spilled fuel off before starting the engine.
• Prevent fires by keeping the machine clean of accumulated trash,
grease, and debris.
Note! See separate instructions if the drill rig is equipped with the
Wiggins fast fuel system.

ID: BG00471036 en-US C.001.1 2018-05-28
4.2.2 Maintenance of the hydraulics
DANGER
CRUSHING HAZARD!
Unexpected boom movement will cause death or severe injury.
Before removing the cylinders or their overcenter or non-return
valves, support the boom, feed and rock drill/top drive carefully so
that they do not move during maintenance. Do not work under
components that are supported only by hydraulics.
WARNING
HIGH-PRESSURE FLUID HAZARD!
High-pressure fluid remaining in hydraulic lines could cause death
or severe injury.
Never carry out maintenance or repair work on a pressurized system.
Relieve pressure before opening fittings, plugs or hydraulic valve
cartridges. Always make sure the parts are not pressurized. Use a
bleeder screw to relieve the pressure behind the valves or
cartridges, or wait until the rig is depressurized before removing the
components.
Protect your eyes by wearing safety goggles.
WARNING
FIRE HAZARD!
Flammable spray resulting from heat near the pressurized fluid lines
could cause death or severe injury.
Do not weld, solder, or use a torch near pressurized fluid lines or
other flammable materials. Pressurized lines can burst when heated.
WARNING
BURN HAZARD!
Contact with the hot oil circulating in the hydraulic systems could
cause death or severe injury.
Let the oil cool down before starting any maintenance work.

ID: BG00471036 en-US C.001.1 2018-05-28
WARNING
HYDRAULIC FLUID INJECTION HAZARD!
High-pressure hydraulic fluid sprays can penetrate the skin and
could cause death or severe injury.
Search for leaks with a piece of cardboard or wood. Never try to
locate a leak by feeling with your hand. Seek immediate medical
attention if you are hit by a hydraulic fluid spray.
Maintenance and repair work on the hydraulics and installation of

components may only be carried out by persons who have received the
training required for the work. Do not start work that is not fully familiar to
you.
• Do not use the drill rig if there is a leak in the hydraulic system.
• Stop the power pack and diesel engine before repairing a leaking hose or
tightening a connector.
• Oil sprays can also easily cause a fire.
• Prevent oil splashes by wrapping a cloth around the component.
• Avoid skin contact with oil.
• Ensure that the new hose connectors and hose types correspond to the
types originally used by the manufacturer and are the same length.
When replacing hoses and connectors, use only original Sandvik parts or
equivalent parts approved by Sandvik (see the parts manual for
additional information). Also ensure that the hoses and connectors are
rated for the pressure level they will be subjected to.
• Ensure that all the connections will be made according to the hydraulic
diagram.
• Check the movements of the rig before use.
4.2.3 Pneumatic system maintenance
WARNING
HIGH PRESSURE INJECTION HAZARD!
Compressed air jets could cause death or severe injury.
Ensure that the pneumatic system is not pressurized before starting
maintenance of the compressor or other pneumatic system
components.
The system may not be pressurized to a higher pressure level than
that specified by the manufacturer. Increasing the pressure level
does not increase the rig’s performance level.

ID: BG00471036 en-US C.001.1 2018-05-28
4.2.4 Maintenance of the rock drill pressure accumulators
WARNING
HIGH PRESSURE PNEUMATIC SYSTEM HAZARD!
High pressure compressed air spray could cause death or severe
injury.
Do not pressurize the accumulators to a pressure greater than that
specified.
The disassembly, inspection, assembly, and pressurization of the pressure

accumulators are discussed in pressure accumulator instructions.
Rock drill pressure accumulators are filled with nitrogen N2. Before
removing the pressure accumulators from the rock drill, release the
accumulators’ pressure by opening the filling valve.
4.2.5 Electric system maintenance - Safety instructions
DANGER
ELECTRICAL HAZARD!
Failure to strictly follow instructions will lead to severe injury and/or
death and/or property damage.
Work on electrical equipment or devices is to be performed only by
persons with the expertise and qualifications required by the
authorities, or under the supervision of a person meeting these
requirements.
Make sure that the instructions set forth below are read and
understood before any electric system maintenance.

ID: BG00471036 en-US C.001.1 2018-05-28
Performing maintenance on electrical components

Failure to follow these instructions could lead to death or severe
injury.
Isolate the machine by turning off the main switch and removing the
power plug from the electrical network before any work on electrical
components.
Ensure that nobody connects the power on during the maintenance
or repair work!
Electrical safety tests and measurements must be done before
operating the machine.
• The work must be carried out according to local electric safety

regulations.
• Always use approved, correct and certified electrical testing equipment
and personal protective equipment.
• When performing electrical work, always ensure that the machine is
disconnected from the supply network before any service, repair or
maintenance. Ensure that the components in question are not live, and
then lock the main switch or arrange appropriate grounding.
• When the electrical cabinet main switch is switched off, always be aware
that this does not normally isolate the electrical supply going into the
machine’s electrical cabinet. Hence, the trailing cable, cable reel and
cable going to the live side of the main switch remain live!
(This is the case unless a separate Pilot core electrical system has been
adopted at the work site and the pilot core is wired through the machine’s
main switch!)
• Do not open live junctions or terminal boxes on electric motors, cable
reel, electrical cabinets, light fittings, HID gas discharge lamp fittings or
the like.
• Check the condition of the drill rig's electrical devices regularly.
• Check the operation of the earth leakage control system from the gate
end panel weekly. If the control does not switch the power off, the control
system must be repaired or replaced before any device connected to it is
started.
• Fuses and the circuit breakers are protecting the wires and electrical
components against overheat and fire in case of overload and short
circuit.
• Breaker tripping or fuse burn is a sign of failure. Before resetting the
breaker or replacing the fuse the failure must be repaired. The original
fuse size and type must be used. Never replace the fuse with a fuse
having higher ampere value than the original.

ID: BG00471036 en-US C.001.1 2018-05-28
Modifications to electrical systems

Electrical modifications to the drill rig require written permission
from Sandvik Mining and Construction Oy's electrical design
department to ensure the correct operation of the modified device.
• When replacing any electrical components or wiring, always use original

parts of original equipment manufacturer and use the correct installation
and testing procedure before operating the machine. All changes or
corrections should be documented for future reference.
• Use the original cable routing and clamping when replacing cables.
• Current settings of circuit devices such as overloads, circuit breakers and
other protective devices shall only be set to the specifications of original
equipment manufacturer.
Replacing the light bulbs

WARNING! ELECTRIC SHOCK HAZARD!
Failure to follow these procedures could result in severe injury!
Cut the supply voltage to the light using the main switches before
replacing the bulbs of the working and driving lights.
Exercise extreme caution when performing work on HID gas
discharge lamps. The light components include high voltage parts.
• Note that parts of the light may be hot after use, so allow it to cool before
commencing repair work.
• The bulbs of gas-discharge lamps are gas-filled, so handle with care.
Use gloves and safety glasses.
• Do not touch the lamp holder or the glass part of the bulb when carrying
out the replacement.
• Use proper servicing stands when changing the light bulbs.

ID: BG00471036 en-US C.001.1 2018-05-28
4.2.6 Maintenance of the batteries

The sulfuric acid in the battery electrolyte is poisonous and strong
enough to burn skin, eat holes in clothing, and cause blindness if
splashed into the eyes. Personal protective equipment and eye
flushing facilities must be available near the charging location.
Always wear protective equipment such as safety goggles, protective
overalls, protective footwear, and protective gloves when working
with batteries. Open flames, smoking, and work that causes a spark
are strictly prohibited during the servicing of batteries. Static sparking
must be prevented with insulating shoes or by safely discharging the
static charge.
DANGER
EXPLOSION, ELECTRIC SHOCK AND CHEMICAL BURN HAZARD!
Incorrect handling of the battery will cause death or severe injury.
Always follow the following special instructions when handling
batteries.
• Electrical work concerning batteries that have a short-circuit current over

1000 A must be performed by qualified electricians only.

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• Always consider the danger of explosion when handling batteries. When

the battery is charged or discharged, lead and acid generate oxygen and
hydrogen, which, in turn, form a highly explosive gas. A battery in use
must always be handled on the assumption that there is explosive gas in
its cells and ventilation ducts. Gas is present even after charging of the
battery for an extended time. A spark near the battery can ignite the
explosive gas. If the battery explodes, the acid will flow around it when it
breaks open. The energy of the short circuit is sufficient for melting the
metallic parts of the short-circuited parts. Thus, drops of melted metal
can also fly around in the explosion. A spark can be caused by, for
example,
- disconnecting or connecting of the battery clamp
- a short circuit between the battery terminals or between the positive
terminal and the frame
- grinding or welding
- use of a match or a lighter
- smoking
- static electricity.
In order to eliminate the risk of explosion, the battery electrolyte level
must be kept stable and checked regularly. Add distilled water, if
required, before starting, never after that. The space remaining for gas in
the cells can be eliminated by keeping the electrolyte level of the battery
as high as possible.
• Open flames are strictly prohibited in the charging room and the
immediate vicinity of the charging area.
• Battery acid must not be stored in the charging area.
• If you get acid on your skin, rinse the affected area immediately with
plenty of water. If battery acid gets in your eyes, neutralize it first with
sodium carbonate. Then rinse with plenty of water and seek medical
advice.
• Always loosen the battery cell caps before charging, to allow the gases
generated during charging to escape. Provide appropriate ventilation to
ensure that the gases generated during charging can escape to external
air.
• Charging is done by the machine's own alternator or charger or by a
separate battery charger. If a separate battery charger is used, see the
charger manufacturer's instructions.
• Do not charge a frozen battery. Warm the battery to approx. 16°C (60°F)
before charging.
• Be especially careful when you are charging an empty battery.
• Batteries cannot be tilted during charging, measurement, or start-up
assistance.
• Do not test electrical equipment by using the battery terminals.
• Never check a battery’s charge by placing a metal object across the
posts. Use a voltmeter or hydrometer.
• Use a flashlight to check the battery’s electrolyte level. Do not use an
open flame.

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Disconnecting and connecting of the cable shoes

• Connection and disconnection of the cables must always be done when
the system is not energized. Turn the battery main switch to the open
position.
• Use insulated tools only.
• Disconnect the grounded (-) battery clamp first, then the power (+)
battery clamp.
• In order to prevent sparking, disconnect the charger cable or switch it off
before connecting the cables to the battery.
• Before connecting the cable shoes, ensure that the power is switched off
to all electrical equipment of the drilling rig.
• The cable shoes must be connected carefully, and the polarity must be
taken into consideration.
• Connect first the power (+) battery clamp and then the grounded (-)
battery clamp. This way you can avoid sparks caused by the tool.
• Do not wear rings or a metallic wristwatch, since these may cause a
short circuit, which could, in turn, result in sparking and burns.
• Check that the battery terminal covers are intact, and put them in their
correct place.

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4.2.7 Tire maintenance
Tire maintenance requires the correct tools, faultless components, and

sufficient skills in order for the installation to be performed both correctly
and safely.
Lift up the rig by lowering the jacks.
DANGER
FLYING MATERIAL HAZARD!
In the event of an accident damaged rim parts will be ejected under
pressure and will cause death or serious injury.
Before loosening the wheel assembly nuts/bolts, release air from the
tire until the pressure is just enough to keep the rim parts firmly in
place.
DANGER
TIRE EXPLOSION HAZARD!
In the event of tire explosion, the resulting power shock and ejected
tire/tool debris will cause serious injury or death.
Always use restraining devices (safety cage or similar protective
enclosure) when inflating tires.
Never stand in front of the assembly while inflating the tire. Use an
extended hose that allows you to stand to the side.
Do not exceed the tire manufacturer's recommended maximum
pressure. Always check after pressurization that the tire sits on the
rim correctly before removing the wheel from the cage.
Unauthorized people are not allowed in the vicinity of the wheel
during the tire is being inflated.

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WARNING
CRUSHING HAZARD!
A falling wheel assembly could cause serious crush injury or death.
Never leave a wheel assembly unsecured in a vertical position. The
wheel assembly may overturn during maintenance. Make sure that
there are no unauthorized persons in the hazard zone.
Do NOT attempt to repair disc wheel assembly parts by soldering,

welding, or modifying them in any way. Replace them with new parts
of the same size, type, and make.
Never keep a spare tire that is installed on detachable rims fully

inflated. With such tires the pressure should be just enough to keep
the rim parts firmly in place. The tire must be inflated to the correct
operating pressure only after the tire-and-rim assembly has been
installed and all nuts/bolts tightened to the correct torque.
See separate instructions in manual "Tire change and rim

inspection".
4.3 Commissioning service advice

The following services should be carried out as follows:
• When taking a new rig into use
• After a major repair
• In educational purposes
• Tighten the engine mounting, air intake and exhaust manifold bolts
• Check air suction hoses and connections
• Tighten the pump mounting flange bolts
• Check tightening torques of all bolts of rock drills
• Tighten all loosened connections and bolts
• Check the wheel bolts and nuts. Re-tighten!
• Operation of warning and shut down system
• Check compressor running temperature
• Check compressor air filter
• Slip ring unit; check tightness of electrical connections
• Slip ring; check the ring-brush alignment
• Cable reel; recheck torque
• Cable; check function of limit switch
• Return filters; replace according to the indicators

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• Clean and lubricate the feed rail/rails
4.4 First maintenance

4.4.1 Maintenance performed according to rock drill percussion hours
Maintenance procedures after first 1-20 h

• Check the tightness of boom bolts and nuts.
• Check the bearing bushings and axle pins of the boom.
• Check boom clearances.
• Check the cylinder pins of the boom.
• Check the tightness of feed bolts and nuts.
4.4.2 Maintenance performed according to diesel engine hours
Maintenance procedures after first 50 h

• Change the transmission oil and replace the oil filter.
• Change the engine oil and replace the oil filter.

• Change the differential gear oil.
• Change the planetary gear oil.
4.4.3 Maintenance performed according to compressor operating hours

• Replace the compressor oil filter.
• Check and retighten main motor cables.

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5 Maintenance instructions

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5.1 General
5.1.1 Washing the drill rig
In addition to washing the drilling module and the front part of the machine
daily, the complete machine should be washed according to the interval
stated in the maintenance cards or at least once a week. The washing
interval should be adjusted to surrounding conditions, i.e. in a dirty
environment the complete machine can be washed more frequently. For
more information, see the section, "Washing".
5.1.2 Checking the steel structures
After washing the complete drill rig, perform a general overview of drill rig
steel structures and welding seams for signs of corrosion, deformations and
fractures. Cracks in the paint or peeling of paint may indicate a fracture in
the structure below the paint surface.
Pay special attention to the following components:
• Boom and boom support
• Drilling module
• Carrier: articulation, steering system, axles, jacks
• Cabin/Canopy
Check tightness and condition of bolts and nuts. Tighten all loose bolts and
replace broken or missing bolts before operating the drill rig.
If structural fractures are found, contact Sandvik service division. The drill
rig must not be used and the fractured component must be replaced or
necessary repairs made before operating the drill rig.

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5.2 Hydraulic rock drill HLX5

5.2.1 Checking the flushing housing seals and the seal housing guide rings
Flushing housing seals (1) 5 pcs and the seal housing guide rings (2) 2 pcs
must be replaced when the flushing air or water escapes from the sides of
the seal housing, and they should be checked whenever the shank is
changed. Seals are easier to install when they are lubricated. Install the
new flushing housing seals making sure they face the right direction (shown
in the figure). The use of a spare flushing housing is recommended, as it
speeds up on-site maintenance of the rock drill.
The flushing housing seals must be installed facing the right direction, determined by the flushing
mode: Water flushing (A), Air flushing (B)
Note! In addition, a damaged seal plate (3) must be replaced due to risk of
corrosion.

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5.2.2 Inspection of the front end with the rock drill on a feed rail
WARNING! FALLING LOAD HAZARD!
The coupling could fall out and cause injury.
When you remove the flushing housing and shank, turn the rock drill
to a horizontal position.
WARNING! HIGH PRESSURE AIR INJECTION HAZARD!

The airpressure blow/burst out the flushing housing could cause
severe injury.
If the shank lubrication is clogged (no air comes from the shank
lubrication return hose), stop the compressor. Before opening the
flushing housing bolts, carefully open the locking screw and let the
air pressure out.
By opening the bolts (4) the flushing housing (1), the shank (2), and the
coupling (3) can be pulled out without removing the rock drill from the feed
rail. The lock-screw (5) holds the rotation bushing (6) in the housing, for
example while changing the shank. Check the condition of the rotation
bushing rear end (6) and the bearing (7).
6
3
5
1
4
Dismountling of the flushing housing

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Checking the bearings of the flushing housing
The bearings must be replaced if the indicator groove is worn off any place.
Coupling
1. Pull the coupling out from the rotation bushing.
2. Check and replace, if the edges of the inner teeth are worn sharp or
visible cracks are seen.
Rotation bushing
The rotation bushing must be replaced if the shoulder A is worn to the

same level with the face or damages are observed. Make sure that also the
outer surfaces of the rotation bushing are in good conditions.
Chuck
The chuck inside the rotation bushing must be changed if the wear is over 1
mm from the original surface B or if there are some hair cracks.

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Rotation bushing bearings inside the gear housing
The bearings must be changed if the wear indication-groove has worn out
from any area.
Wear limits of the shank

The shank must be changed if the 1 mm bevel of the striking head is worn
out or any other wear limit is exceeded.
PROPERTY DAMAGE RISK!

When installing a new shank, take care that no dirt enters inside the
rock drill with the shank. Insert the shank carefully through the
flushing housing, so that the flushing device seals are not damaged.

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5.2.3 Checking and tightening bolts and tie rods

The most important maintenance task is to check the tightness of the bolts,
particularly the tie rods and mounting bolts. Loose tie rods cause rapid
wear of the body section faces, shortening the service life of the rock drill.
Following procedure is recommended for checking the bolt tightness during
normal maintenance:
1. Check the tightness of each bolt by using 10 % higher torque than
specified and the correct tightening order.
2. The joint being tested is loose if the wrench turns. In this case loosen all
the bolts being tested and retighten with the correct order.
3. If the threads are not clean the bolts cannot be tightened correctly. In
such cases the bolt must be removed, the threads checked, cleaned, and
lubricated with grease.
Note! Use only an inspected, high-quality torque wrench.
2
1
Rock drill bolts

1 Tie rod bolts (6 pcs)
2 Pressure accumulator bolts (4+4 pcs)
3 Flushing housing bolts (4 pcs)
4 Flushing housing front cover bolts (4 pcs)

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Tie rod tightening

The tools required:
• torque wrench
• 24 mm ring end
1. Lubricate the threads and the nut faces with grease.
1 4
5 6
3 2
2. Pretighten to 200 Nm (20 kpm).

Correct tightening order is (1-2-3-4-5-6).
3. Final tightening torque is 400 Nm (40 kpm).
Same tightening order (1-2-3-4-5-6) should be used.
Pressure accumulator bolts

The tools required:
• torque wrench
• 24 mm socket
1. Lubricate the bolt threads with grease.
2 4
3 1
2. Pretighten all four bolts to 100 Nm (10 kpm).

Correct tightening order is (1-2-3-4).
Same tightening order (1-2-3-4) should be used.

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Flushing housing bolts

The tools required:
• torque wrench
• 24 mm ring end
4
1
3

Flushing housing front cover bolts

The tools required:
• torque wrench
• 24 mm socket
1 4
3 2


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5.2.4 Checking the charge gas pressure of the pressure accumulators

The charge gas pressure of a pressure accumulator must be checked once
a week. The check is performed by using a pressure gauge included in the
rock drill’s special toolkit. The pressure gauge range is 0 to 100 bar for the
high-pressure accumulators, and 0 to 10 bar for the low-pressure
accumulators. Use a gauge meant for gas pressure measurement. The
pressure gauge used must not be a liquid damped gauge.
3
2
1. Remove the rubber protection cap (1).

2. Remove the metal cap (2).
3. Screw the pressure gauge to the filling valve.
4. Open the locking nut (3).
5. Wait until the gauge pointer stops moving. Check the reading.
6. Close the locking nut (3).
7. Disconnect the gauge from the filling valve and replace the metal cap (2)
and the rubber protection cap (1).

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5.2.5 Rock drill overhaul

The rock drill should be disassembled and its components checked
regularly.
The recommended maintenance interval for the rock drill overhaul is 500
percussion hours, but the interval varies according to local conditions and
must therefore be determined on the basis of experience. It is better to
perform preventive maintenance than repair the machine after the damage
has already happened.
Write down the percussion hours and/or number of meters drilled per shift
during each maintenance interval. Fill in the rock drill maintenance card.
Overhaul instructions and maintenance tasks are defined in the rock drill
technical manual, chapter Rock drill overhaul.
5.2.6 After rock drill service
After the rock drill service the reassembled parts will settle down to their
proper position during drilling under normal drilling loads. Especially if the
parts have worn surfaces it may result that the tie rods and the mounting
bolts do not keep their tightness. Therefore a re-tightening of these bolts is
required after each rock drill service or if the rock drill has been removed
and remounted on the feed rail.
After the rock drill service and 1 round / 100-300 meters drilling:
1. Re-tighten the rock drill mounting bolts on the feed rail.
2. Re-tighten the rock drill tie rods and flushing device bolts.

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5.3 Hydraulic rock drill HLX 5T, HFX 5T

5.3.1 Removing the flushing housing
RISK OF PROPERTY DAMAGE!
NOTICE In replacing the shank, the rock drill must be tilted to as horizontal
an orientation as possible to prevent the parts from falling.
9
8
6
4
10
1
7 2
3
1. Remove the guard (2).

2. Open the bolts (3).
3. Remove the flushing housing (1).
4. Remove the gasket plate (10).
5. Remove the shank (4, if attached).
NOTE! When pulling the shank (4) out from the flushing housing the seal
housing (5) will drop. Do not let it hit anything.
6. Pull the coupling (6) out of the rotation bushing (8).
7. Open the screw (7).
The screw (7) prevents the rotation bushing (8) from falling, for example
when the shank is changed.
8. Pull the rotation bushing (8) out from the rock drill.
9. Pull the chuck (9) out of the rotation bushing (8).

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5.3.2 Checking the stabilizer pins
1. Check the condition of the stabilizer pins (1).

5.3.3 Wear limits for the flushing housing bushings
1 2 3
A A
1. Check the condition of the bearing bushings (1 and 2) and shank bushing
(3).
The bearing must be replaced when the bearing surface is worn to the
level of the wear indicator groove (A) at any point around the
circumference.
The shank bushing must be replaced when 1 mm has worn from its
surface (B) or the shank bushing has cracks in it.

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5.3.4 Checking the rotation bushing bearings inside the gear housing
1 2
1. Check the condition of the rotation bushing bearings (1 and 2).

level of the wear indicator groove at any point around the circumference.
5.3.5 Checking the rotation bushing
1. Check the wear of the rotation bushing teeth and the bearing surfaces.
The rotation bushing must be replaced if there is damage on its surface
or teeth.

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Replacing the chuck bearing
1. Check the condition of the bearing bushing.

circumference.
2. Press the bearing (1) out of the rotation bushing.
Use the hydraulic press and punches (T4 and T18).
T4
T18
3. Clean the parts.

4. Lubricate the parts with hydraulic oil.

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5. Install the new bearing (1) to the rotation bushing.

NOTE! Make sure that the bearing is installed in feathered edge (A) first.
Use a hydraulic press and punches (T4 and T18).
T4
T18
5.3.6 Checking the coupling
1. Pull the coupling out of the rotation bushing.

2. Check the coupling.
Replace the coupling if the edges of the inner teeth are worn to a pointed
shape, or visible cracks are seen.

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5.3.7 Checking the chuck
B
A
A B
1. Check the chuck.

The chuck must be replaced if its front surface (A) has worn by over 1
mm or if the chuck has cracks in it.
The chuck must be replaced if its rear surface has worn to the level (B) at
any point.
5.3.8 Checking the shank
Remove the storage grease and labels off from the new shank,
before installing it to the rock drill.
NOTICE When installing a new shank, take care that no dirt enters inside the
rock drill with the shank. Insert the shank carefully through the
flushing housing, so that the flushing device seals are not damaged.
1. Measure the shank.

The shank must be replaced when any of the bevels at its rear have worn
off, the drive teeth has worn off or any other wear limit is exceeded.

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5.3.9 Disassembling the flushing housing
4
3
7
7
8
7 8 6

2. Pull out the cover (3) from the flushing housing (1).
4. Remove the O-ring (5) from the flushing housing (1).
5. Remove the U-seals (7) from the cover (3).
6. Remove the U-seals (7) from the seal housing (6).
7. Check the condition of the guide rings (8).
Guide rings should be replaced if too much wear allows the shank to
move sideways inside the seal housing.
The purpose of the guide rings is to guide the shank so that the
movement of the shank rod does not cause uneven wear to the U-seals.

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5.3.10 Changing the flushing housing bushings

NOTE! Do not install seals to the cold parts, they may become brittle and
break. Let the parts warm up before installing the new seals.
1. Check the parts.
If a part is damaged replace it with a new one. If one or more of the
bushings have worn to the level of the indicator groove, replace them as
described below.
Bushings must be changed if they have been used for 500 hours. Check
the time used from the rock drill service card.
2. Press the bushing (1) out of the front cover (2).
Use the hydraulic press, the punch (T1) and the thrust (T2)
T1 T2
2 1
3. Clean the parts.


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5. Install the new bushing to the front cover.

Use a hydraulic press.
NOTE! The gap must exist between the cover and bearing to indicate
that the bearing is properly installed.
6. Install the new U-seals to the front cover and to the front cover bushing.
NOTE! The orientation in which the seals should be installed depends on
the flushing mode:
A Air flushing.
B Water / Water mist flushing.
A B

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7. Press the shank bushing (3) our of the flushing housing (4).
T4 T3
4 3
8. Press the shank bushing bearing (5) out of the shank bushing (3).
Use a hydraulic press, punch (T1) and thrust (T2).
T1 T2
3 5
9. Clean the parts.


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11. Install the new shank bushing bearing in the shank bushing.
12. Install the new U-seal to the shank bushing bearing.

NOTE! The orientation in which the seal should be installed depends on
the flushing mode:
A Air flushing.
A B
13. Install the new O-ring in place on the shank bushing bearing.
14. install the shank bushing to the flushing housing.


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5.3.11 Assembling the flushing housing

1. Install the new guide rings (2) into the seal housing (1).
3 1 2 3
2. Install the new U-seals (3) into the seal housing (1).
Orientation of the U-seals are same at the air flushing and the water /
water mist flushing.
3. Put the new gasket plate (5) onto the front cover (6).
NOTE! Damaged gasket plate must be replaces due to risk of corrosion.
4. Put new lockwashers onto the bolts (7).

5. Install the front cover (6) to the flushing housing (4).
6. Tighten the bolts (7).
See the section "Flushing housing front cover bolts" for the bolt tightening
instructions.
7. Put the new O-ring (8) onto the flushing housing (4).

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5.3.12 Attaching the flushing housing
1
5
2
3
4
7
10
6
9
11
12
1. Push the chuck (2) in the rotation bushing (3).

2. Push the rotation bushing (3) in the rock drill (1).
3. Install the coupling (4) in the rotation bushing (3).
4. Install the screw (5) to the rock drill (1).
5. Check that the mating surfaces of the flushing housing (9) and rock drill
(1) are clean.
6. Install the gasket plate (6) to the flushing housing (9).
7. Carefully push the shank (7) into place through the flushing housing (9)
and the seal housing (8).
8. Install the new O-ring (10) on the flushing housing (9).
9. Install the flushing housing (9) to the rock drill (1).
10. Lubricate the bolts (11) with grease.
See the section "Checking the flushing housing bolts" for tightening
instructions.
12. Install the guard (12).

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5.3.13 Checking the accumulator filling valve and cover plug condition
WARNING
HIGH PRESSURE HAZARD!
High pressure could cause death or severe injury
Do not remove the filling valve from a pressurized accumulator.
Required tools:
• Wrench, 10 mm
• Wrench, 19 mm
• Torque wrench
• Socket, 19 mm
4
3
2
1
1. Check that the filling valve (4) is tightened.

2. Check that the rubber protection cap (1) or the metal cap (2) is installed
on the filling valve (4) thread.
Note! There must be a cap protecting the thread.
Replace the cap with a new one if it is damaged or missing.

3. Remove the rubber protection cap (1) or the metal cap (2).
4. Check that the filling valve or its parts are not damaged.
Refer to the separate Pressure accumulator maintenance instructions to
change the damaged valve. Do not remove the filling valve from a
pressurized accumulator!
5. Check that the locking nut (3) is tightened to 15 Nm.
6. Install the rubber protection cap (1) or the metal cap (2).

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5.3.14 Checking the accumulator pressure

RISK OF DAMAGING THE ROCK DRILL!
An empty pressure accumulator causes cavitation, which will
NOTICE damage the rock drill.
Check the accumulator pressure regularly. Change or repair the
accumulator immediately if there is no pressure.
Check the accumulator pressure every 50 hours or earlier, if necessary.

Pressure loss may be a result of a damaged filling valve or a broken
diaphragm. Replace the filling valve and the diaphragm to ensure flawless
operation of the accumulator.
1. Check the accumulator pressure.
Detailed instructions are in the manual Pressure accumulator for
hydraulic rock drill.
5.3.15 Checking the bolt tightness and tightening torques
Checking the tightness of the bolts is an important maintenance procedure
for a rock drill.
Check the bolts during regular maintenance.
1. Check that the threads are clean.
The bolts cannot be tightened to the correct torque if the threads are not
clean. If necessary, clean and check the threads and lubricate them with
grease.
2. Check the tightness of the bolts.
When checking the tightness of the bolts, use the correct tightening
sequence and a tightening torque 10% greater than what is specified.
A bolt is too loose if it can turn. In this case, other appropriate bolts must
be loosened and re-tightened according to the tightening instructions.
Note! Only use calibrated, high-quality torque wrench.

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Accumulator bolts
RISK OF DAMAGING THE ACCUMULATOR!
NOTICE The four-bolt accumulator must be tightened by using a cross-
tightening method.
Required tools:
• torque wrench
• socket, 24 mm
A
D
C
B
1. Lubricate the bolts with grease.

2. Put new lockwashers onto the bolts.
3. Pre-tighten the low- and high-pressure accumulator bolts to 100 Nm (10
kpm).
Use torque wrench. Use the tightening sequence A, B, C, D.
4. Tighten the bolts to 200 Nm (20 kpm).
5. Pre-tighten the stabilizer accumulator bolts to 100 Nm (10 kpm).
Use torque wrench.
Use torque wrench.

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Flushing housing mounting bolts

Required tools:
• torque wrench
• socket, 24 mm
C
A
1. Lubricate bolt threads with grease.

2. Pre-tighten bolts to 200 Nm (20 kpm).
3. Tighten bolts to 400 Nm (40 kpm).

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Required tools:
• torque wrench
• socket, 24 mm
C
A
B
D

3. Pre-tighten the bolts to 100 Nm (10 kpm).

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Side bolts
Required tools:
• torque wrench
• socket, 24 mm
E
B
A
F
C
1. Lubricate the cap nut threads with grease.

2. Pre-tighten the cap nuts to 200 Nm (20 kpm).
Use torque wrench. Use the tightening sequence A, B, C, D, E, F, G, H.
3. Tighten the cap nuts to 400 Nm (40 kpm).
Use torque wrench. Use the tightening sequence A, B, C, D, E, F, G, H.

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Rear cover bolts

Required tools:
• torque wrench
• socket, 19 mm
C
D
B

regularly.
After the maintenance is complete, the reinstalled components, especially
when surfaces are worn, settle into their proper places for a while, causing
the side bolts and mounting bolts to loosen.
Following maintenance, re-tighten all the rock drill bolts after drilling
about 100–200 meters.

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5.4 Hydraulic rock drill RD520/RD525

5.4.1 Removing the flushing housing
NOTICE In replacing the shank, the rock drill must be tilted to as horizontal
an orientation as possible to prevent the parts from falling.
5
4
6
3
1
2

2. Remove the flushing housing (1).
4. Remove the shank (3, if attached).
5. Remove the coupling (4).
6. Remove the chuck (5).

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5.4.2 Checking the pistons head and chuck bearing
1. Check the condition of the piston head (A).

Replace the piston if bevel has worn off.
2. Check the condition of the stabilizer long movement piston head (B).
Replace the stabilizer long movement piston if it has hairline cracks.
3. Check the condition of the chuck bearing (C).
level of the wear indicator groove at any point around the circumference.

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5.4.3 Wear limits for the flushing housing bushings
1 2 3
A A
1. Check the condition of the bearing bushings (1 and 2) and shank bushing
(3).
circumference.
The shank bushing must be replaced when 1 mm has worn from its
surface (B) or the shank bushing has cracks in it.
5.4.4 Checking the coupling
1. Pull the coupling out of the rotation bushing.

2. Check the coupling.
Replace the coupling if the edges of the inner teeth are worn to a pointed
shape.

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5.4.5 Checking the chuck
A B
B
A
The chuck must be replaced if its front (A) or rear (B) surface has worn by
over 1 mm or if the chuck has cracks in it.

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5.4.6 Checking the shank

Remove the storage grease and labels off from the new shank,
before installing it to the rock drill.
NOTICE When installing a new shank to the rock drill, ensure that no
impurities are carried into the rock drill with the shank.
Push the shank carefully through the flushing housing to avoid
damaging the flushing housing seals.
1 mm 1 mm
1 mm
1. Measure the shank.

The shank must be replaced when any of the bevels at its rear have worn
off, the drive teeth has worn off or any other wear limit is exceeded.

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5.4.7 Disassembling of the flushing housing
7
2
7
8
7 8 6
1. Open the bolts (2)

2. Pull out the cover (3) from the flushing housing (1).
4. Remove the O-ring (5) from the flushing housing (1).
5. Remove the U-seals (7) from the cover (3).
6. Remove the U-seals (7) from the seal housing (6).
7. Check the condition of the guide rings (8).
Guide rings should be replaced if too much wear allows the shank to
move sideways inside the seal housing.
The purpose of the guide rings is to guide the shank so that the
movement of the shank rod does not cause uneven wear to the U-seals.

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5.4.8 Changing the flushing housing bushings

NOTE! Do not install seals to the cold parts, they may become brittle and
break. Let the parts warm up before installing the new seals.
1. Check the parts.
If a part is damaged replace it with a new one. If one or more of the
bushings have worn to the level of the indicator groove, replace them as
described below.
Bushings must be changed if they have been used for 500 hours. Check
the time used from the rock drill service card.
2. Press the bushing (1) out of the front cover (2).
Use the hydraulic press, the punch (T1) and the thrust (T2)
T1 T2
2 1
3. Clean the parts.


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5. Install the new bushing to the front cover.

NOTE! The gap must exist between the cover and bearing to indicate
that the bearing is properly installed.
6. Install the new U-seals to the front cover and to the front cover bushing.
NOTE! The orientation in which the seals should be installed depends on
the flushing mode:
A Air flushing.
A B

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7. Press the shank bushing (3) our of the flushing housing (4).
T4 T3
4 3
8. Press the shank bushing bearing (5) out of the shank bushing (3).
Use a hydraulic press, punch (T1) and thrust (T2).
T1 T2
3 5
9. Clean the parts.


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11. Install the new shank bushing bearing in the shank bushing.
12. Install the new U-seal to the shank bushing bearing.

NOTE! The orientation in which the seal should be installed depends on
the flushing mode:
A Air flushing.
A B
13. Install the new O-ring in place on the shank bushing bearing.
14. install the shank bushing to the flushing housing.


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5.4.9 Assembling the flushing housing

1. Install the new guide rings (2) into the seal housing (1).
3 1 2 3
2. Install the new U-seals (3) into the seal housing (1).
Orientation of the U-seals are same at the air flushing and the water /
water mist flushing.
3. Put the new gasket plate (5) onto the front cover (6).
NOTE! Damaged gasket plate must be replaces due to risk of corrosion.
4. Put new lockwashers onto the bolts (7).

5. Install the front cover (6) to the flushing housing (4).
See the section "Flushing housing front cover bolts" for the bolt tightening
instructions.
7. Put the new O-ring (8) onto the flushing housing (4).

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5.4.10 Attaching the flushing housing to the rock drill
5
4
7
6
3
1
2
1. Push the chuck (5) into place the right way (see figure).
2. Push the coupling (4) into place.
3. Carefully push the rod shank (3) into place through the flushing housing
(1) and seal housing.
4. Insert the new gasket plate (6) in its place.
5. Install the new O-ring (7) in its place.
6. Fit the flushing housing into place and tighten the bolts (2).
See the section "Checking the bolt tightness and tightening torques" for
tightening instructions.

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5.4.11 Checking the accumulator filling valve and cover plug condition
WARNING
High pressure could cause death or severe injury
Do not remove the filling valve from a pressurized accumulator.
Required tools:
• Wrench, 10 mm
• Wrench, 19 mm
• Torque wrench
• Socket, 19 mm
4
3
2
1
1. Check that the filling valve (4) is tightened.

2. Check that the rubber protection cap (1) or the metal cap (2) is installed
on the filling valve (4) thread.
Note! There must be a cap protecting the thread.
Replace the cap with a new one if it is damaged or missing.

3. Remove the rubber protection cap (1) or the metal cap (2).
4. Check that the filling valve or its parts are not damaged.
Refer to the separate Pressure accumulator maintenance instructions to
change the damaged valve. Do not remove the filling valve from a
pressurized accumulator!
5. Check that the locking nut (3) is tightened to 15 Nm.
6. Install the rubber protection cap (1) or the metal cap (2).

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5.4.12 Checking the accumulator pressure

An empty pressure accumulator causes cavitation, which will
NOTICE damage the rock drill.
Check the accumulator pressure regularly. Change or repair the
accumulator immediately if there is no pressure.
Check the accumulator pressure every 50 hours or earlier, if necessary.

Pressure loss may be a result of a damaged filling valve or a broken
diaphragm. Replace the filling valve and the diaphragm to ensure flawless
operation of the accumulator.
1. Check the accumulator pressure.
Detailed instructions are in the manual Pressure accumulator for
hydraulic rock drill.
5.4.13 Checking the bolt tightness and tightening torques
Checking the tightness of the bolts is an important maintenance procedure
for a rock drill.
Check the bolts during regular maintenance.
1. Check that the threads are clean.
The bolts cannot be tightened to the correct torque if the threads are not
clean. If necessary, clean and check the threads and lubricate them with
grease.
2. Check the tightness of the bolts.
When checking the tightness of the bolts, use the correct tightening
sequence and a tightening torque 10% greater than what is specified.
A bolt is too loose if it can turn. In this case, other appropriate bolts must
be loosened and re-tightened according to the tightening instructions.
Note! Only use calibrated, high-quality torque wrench.

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Accumulator bolts
RISK OF DAMAGING THE ACCUMULATOR!
NOTICE The four-bolt accumulator must be tightened by using a cross-
tightening method.
Required tools:
• torque wrench
• socket, 24 mm
5
3
6
1. Lubricate the bolts with grease.

3. Pre-tighten the low- and high-pressure accumulator bolts to 100 Nm (10
kpm)
Use torque wrench. Use the tightening sequence 1-2-3-4.
Use torque wrench. Use the tightening sequence 1-2-3-4.
5. Pre-tighten the stabilizer accumulator bolts to 100 Nm (10 kpm)
Use torque wrench.
Use torque wrench.

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Flushing housing mounting bolts

Required tools:
• torque wrench
• socket, 24 mm
2
4
1. Lubricate bolt threads with grease.

2. Pre-tighten bolts to 200 Nm (20 kpm).
Use torque wrench.
Use the tightening sequence 1–2–3–4.
3. Tighten bolts to 400 Nm (40 kpm).
Use torque wrench.
Use the tightening sequence 1–2–3–4.

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Required tools:
• torque wrench
• socket, 24 mm
1
3
4
2

Use torque wrench.
Use the tightening sequence 1-2-3-4.
Use torque wrench.

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Side bolts
Required tools:
• torque wrench
• socket, 24 mm
3 4
1. Lubricate the threads with grease.

2. Pre-tighten the nuts to 200 Nm (20 kpm).
Use torque wrench.
3. Tighten the nuts to 400 Nm (40 kpm).
Use torque wrench.

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Rock drill mounting bolts

Incorrect tightening sequence could cause damage to the rock drill.
Incorrect tightening sequence will cause the mounting bolts to
NOTICE loosen rapidly.
Use the correct tightening sequence when installing the rock drill to
the carriage.
3
2
1
1. Screw all the bolts in, but leave them slightly loose.
2. Pre-tighten the mounting bolt pair (1) to 200 Nm.
3. Pre-tighten the mounting bolt pairs (2) and (3) to 200 Nm.
4. Tighten the mounting bolt pair (1) to 400 Nm.
5. Tighten the mounting bolt pairs (2) and (3) to 400 Nm.

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regularly.
After the maintenance is complete, the reinstalled components, especially
when surfaces are worn, settle into their proper places for a while, causing
the side bolts and mounting bolts to loosen.
Following maintenance, re-tighten all the rock drill bolts after drilling
about 100–200 meters.
5.5 Boom TB/SB

WARNING! RISK OF PERSONAL INJURY!
When the feed is turned 90° degrees by using the feed swing cylinder
and when both feed and rock drill are moved onto their front
position, the rotary actuator may allow feed to descent slowly.
To prevent unexpected movements during maintenance, support the
feed beam on to the stands or by the crane.

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5.5.1 Greasing points of the TB/SB boom

Note! For correct lubrication grease, refer to the rig's maintenance manual
- chapter lubrication grease.
Lubricate the greasing points until the grease starts to come out from the
joints. If the grease does not come out from the joints or grease comes out
only from the grease nipple area, check the possible blockages in the
grease channels. If necessary, open the channels and remove the
blockages.
Greasing the rotary actuator

Note! For correct lubrication grease, refer to the rig's maintenance manual
- chapter lubrication grease.
Use only manual grease gun to avoid seal damages.
1. Rotate the rotary actuator 90° so that the grease nipple (1) is pointing
down.
2. Slowly press the recommended grease with the grease gun into the
grease nipple.
3. Press the grease so much that it comes out from the relief valve (2) on
the opposite site.

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Note! The rotary actuator lubricates more effectively, when you press the
grease slowly with the manual grease gun into the grease nipple and
so much that the grease comes out from the relief valve on the
opposite site.
4. Rotate the rotary actuator 180° so that the grease nipple is pointing up.
5. Repeat the greasing steps 2 and 3.
5.5.2 Checking bearing bushings and axle pins
DANGER
IMPACT OR CRUSHING HAZARD!
Uncontrolled falling of the boom or its component will cause death
or severe injury.
Support the boom correctly. Additional support is required when
changing the main components of the boom.
In order to check the condition of the axle pin and bearing bushing or the
mounting ear, support the boom or its component to a position where the
weight of the boom or component does not rest on the component to be
checked.
In this position, using the boom movements, rock the boom or its
component back and forth against the support. Any play between the
mounting ears, bearing bushings and axle pins can be easily detected by
observing the free movement of the bearing bushing and axle pins from
safe distance. If any excessive movement in the mounting ear, bearing
bushing or in the axle pin is noticed, replace the worn components. Refer to
the technical manual.

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5.5.3 Checking the tightness of bolts and nuts

Check the tightness of bolts and nuts:
• visually before each shift
• with suitable tools every 50 percussion hours or after collisions
Pay special attention to bolts marked in the figures below.
If loose, missing or broken bolts are found, do not use the machine before
all bolts in that joint are checked and replaced as required.
Standard bolts (A) and (B) are tightened using the torque of 550 Nm.
Use oil to lubricate all the bolt threads.

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5.5.4 Checking the slide pieces of the cradle

The feed beam is mounted to the cradle with wear pieces and moved with
the feed extension cylinder.
Each slide piece is mounted to the cradle with bolts through the slide piece
body. The bolts secure the slide piece lengthwise. Securing in the
crosswise direction is achieved by the form of the slide pieces and the slide
piece body.
The slide pieces must be changed, they are not adjustable. Correct
clearances and positioning in relation to the beam centre line is achieved
with the aid of the mounting shoulders on the cradle.
3 2
1 Steel strip
2 Slide piece
3 Slide piece body
4 Mounting shoulder

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1. Check the clearance between the steel strip (1) and the slide piece (2).
If the pieces are so worn that the clearance is over 2 mm, the slide
pieces should be replaced.

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5.5.5 Checking the slide plates and slide pieces

Wear of the slide plates (24) and slide pieces (19) can be checked by
measuring the distance (C) between the inner (14) and the outer (13) tube.
If the value of C is below 2 mm, the slide plates (24) must be replaced. Or if
the value of D (top/side) is more than 7 mm, the slide pieces (19) must be
replaced.
14
19 24
13
19
24
14
5.5.6 Checking boom clearances

To check the clearances, move the boom into different positions and
separately follow the movements at each joint and sliding surface during
the movements. Check especially the hydraulic cylinders and their
mountings. Replace worn bushings between cylinder pins and cylinder
mounting brackets as necessary. A new bushing is easier to install if the
body and the cylinder bracket is warmed up with a blowtorch before
installation.

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5.5.7 Checking the cylinder pins
DANGER
IMPACT OR CRUSHING HAZARD!
Uncontrolled falling of the boom or its component will cause death
or severe injury.
Support the boom correctly. Additional support is required when
changing the main components of the boom.
The cylinder pins are adjustable conical pins that are tightened clearance-
free to the bracket.
In order to check the condition of the cylinder pin and bearing bushing or
the mounting ear of the cylinder, support the boom or its component to a
position where the weight of the boom or component does not rest on the
cylinder to be checked.
In this position, using he boom movements, rock the boom or its
component back and forth against the support. Any play between the
mounting ears, bearing bushings and cylinder pins can be easily detected
by observing the free movement of the bearing bushing and cylinder pins
from safe distance. If any excessive movement in the mounting ear, bearing
bushing or in the cylinder pin is noticed, replace the worn components.
Refer to the technical manual.
A Cylinder eye
B A B
B Bracket
X There must not be any clearance
1. Check the tightening torque. The correct values are as follows:

Tightening torques of the cylinder pins
Size of cylinder pin Using torque wrench Using pneumatic tool
M12 60 Nm 55 Nm
M16 150 Nm 135 Nm
M20 290 Nm 270 Nm
M24 530 Nm 490 Nm

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2. Check the position of the cut (A) in the pins.

The cut must be at a right angle to the cylinder’s direction of movement,
and downwards if possible.
3. Lubricate the pins carefully before installing

See lubrication recommendations in “Lubricants and capacities”.
5.5.8 Checking the sensor boxes
1. Check the sensor boxes
5.5.9 Lubricating the electric box connections
1. Lubricate the electric box connections

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5.5.10 Checking of the angle restriction function

Note! The angle restriction function should be checked every 6 month or if
the hydraulic connections of the boom has been opened.
Use about two-meter length of sturdy pipe (or similar) for depressing the
plunger (1).
1. Move the boom to a parallel and horizontal position to the rig.
2. Move the lift cylinder upwards and simultaneously push the knob (1) on
the plunger valve (2) at the point shown by the arrow. The boom should
turn in the same direction as the knob is pressed.
3. Move the lift cylinder downwards and simultaneously push the knob (1)
on the plunger valve (2) at the point shown by the arrow. The boom
should turn in the same direction as the knob is pressed.
4. Repeat the same functions on the the plunger valve (2) situated on the
other side of the boom.
5. Turn the boom to the right and simultaneously press the knob (1) on the
right side. The boom should turn to the left.
6. Turn the boom to the left and simultaneously press the knob (1) on the
left side. The boom should turn to the right.

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5.5.11 Testing the lift/swing cylinder seals
A Seals
WARNING
FALLING LOAD HAZARD!
Uncontrolled boom descent may cause death or severe injury.
Never go beneath the boom unless it is supported. Before
disconnecting hydraulic hoses or valves, always make sure that the
system is not under static load. Before starting any repair work,
always release the static load by running the boom to rest against a
suitable mechanical support or to its extreme position.
WARNING
Uncontrolled boom descent due to excessive pressure in the
cylinder or hoses may cause death or severe injury.
THIRD CHAMBER CYLINDERS ONLY: Never plug the third chamber
hose connector Y if the cylinder is used. If plugged, the oil in the
third chamber cylinder cannot escape, generating excess pressure
and risk of explosion of the cylinder and hoses.

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WARNING
Uncontrolled boom descent due to faulty third chamber seals in the
third chamber cylinder and a damaged or disconnected Y port hose
may cause death or severe injury.
Malfunctioning of automatic parallelism can be an indication of faulty
cylinder seals. Test the seals every 500 percussion hours and check
the condition of the Y port hydraulic hose and the tightening torque
of the connector daily.
WARNING
Uncontrolled boom descent due to faulty boom operation will cause
The faulty operation of a boom function is an indication of a system
fault. In such an event, immediately stop all work with the rig in
question. Determine and properly repair the cause of the fault before
continuing work.
Note! The seals of the cylinder's third chamber must be tested every 500
percussion hours. If the seals have failed, the cylinder must be
properly repaired before work resumes. See test instructions in the
boom's technical manual, chapters "Testing the boom lift cylinder
seals" and "Testing the boom swing cylinder seals".
Swing/lift cylinders shall be overhauled every 1000 percussion hours
or every 12 months.
5.5.12 Lift/swing cylinders overhaul

Lift/swing cylinders shall be overhauled every 1000 percussion hours or
every 12 months whichever comes first.

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5.6 SUB utility boom

5.6.1 Lubricating the pins and bearings of the utility boom
Blocked or damaged grease nipples must always be replaced immediately.
If the holes in the joint pins get blocked, the pin must be removed and the
hole opened to ensure proper lubrication.
General greasing instructions:
• Use a grease gun and lithium based greases with penetration 265 / 295
and dropping point 180 °C.
• Grease the boom extension beam lower surface by hand using a brush
and same grease as specified above.
• Grease the boom extension beam inner surfaces using a high pressure
device and suitable oil.

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5.6.2 Inspecting the cylinder joint pins, pin lockings and bearings
Check all nuts, pins, pin lockings, shields and bearings for proper
installation. Inspect especially if excessive wear, cracks or distortion
appear.
1. Inspect the boom lift joint pin, pin locking and bearing.
2. Inspect the lifting cylinder joint pin, pin locking and bearing.
3. Inspect the extension cylinder joint pin, pin locking and bearing.
4. Inspect the swing cylinder joint pin, pin locking and bearing.
5. Inspect the stabilization cylinder joint pin, pin locking and bearing.
6. Inspect the basket tilt cylinder joint pin, pin locking, bearing and bearing
housing .
Inspect especially if permanent deformations, bad wear, bruises or
corrosion damages appear. There should not be any visible fractures or
cracks in the welding seams.
WARNING! CRUSHING HAZARD!
Being under a part of the machine when it falls could cause death or
severe injury.
Support the basket correctly when operating with cylinders.

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5.6.3 Adjusting the boom extension clearance

The lateral clearance of the telescope extension is limited by means of
guide pieces. When this clearance grows, excessive partial tilt of the boom
basket will result. Check the clearance at regular intervals.
Side clearance
1. Loosen fixing screws (1)
2. Tighten the cover (2)
3. Check that there is 0.5 mm clearance between the frame column and the
guide piece.
4. Tighten the fixing screws.
1 2
Upper clearance
1. Loosen fixing screws (1)
2. Loosen the cover (2)
3. Install a new guide piece (3)
4. Check that there is 0.5 mm clearance between the frame column and the
guide piece.
2 3
2 3 1

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5.6.4 Checking hydraulic pressures
A measurement fitting is provided on the side of the control valve blocks.

Pressure should be checked when the oil is at normal operating
temperature. Pressure gauge (0 - 250 bar) is connected to the
measurement point and the relevant function (desired function) of the boom
is driven to its extreme position by the control lever. Pressure values shown
in the hydraulic scheme are absolute top limits, which must not be altered
without manufacturer’s permission.
The specified pressure values must not be exceeded without the
manufacturer’s permission. If hoses or other components are changed, the
involved movement needs air bleeding by driving the relevant function a
few times to the extreme position.
Note! Air in the hydraulic system can cause malfunctions and dangerous
situations. Bleed the boom swing cylinder by using the air-bleeding
nipple.

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5.6.5 Inspecting the turning joint lug welding and the basket tilt cylinder fixing lug
welding
WARNING
Mechanical failure of the welded seams could result in death or
severe injury.
Inspect the welding seams regularly. Do not use the utility boom if
any visible fracture or crack is found.
1. Inspect the turning joint lug welding.

2. Inspect the basket tilt cylinder fixing lug welding.
5.6.6 Inspecting the condition of the boom beams
Check boom structure, boom members and their connections for absence
of fractures, cracks, permanent deformations, bad wear, bruises or
corrosion damages. Inspect paint and overall appearance.
5.6.7 Changing the tilting cylinder joint pin and bearing
Joint pins and bearings must be changed to new ones at the latest every
1000 operating hours.
5.7 Feed TF/TFX

5.7.1 Checking the tightness of bolts and nuts
1. Check all self-locking nuts.
2. Replace all loosened self-locking nuts.
3. Check all ordinary bolts.
4. Tighten all loosened ordinary bolts.
Note! If an ordinary bolt connection loosens repeatedly, use a self-locking
nut or chemical thread locking compound.
5.7.2 Checking the condition and mounting of the impulse cylinders / inductive
sensors
1. Check the condition and mounting of the impulse cylinders / inductive
sensors.
Note! Impulse cylinders must be bled after repair operation.

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5.7.3 Checking the front centralizer

1. Check the condition of hard metal pins / buffer.
5.7.4 Lubricating the hose reel

1. Lubricate the hose reel.

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5.7.5 Adjusting the slide pieces (TF500)
A
B
The slide pieces normally require no adjustments when replaced, as the

pieces are located to correct clearances at the beam centre line with the aid
of locating shoulders on the carriers and the frame strips.
If the slide pieces are so worn that the clearance is more than 3 mm, the
clearance can be adjusted to the specified value with the slotted holes in
the carriages. After adjustment, the screws are tightened to 120 Nm.
A = max. 1,5mm
B = 0 (clearance)

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5.7.6 Adjusting the slide pieces (TFX500)
Adjusting slide pieces using (1 = adjusting screws). The adjustment is

carried out before tightening of the screws. Adjust the slide piece frames so
that the clearance between the slide piece and the steel strip is less than
1.5 mm.
A = max. 1,5mm
B = 0 (clearance)
5.7.7 Checking the tightness and condition of the feed wires
1. Check the tightness and condition of the feed wires.
Adjust as necessary.

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Adjusting wire tension

Check the wire tension visually from the operator station while drilling. The
return wire should not have greater slack (D) than approximately 50 mm.
A new wire tends to stretch at first until the wire strands have become
somewhat straightened. Therefore, retighten the wires after replacement
when, for instance, one round has been drilled.
Adjustment is done when the wire is unloaded and the hose reel is in the
rear position.
3 4 HLX5T: 85 to 88 mm
HLX5: 150 to 153 mm 5 2 1 6
C RD520/RD525: 101 to 104 mm
D Max. 50 mm
1. Adjust the return wire (5) at the wire end connected to the hose support.
The wire end is provided with a threaded piece and locking nuts.
a) Open the locking nut (2) at the hose support and use the other nut
(1) to tighten the wire. Use a suitable tool to prevent the wire from
turning.
b) Tighten the locking nut (2).
2. Tighten the pulling wire (6) using the tubular nut (3) at the rear end of the
feed.
a) Open the locking nut (4) through the opening at the rear end of the
beam.
b) Use a suitable tool to prevent the wire from turning, and tighten the
wire so that a correct clearance (C) (85 to 88 mm for HLX5T, 150 to
153 mm for HLX5 or 101 to 104 mm for RD520/RD525) is left
between the rear of the rock drill and the front edge of the hose
reel.
c) Tighten the locking nut (4).

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5.7.8 Checking the tension of the hoses

1. Check the tension of the hoses.
2. Adjust the tension if necessary.
Adjusting the tension of the hoses

Note! When adjusting tension of the hoses, leave the percussion pressure
hose slightly less tensioned than the others.
1. Open the locking screws (1).

2
1 1
2. Pull the hoses to appropriate tightness (the suitable slack of the hoses is
approximately 5 cm).
3. Lock the hoses with clamps (2) and tighten the locking screws (1).

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5.7.9 Checking the condition of the steel strips

The steel strips on the beam can become damaged, for instance, by rocks
falling on the beam. The steel strips are available as spare parts.
1. Check the condition of the steel strips (1).
2. Replace steel strips if necessary.

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5.7.10 Checking the condition of the hose reel components

Check the condition of the hose reel components at least in conjunction
with every second rock drill overhaul.
1. Disconnect the rock drill hoses and plug them.
2. Lift the hoses off the drum.

3. Disconnect the return wire.
4. Disconnect the hose drum base plate from the hose drum carriage and
lift the hose drum off.
5. Open the four bolts (1).
6. Remove the cover (2).
7. Open the axle nut (3).

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8. Lift the hose reel (4) off the axle.

9. Remove the bushing (5).
10. Lift the return wheel (6) off.
11. Check the condition of the ball bearings (7 and 8). Replace if necessary.
5.8 Carrier
5.8.1 Machine greasing points
Use a grease gun with recommended grease.
FIRE HAZARD!
Accumulated grease or oil on the carrier is a fire hazard.
Remove debris any time a significant quantity oil is spilled on the
carrier.
Lubricate the propeller shaft fittings. All drive line sections are furnished
with grease nipples on universal joints and telescopic sections. Lubrication
must be done carefully to avoid damage of the seals.
Greasing points:
• Propeller shaft fittings
• Seat hinge pins
• Transmission
• Center hinge
• Support bearings
• Rear oscillation
• Cable reel hinges
• Switchgear hinges
• Steering cylinder pins

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5.8.2 Checking the planetary gear oil level
1. Rotate the wheel hub so that the center point of the oil filler opening is at
the same horizontal level than the center point of the axle.
2. Remove the oil plug.
3. Check the oil level. The oil level must be at the lower level of the filler
opening.
4. Add oil if necessary. Allow the oil to settle for a few minutes. There is
enough oil when a drop of oil comes out of the opening during filling.
5. Reinstall the oil plug.
5.8.3 Checking the differential oil level
1. Set the axle and its components in a horizontal position.

2. Clean the breathers.
3. Remove the inspection/filler plugs (A) from the cover of the axle housing.
4. Check the oil level The oil level must be at the bottom of the inspection/
filler plug (A).
5. Add oil if necessary. Allow the oil to settle for a few minutes.
6. Reinstall the inspection/filler plugs (A).

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5.8.4 Checking the battery electrolyte level

1. Check the battery electrolyte level.
5.8.5 Checking the pressure of the brake accumulators
B
A
The pressure should be about 65 bar in TC 7-8 / NC 7 -series carriers.

The pressure should be about 80 bar in TC 9-12 carriers.
The pressure should be about 100 bar in NC 4 carrier.
Check the pressure as follows:
1. Remove the cap (A).
2. Screw the pressure gauge to the filling valve.
3. Undo the lock nut (B).
4. Wait until the needle of the gauge stops and then read the gauge
indication.
5. Close the lock nut (B).
6. Unscrew the gauge from the filling valve and fit the cap (A) in place.

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5.8.6 Releasing the pressure from the brake accumulators

To release pressure from the brake accumulators, proceed as follows:
1. Shut down the engine.
2. Turn the ignition switch to the middle position.
3. Press the brake pedal several times.
4. Verify depressurized brake system from the brake pressure gauges in the
tramming panel.
Gauges should show 0 bar.
Note! The system may still be pressurized even when the brake
pressure gauges indicate 0 bar.

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5.8.7 Filling the brake accumulators

The only allowable filling gas is nitrogen (N2 ).
Repair of a pressure accumulator by welding or by other means is

strictly forbidden.
Do not fill an unchecked or a too worn accumulator.
9 7 6 5 4 2 1
10
N2 8 3
If the pressure accumulators need to be filled, do as follows:

1. Release the pressure from the brake accumulators, according to the
chapter "Releasing the pressure from the brake accumulators".
2. Remove the cap (3).
3. Screw the elbow adapter (10) to the filling valve (1).
4. Push the quick coupling sleeve (5) onto the stem (4).
5. Undo the locking nut (2).
6. Turn the pressure regulating valve (8) open.
7. Open the nitrogen bottle valve (9). The gauge (7) indicates the pressure
in the bottle.
8. Adjust the pressure slowly in to 65 bar (TC 7-8 / NC 7) or to 80 bar (TC
9-12) by turning the regulating valve (8). Gauge (6) indicates the
pressure in the accumulator.
9. Close the filling valve (1) by turning the locking nut (2).
10. Close the nitrogen bottle valve (9).
11. Turn the pressure regulating valve (8) open.
12. Disconnect the quick couplings (4) and (5).

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13. Release the elbow adapter (10) from the filling valve (1).
14. Tighten the locking nut (2) to 20 Nm.
15. Refit the cap (3).
16. After filling the pressure accumulators, check the brakes as follows:
a) Put the parking brake on.
b) Check that the drive selector is in the middle position (neutral).
c) Start the diesel engine and let it run for at least three minutes and
that you can see the warning lights are turned off.
d) Turn off the diesel engine.
e) Switch the power on by turning the ignition switch to the middle
position.
f) Pump the brake pedal all the way down at least five times and
make sure the brake pressure stays over 80 bars (gauges P3 and
P4).
1 2
1 Pressure gauge and indicator light of front brake circuit (P3)

2 Pressure gauge and indicator light of rear brake circuit (P4)
Note! Next time when you start the engine make sure that all the
pressure warning lights turn off.

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5.8.8 Bleeding the brakes
WARNING
Uncontrolled movement of the brakeless drill rig could cause death,
severe injury or property damage.
Park the drill rig on a level surface if possible. Lock the wheels
before bleeding the brakes.
For the trouble-free operation of the parking brakes it is important that the
hydraulic system is entirely free from air. Air may enter the system for
example in connection with component replacements or repairs and as a
result of possible oil leaks. The brake is released through hydraulic
pressure. If the system contains air, this causes the pressure to decrease
and the brake is not released properly, or it will engage after a while. For
this reason the brake circuit must be bled after every repair operation and
also at other times if malfunctions occur.
Bleeding the parking brakes

1. With the engine running and parking brake engaged off.
2. Open the hose connector (B1, inner) slightly and let oil flow out until the
air comes out.
3. Close the connector.
When necessary the above measures must be carried out several times.
After bleeding check the operation of the brakes and adjust them.

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B1 B1
Bleeding the parking brakes (TC7-TC9, NC 7 -Series)
Bleeding the service brakes

If full braking effect is to be achieved, the oil in the centre gears, where the
brakes are located, must not contain any air. The brakes must be bled if air
has for some reason entered the system and the effect of the brakes has
diminished. Make sure the carrier is levelled, and that the wheels are
blocked against movement, before bleeding the brakes.
1. Install plastic tubes on the nipples.
2. Start the engine.
3. Open the nipples (B2, outer) about half a turn.
4. Press the brake pedal fully down (do not pump it).
5. Close the nipples when the oil is free of air.
Bleed the axle at the other end in the same way.

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B2
B2
Bleeding the service brakes (TC7-9 / NC7-series axles, TC10-12 rear axle)

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5.8.9 Checking the steering wheel and control arm

Check steering wheel and control arm:
• Swing the steering wheel to check there is no vertical or horizontal play in
steering wheel or control arm
• If any play is noticed;
- Check the fastening of the steering wheel
- Check the fastening of the control arm by dismounting the cover
plate (1).
• If necessary, replace worn/damaged components

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5.8.10 Checking the tightness of boom support bolts

Boom support fixing bolts may break down and boom support with
booms may fall down if the bolts tightness is not regularly inspected.
Units with canopy

• Disconnect all necessary covers to get access to the bolts.
• Correct tightness of the bolt is 1100 Nm.
• If any of the bolts are missing, slackened or stretched, replace them
immediately with new ones.
• When using new bolts, lubricate the bolts and tighten them to specified
torque.

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Units with cabin
Checking the front side bolts

Front side bolts can be checked with the following procedure:
• Disconnect all necessary covers to get access to the bolts.
torque.
Checking the rear side bolts (TC7-TC12)

To gain access to tighten the rear bolts properly, the cabin must lift up for
200-350 mm according to following instructions:
• Support the unit to the ground with the jacks.
• With help of crane, support the cabin from the lifting points
• Untighten the rear (2) and front (2) cabin mounting bolts M16x110.
• Disconnect all necessary cables and hoses in order to lift the cabin for
250-350 mm.
- Especially in electrically controlled jumbos disconnect the cable for
the diesel engine.
- Especially in hydraulically controlled jumbos disconnect the cable for
the diesel engine and the boom and drilling hoses from the THC.
• Lift the cabin for 250-350 mm up in order to get access to rear side bolts
torque.
• After replacing and tightening the bolts, reconnect all the cables and
hoses.

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• Lower the cabin and refit the bolts and tighten them with correct
tightness.
Checking the rear side bolts (NC7)

To gain access to tighten the rear bolts properly, there is no need to lift the
cabin
• Tighten the bolts via the service hatch.

torque.

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5.8.11 Replacing the transmission oil filter

Extreme high temperature conditions, extended periods of high
temperature, or difficult climatic conditions will accelerate deterioration and
contamination of the oil.
The normal filter replacement frequency is intended for average
environmental and operational conditions. In extreme conditions, assess
and alter the maintenance frequency according to the conditions.
2 1
T20000
3 1
5
2
HR32000
Replace the filter as follows:

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1. Turn off the engine.

2. Open the filter (3) by turning it.
3. Clean the filter housing.
4. Lubricate the rubber seal and install a new filter.
5. Tighten the filter to 2.8–3.4 kpm.
5.8.12 Changing the differential oil
Change the oil while it is warm.

1. Clean the area around the inspection/filler plugs (A) and remove the
plugs.
2. Place a receptacle under the drain plugs (B).
3. Remove the drain plugs (B) of the front and rear axle differentials.
4. Let the oil flow into the receptacles.
5. Reinstall the drain plugs (B).
6. Fill the differentials with the recommended oil through the inspection/filler
plugs (A) until the oil level is at the bottom of the inspection/filler plug (A).
7. Reinstall the inspection/filler plugs (A).

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5.8.13 Spicer axle types 37R, 43R
WARNING
RUN OVER HAZARD!
Uncontrolled machine movement during brake disc wear check
could cause death, severe injury or property damage.
Always exercise extreme caution when going under the drill rig.
Apply parking brake and use wheel wedges to prevent the drill rig
movement. Make sure the drill rig can not be started unexpectedly.
Make sure the drill rig is on a steady and level surface. Apply the parking
brake and wheel wedges on place.
This check is recommended to be carried out when the oil in the centre
gear is to be changed and must be carried out for both sides of the axle.
1. Remove the plug from side of the trumpet arm, next to the center section.
The brake discs can be seen through the hole.
2. While parking brake applied, check the clearance between the reaction
plates.
3. If the clearance between the reaction plate ears is less than 4,5mm
(0.177 in), replace the friction plates and reaction plates on the both
sides of the axle.
Checking the brake discs for wear (Spicer axle types 37R, 43R)
Brake test is always performed before tramming. If the brakes do not hold
during the test and the brake pressures are correct, it is likely that the brake
discs have been worn. Replace the brake discs and intermediate discs on
the both sides of the axle.

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5.8.14 Spicer axle types 113, 114, 123, 213
WARNING
RUN OVER HAZARD!
Uncontrolled machine movement during brake disc wear check
could cause death, severe injury or property damage.
Always exercise extreme caution when going under the drill rig.
Apply parking brake and use wheel wedges to prevent the drill rig
movement. Make sure the drill rig can not be started unexpectedly.
Make sure the drill rig is on a steady and level surface. Apply the parking
brake and wheel wedges on place.
This check is recommended to be carried out when the oil in the center
gear is to be changed and must be carried out for both sides of the axle.
1. Remove the inspection plug from side of the trumpet arm, next to the
center section. The brake discs can be seen through the hole.
2. While parking brake applied, check the clearance between the reaction
plates with feeler gauge.
3. If the clearance between the reaction plate is less than 5.2 mm (0.205
in), replace the friction plates and reaction plates on the both sides of the
axle.
4. Install the inspection plug and tighten to correct tightening torque.

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Brake test shall always be performed before tramming. If the brakes do not
hold during the test and the brake pressures are correct, it is likely that the
brake discs have been worn. Replace the brake discs and intermediate
discs on the both sides of the axle.
5.8.15 Checking the middle-joint bearings
Turn the steering back and forth with small movements to check the middle-
joint bearings. Check the play that may have developed in the middle-joint
bearings. If there is any play, replace the bearings.
5.8.16 Checking the oscillation axle bearings
Rear-axle oscillation allows the carrier to turn in the longitudinal direction of
the axle.
Lift the rear axle off the ground and, using small movements, check the play
that may have developed in the oscillation bearings. If there is any play,
replace the bearings.
5.8.17 Replacing the safety cartridge of the air filter
3 4 1
1. Undo clip fasteners (1).

2. Take off hood (2) and remove cartridge (3).
3. Replace safety cartridge (4).
4. Install cartridge (3), replace hood (2) and do up clip fasteners (1).

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5.8.18 Changing the transmission oil

Extreme high temperature conditions, extended periods of high
temperature or difficult climatic conditions will accelerate deterioration and
contamination of the oil.
Normal oil replacement frequency is intended for average environmental
and operational conditions. In extreme conditions, assess and alter the
maintenance frequency with consideration of the conditions.
T20000
2 1
1. Drain the oil from the transmission through the drain plug (5) when the oil
is warm.
2. Fill the transmission with fresh oil up to the upper mark on the dipstick
(4).
3. Start the engine and let it idle (at 500–600 rpm).
4. Check the oil level when the engine is running and add oil up to the lower
mark on the dipstick.
5. When the oil temperature is 82.2–93.3 °C, check the oil level and add oil
up to the upper mark on the dipstick.

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HR32000
3 1
5
2
1. Open the drain plug (2) and drain the oil from the transmission when the
oil is warm.
2. When oil has been drained, close the drain plug (2).
3. Open the filler plug (1).
4. Refill transmission to LOW mark (5). Pour fresh oil into the torque
converter through filling hole (1). Refer to table of oil recommendation for
appropriate oil type and quantity.
5. Run engine at 500...600 rpm to prime converter and lines.
6. Recheck level with engine running at 500...600 rpm and add oil to bring
level to LOW mark (5). When oil temperature is hot (82.2 ... 93.3 °C)
make final oil level check. Bring oil level to FULL mark (4).
5.8.19 Changing the planetary gear oil
Change the oil while it is warm.

1. Rotate the wheel hubs so that the oil plug points down.
2. Place a receptacle under the oil plug.
3. Remove the oil plug.
4. Let the oil flow into the receptacle.
5. Rotate the wheel hub so that the center point of the oil filler opening is in
the same horizontal level than the center point of the axle.
6. Fill the planetary gear with recommended oil. Allow the oil to settle for a
few minutes. There is enough oil when a drop of oil comes out of the
opening during filling.
7. Reinstall the oil plug

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5.8.20 Checking the specific gravity of the electrolyte and cleaning the battery terminals
1. Check the specific gravity of the electrolyte and clean the battery
terminals.
5.8.21 Servicing the Ansul fire suppression system (optional)

Service shall be performed every 1000 hours or every 6 months (whichever
comes first).
Refer to manufacturer's instructions.

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5.8.22 Maintenance procedures done as required
A B C D E F
SERVICE SERVICE PARKING PARKING CHARGING OF CLUTCH
BRAKE BRAKE BRAKE BRAKE ACCUMULATORS

FRONT REAR FRONT REAR
70 bar 70 bar 100 bar 30 bar 135-160 bar 17-19 bar

NC7, TC7-8

Measuring point assembly (284)
Checking the service brake pressure

Follow these steps:
1. Attach a pressure gauge to the front brake circuit's pressure inspection
point (A).
3. Press the service brake pedal to the end of its movement path.
4. The pressure should be 70 bar (TC9-12) / 80 bar (TC7–8, NC7).
5. Repeat the same measurement for the rear brake circuit by attaching a
pressure gauge to the rear brake circuit 's pressure inspection point (B).
Checking the front axle's parking brake pressure

Follow these steps:
1. Attach a pressure gauge to the front axle's parking brake pressure
inspection point (C).
3. Release the parking brake.

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4. The release pressure should be 100 bar (TC10-12) / 30 bar (TC7–9,

NC7).
Checking the rear axle's parking brake pressure

Follow these steps:
1. Attach a pressure gauge to the rear axle's parking brake pressure
inspection point (D).
3. Release the parking brake.
4. The release pressure should be 30 bar.
Checking the charging oil pressure of the service brake accumulators

Follow these steps:
1. Attach a pressure gauge to the pressure accumulator's pressure
inspection point (E).
3. The pressure should rise quickly to 135-160 bar.
Checking the steering pressure

The pressure must be checked when the oil is at operating temperature
and the engine is running at full speed.
1. Connect the manometer to the checking point (A).

2. Turn the machine to the full turning angle against the end stops.
3. The maximum allowed pressure is 140 bar.
4. If the desired pressure differs from the given value, adjust it by turning
the adjustment screw (B, 263.01) to the desired direction.

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5.8.23 Filling the gas pre-charge pressure for the brake accumulators
The only allowable filling gas is nitrogen (N2).
Repair of a pressure accumulator by welding or by other means is

strictly forbidden.
Do not fill an unchecked or a too worn accumulator.
9 7 6 5 4 2 1
10
N2 8 3
1 Filling valve 2 Locking nut

3 Cap 4 Quick coupling stem
5 Quick coupling sleeve 6 Accumulator pressure gauge
7 Gas bottle pressure gauge 8 Pressure regulating valve
9 Shut-off valve 10 Elbow adapter
If the pressure accumulators need to be filled with gas pre-charge pressure,

do the following:
1. Release the oil pressure from the brake accumulators, according to
instructions in section Releasing the oil pressure from the brake
accumulators.
2. Remove the cap (3).
3. Install the elbow adapter (10) to the filling valve (1).
4. Push the quick coupling sleeve (5) onto the stem (4).
5. Open the locking nut (2).
6. Turn the knob (8) to open the pressure regulating valve.
7. Turn the knob (9) to open the nitrogen bottle shut-off valve. The gauge
(7) indicates the pressure in the bottle.

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8. Turn the knob (8) to adjust the regulating valve pressure slowly to 80 bar.
Gauge (6) indicates the pressure in the accumulator.
9. Close the locking nut (2).
10. Turn the knob (9) to close the nitrogen bottle shut-off valve.
11. Turn the knob (8) to open the pressure regulating valve.
12. Disconnect the quick coupling stem (4) and sleeve (5).
13. Remove the elbow adapter (10) from the filling valve (1).
14. Tighten the locking nut (2) to torque 20 Nm.
15. Reinstall the cap (3).
16. After filling the pressure accumulators, check the brakes:
a) Engage the parking brake.
b) Select neutral gear.
c) Start the diesel engine and let it run for at least three minutes.
d) Shut down engine.
e) Press the brake pedal all the way down at least five times and
make sure the brake pressure stays over 80 bar (check front/rear
charge pressure values from Tramming display - Brakes tab).

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5.9 Diesel engine MB

5.9.1 Replacing the engine oil and filter
Note! Change the engine oil while the engine is warm.
WARNING! BURN HAZARD!

Hot oil could cause burns.
Let the engine cool down before starting any maintenance work.
Always use approved safety gloves when changing the engine oil.
Special tool: oil filter opener

Open the oil filter cover with the
oil filter opener. Empty the filter
housing of oil.
Remove the cover (1) and the

oil filter element and click the fil-
ter element (3) off by pressing
the bottom edge to the side.
Ensure that no foreign objects
can enter the filter housing. Nev-
er wipe the filter housing clean.

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Siphoning/draining engine oil
Suction the engine oil off

through the dipstick tube.
Remove the dipstick (ar-
row) and push the suc-
tion device (cup) with the
O-ring seal to the dipstick
tube.
Alternative method:
Place a suitable recepta-
cle under the oil drain
plug in the oil pan. Open
the drain plug carefully,
and let the oil flow out.
Dispose of the engine oil and filter in accordance with the applicable regu-
lations.
Replace the cover seal

(2).
Place a new filter ele-
ment to the cover and
press the filter until it
clicks into place.
Screw the cover to the oil
filter housing and tighten
the cover to the correct
tightness. The tightening
torque is 25 Nm.
If the engine oil is drained through the oil pan, replace the drain plug with
a new seal and tighten the plug to the correct tightness. The tightening tor-
que is 80 Nm.

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Add new engine oil

through the filler opening
neck (arrow) until the oil
level is in the level of the
max mark in the dipstick.
Start the engine so that the throttle pedal is in the idling position and pay
attention to the oil pressure gauge
Let the engine idle until the engine oil pressure rises to the correct level. If
the engine oil pressure does not rise to the correct level in about 10 sec-
onds, switch the engine off and determine the cause of the fault.
Check the filter and oil drain plug for leaks.
Shut down the engine. Check the oil level again in about 5 minutes. Add
oil to the max mark in the dipstick as necessary.

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5.9.2 Replacing the fuel filter
1. Unscrew the cap (1) together with the filter element (3) and pull a short
distance out of the filter casing (5). Allow the fuel to drain off.
2. Remove the cap with the filter element. Unclip the filter element (3) by
pressing the lower edge of the filter element to the side.
3. Pull the dirt collector (4) from the filter casing by the tags.
Dirt and water must not be allowed to get into the filter casing. Do not
empty the dirt collector into the filter casing.
4. Clean the cap (1).
5. Clean any dirt from the collector (4).
6. Renew the sealing ring (2).
7. Clip the new filter element into place in the cap.
8. Oil the sealing ring and filter element seals lightly.
9. Insert the dirt collector into the filter casing, ensuring the correct
installation position.
10. Screw the cap with the filter element and tighten. Tightening torque 25
Nm.

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5.9.3 Replacing the fuel water separator filter
5
1
1. Place a receptacle under the separator.

2. Open the drain valve (1) and bleeder screw (3) and drain the filter
cartridge (4).
3. Remove the filter cartridge (4) and separation container (5) from the filter
head.
4. Remove the separation container (5) from the filter cartridge (4).
5. Clean the seal ring groove on the separation container (5).
Note! The separation container is reusable, so do not damage it.
Note! Dispose of the old filter cartridge in accordance with
environmental regulations. Do not dispose of it as household waste.
6. Lubricate a new seal ring with clean diesel or engine oil and install it on
the groove on the separation container (5).
7. Install the separation container (5) firmly on the new filter cartridge (4) by
twisting it into place.
Note! Do not use tools.
8. Lubricate a new seal ring with clean diesel or engine oil and install it on
the groove on the filter cartridge (4).
9. Install the filter cartridge (4) firmly on the new filter head by twisting it into
place.
Note! Do not use tools.
10. Close the drain valve (1).
11. Fill the filter with the hand pump (2).
12. Continue pumping until the fuel coming out of the bleeder screw (3) is
free of air bubbles.
13. Tighten the bleeder screw (3).
14. Check for leaks.
Note! Make sure that the drain hose (6) is not close to the hot exhaust pipe.

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5.9.4 Checking the condition of poly V-belt

Special tool (turning tool) required.
Inspection hole, flywheel housing
1. Fit the turning tool to the inspection hole in the flywheel housing.
2. Make a mark on the poly V-belt with chalk.
3. Check the poly V-belt section for signs of damage. To do this, turn the
engine or poly V-belt gradually on until the chalk mark is reached again.
The poly V-belt must be renewed if any of the damage patterns listed
appear.
4. Remove the turning tool again.

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Damage patterns
1 Condition as new (trapezoi- 2 Wear on one side (wedge-
dal ribs) shaped ribs)
3 Cord visible in base of ribs 4 Ribs split
5 Transverse cracks in several 6 Nodules of rubber in base of
ribs belt
7 Deposits of dirt/stones 8 Rips separated from base of
belt
9 Cord torn out to the side 10 Outer cords frayed
11 Transverse cracks on the re- 12 Transverse cracks in several
verse of belt ribs

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Removing/installing poly V-belt

ENTANGLEMENT HAZARD!
The tensioning mechanism is springloaded and could cause severe
injury.
Use proper service tools and be careful.
Removing/installing poly-V-belt
1. Plug the spanner (2) with a 17 mm socket insert onto the hexagonal bolt
on the tensioner pulley (1).
2. Turn the tensioner pulley upwards and remove the poly-V-belt.
3. Turn the tensioning mechanism back.
4. Check the tensioning mechanism and pulleys for damage (e.g. worn
bearing on tensioning mechanism, tensioner and deflector pulleys, or
pattern wear on poly-V-belt pulleys). If necessary, renew parts.
5. Lay the poly-V-belt (new) on all the pulleys except for the tensioner pulley
(see illustrations for correct routing of the poly-V-belt).
6. Turn the idler pulley upward with the handle, place the poly-V-belt onto
the idler pulley and turn the idler pulley downward.
7. Remove the handle and check that the poly-V-belt is seated correctly on
the pulleys.

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Routing of poly-V-belt (engine without refrigerant compressor)
1 Crankshaft
2 Generator
3 Coolant pump
4 Tensioner pulley
Routing of poly-V-belt (engine with refrigerant compressor)
1 Crankshaft
2 Generator
3 Coolant pump
4 Tensioner pulley
5 Refrigerant compressor
6 Deflector and guide pulley

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guard for alternator
When installing the body V-belt, make sure that the guard for alternator is
installed back on its place.
5.9.5 Checking the engine for leaks and general condition
Check the engine visually for signs of leakage. Slight dampness at sealing
points is acceptable.
Cause for more severe leaks must be identified and repaired without delay.
5.9.6 Checking the lines and hoses of the engine
1. Check for leaks and general condition.
2. Visually inspect lines and hoses. At the same time, check that all pipes
and hoses are undamaged, correctly positioned to avoid abrasion, and
properly secured.
5.9.7 Checking the intake pipe between air cleaner and engine
1. Check that rubber boots, intake pipes and connecting hoses are
undamaged and free from leaks.
2. Check tightness of hose clips, flange connections and the intake
manifold.

ID: BG00471036 en-US C.001.1 2018-05-28
5.9.8 Checking the engine cooling system

Check fluid level and corrosion inhibitor/antifreeze concentration, and
correct if necessary.
Only use service products approved by engine manufacturer.
WARNING
BURN HAZARD!
Hot and pressurized coolant can cause serious burns.
Never open the cap of the engine cooling system if the coolant is at
normal operating temperature. Only check and correct coolant level
when the coolant temperature is below 50 °C. Remove cap slowly.
Use safety gloves.
Before correcting the coolant level, check the corrosion inhibitor/antifreeze

concentration. When topping up, use only a pre-prepared coolant mixture
containing 50% corrosion inhibitor/antifreeze by volume.
1. Open the cap of the engine cooling system slowly to allow excess
pressure to escape.
2. Check the concentration of corrosion inhibitor/antifreeze with a suitable
tester. The correct concentration of corrosion inhibitor/antifreeze, that is
50% by volume, protects the system down to a temperature of -37 °C. If
a lower level of antifreeze protection is shown, correct the concentration.
If the concentration is too low, there is a risk of corrosion/cavitation in the
cooling system. Concentrations of more than 55% by volume should not
be used, as this is the level which affords maximum antifreeze protection
(down to -45 °C), when higher concentrations adversely affect heat
dissipation.
3. Check the coolant level. The cooling system is correctly filled when the
coolant has reached the mark in the filler neck.

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5.9.9 Replacing the intake air cleaner filter
3 4 1
1. Undo clip fasteners (1).

2. Take off hood (2) and remove cartridge (3).
3. Clean cartridge (replace at least once a year).
4. Clean cartridge (3).
a) Using dry compressed air (max. 5 bar), blow out from inside
outwards, or
b) Tap out (in emergencies only). Do not damage the cartridge, or
c) Wash out according to manufacturer’s specifications
5. Check paper filter (light showing through) and gaskets for damage.
Replace if necessary.
6. After five filter services or after two year at the latest, replace safety
cartridge (4) (never clean!).
7. Install cartridge (3), replace hood (2) and do up clip fasteners (1).

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5.9.10 Adjusting the valve clearances
Layout of cylinders and valves
Valve clearance adjustment
WHITE ARROW = Inlet valve

BLACK ARROW = Exhaust valve
X = Flywheel end
Special tool (turning tool) required.
Valve clearance
Inlet valves = 0,40 mm
Exhaust valves = 0,60 mm
Note! Adjust the valve clearance when the engine is cold (at least 30
minutes after it was switched off, even if it was only run for a short
time). Clean a heavily soiled cylinder head cover before removing it.

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Removing/installing cylinder head cover
Removing/installing cylinder head cover
1. Remove the cover.

2. Remove the crankcase breather hose (6) from the cylinder head cover.
3. Unscrew the hexagon socket-headed bolt (2) from the cylinder head
cover, together with its sealing washer (3). To install: Insert the hexagon
socket-headed bolt with a new sealing washer and tighten with a
tightening torque of 30 Nm.
4. Remove cylinder head cover.
To install: Clean the sealing surfaces of the cylinder head and the cylinder
head cover as necessary. Check the gasket between the cylinder head
cover and the charge air manifold (1). Renew as necessary. The gasket (5)
between the cover and the cylinder head must always be renewed.
The cylinder head cover is installed in reverse order.
Fit the turning tool into the inspection hole on the flywheel housing.
Valve clearance adjustment - method 1

Adjust each cylinder in the order in which fuel is injected.
• Use the turning tool to turn the crankshaft until the piston of the cylinder
at which the valve clearancea are to be set is exactly at the top dead
centre of the compression stroke. The valves must be closed and it must
be possible to turn the pushrods without effort. This position has been
reached when the valves of the cylinder in which the piston has reached
the same position overlap (see table).
Engine
OM 904 LA Injection sequence 1 3 4 2
OM 904 LA Overlap 4 2 1 3

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Engine
OM 906 LA Injection sequence 1 5 3 6 2 4
OM 906 LA Overlap 6 2 4 1 5 3
Inspection hole, flywheel housing
Valve clearance adjustment - method 2

All valves can be adjusted in two crankshaft positions.
• Use the turning tool to turn the crankshaft until No. 1 cylinder is at the
ignition TDC position or at the overlap TDC position (at ignition TDC, all
valves are closed and the valves of No. 4 cylinder overlap).
• Check and adjust valves in accordance with the following table.
Crankshaft position Cylinders/valves to be adjust-
Engine
No. 1 cylinder ed
1 2 3 4 5 6
OM 904 LA Ignition TDC I/E I E -
OM 904 LA Overlap TDC - E I I/E
OM 906 LA Ignition TDC I/E I E I E -
OM 906 LA Overlap TDC - E I E I I/E
I - Inlet valve
E - Exhaust valve

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Checking/adjusting valve clearance
Peephole, flywheel housing
1. Measure the valve clearance with a feeler gauge between the rocker arm
and valve stem (exhaust valve) or valve bridge (inlet valve) (arrows). It
should be possible to pull the feeler gauge through with no more than
light resistance.
2. To adjust the valve clearance, unscrew the locknut (2). Set the correct
valve clearance by turning the adjusting screw (1).
3. Retighten the locknut to a tightening torque of 25 Nm.
4. Check the valve clearance again and readjust if necessary.
Concluding operations
1. Reinstall cylinder head cover.
2. Remove the turning tool from the inspection hole in the flywheel housing.

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5.9.11 Cleaning the fuel pre-filter
1. Clean the outside of the fuel pre-filter and cover over any hoses or pipes
located beneath it.
2. Unscrew the filter bowl (1).
3. Clean the filter bowl (1) and filter element (2). Note! If the filter element is
heavily soiled or damaged, it should be renewed. Dispose of the used
filter and of residual fuel in accordance with applicable rules and
regulations.
4. Check the seal (3) for the filter casing and renew if necessary.
5. Insert the filter element (2) into the filter bowl (1) and screw the filter bowl
onto the filter casing with a tightening torque of 10 Nm.

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5.9.12 Checking the general condition of cooling and heating system

Check the general condition and look for possible leaks.
Special tool (pressure tester) required.
Note! The fluid level and corrosion inhibitor/antifreeze concentration
(correcting if necessary) must be checked first.
Note! A safety valve is incorporated into the tester to prevent the pressure
from exceeding 1,2 bar.
Compressed air valve
1. On heating systems, open the regulating and cut-off valves.

2. Remove the cap from the coolant expansion tank.
3. Connect up the tester.
4. Connect the compressed air hose with the tyre inflation union to the valve
and allow pressure to build up to a level corresponding to the opening
pressure of the cooling system. The opening pressure of the cooling
system can be identified from the code on the cap or on the pressure
relief valve. Example: Code 70 = 0.7 bar gauge pressure.
5. Check all radiators, the coolant pump, the engine oil cooler, the engine
covers (corehole covers) and the heat exchanger for leaks.
6. Check all pipes and hoses for the cooling and heating system for
freedom from leaks and damage, correct positioning to avoid abrasion
and secure fastening in the specified manner.
7. Check the radiator for external contamination. The fins must not be
clogged with dirt.
8. Relieve pressure in the cooling and heating system at the valve on the
tester. Remove and re-attach the cap.
9. Close the heating system regulating valves.

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5.9.13 Renewing the coolant

Only use a corrosion inhibitor/antifreeze approved by Mercedes-Benz.
WARNING
BURN HAZARD!
Hot and pressurized coolant could cause serious burns.
Never open the cap of the engine cooling system if the coolant is at
normal operating temperature. Only check and correct coolant level
when the coolant temperature is below 50 °C. Remove cap slowly.
Use safety gloves.
Note! Before renewing the coolant, check that the cooling and heating
system is in good condition and free from leaks. Confirm the coolant
renewal with an entry in the Maintenance Booklet.
Note! There are other drain plugs, for example on the radiator. Pipes etc.
below the drain plugs should first be covered over and a receptacle
suitable for the quantity of coolant should be placed underneath.
Coolant drain plug
1. Open the cap of the engine’s cooling system slowly to allow excess
pressure to escape and remove the cap.
2. On heating systems: Open the heating system regulating valves.
3. To drain the coolant from the engine, attach the hose (interior diameter
approx. 12,5 mm) to the drain plug on the engine. The coolant will drain
off after the plug has been turned through 1 to 2 turns.
Dispose of the used coolant in accordance with applicable legal
stipulations.
4. Free drain apertures if blocked by deposits.
5. Screw in the coolant drain plug on the engine tight again and remove the
drain hose.
6. Screw in other drain plugs (without hose connection) with new seals.

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7. Add coolant in the specified concentration until the mark in the filler neck
is reached. Seal the cooling system again.
8. Start the engine and run it for about 1 minute at varying speeds.
9. Stop the engine and check the coolant level. Top up if necessary.
5.9.14 Replacing the poly V-belt
Replace the poly V-belt. Refer to section Checking the condition of poly V-
belt.
5.10 Cable and water hose reel

5.10.1 Lubricating the cable spooling system
WARNING
MOVING CABLE GUIDE AND CHAIN DRIVE HAZARD!
Moving and rotating parts can crush and cut and that could result in
ALWAYS keep your hands away from moving and rotating parts.
LOCKOUT power before maintenance.
1. Lubricate the cable spooling system.

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5.10.2 Checking the guide rollers of the cable reel

1. Visually check the condition of the guide rollers.
5.10.3 Checking the guide rollers of the water hose reel

1. Visually check the condition of the guide rollers.
5.10.4 Lubricating the chain of the cable reel

1. Lubricate the chain.

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5.10.5 Lubricating the chain of the water hose reel
Lubricate the chain.

5.10.6 Checking the tightness of the chain of the cable reel
1. Visually check the tightness of the chain.

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5.10.7 Checking the tightness of the chain of the water hose reel
Visually check the tightness of the chain.

5.10.8 Checking the cable fastening to the reel
Check the cable fastening to the reel.

5.10.9 Checking the operation of the cable reel limit switch
Pull the cable off the reel and check the operation of the limit switch.
• The first limit turns on indicator SH3 on the tramming panel and engages
the parking brake. The parking brake can be released by pressing button
SH3. The cable can be reeled in.
• The second (last) limit turns on indicator SH3 on the tramming panel and
engages the parking brake. The parking brake cannot be overridden. It
may be necessary to remove the cable and then reel it in.

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5.10.10 Changing the gear box oil of the cable reel

Service shall be performed every 1000 hours or every 12months
(whichever comes first).
WARNING! ENVIRONMENTAL HAZARD!
Incorrect disposal of the used oil could cause damage to the
environment.
Dispose of the used oil in accordance with local regulations.
1. Open the filling hole plug (1).
2. Place a waste oil receiver under the drain plug (2) and open the plug (2).
3. When no more oil flows through the hole, close the drain plug (2).
4. Fill in with clean oil through the filling hole (1) until the oil is almost level
with the bottom of the sight glass (3).
5. Close the filling hole plug (1).

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5.10.11 Checking the cable reel slip rings and carbon brushes
WARNING
Cut off the voltage with the main switch of the tunnel power supply
center and disconnect the drill rig cable from the power supply
center every time before starting maintenance work. Make sure that
electricity cannot be switched on accidentally during the
maintenance procedures.
Check the fastening and tightness of the connections and the limit switch.
Make sure that the carbon brushes (1) are in their grooves. The carbon
brushes are positioned on different sides of the slip ring (4 brushes/groove).
If the carbon brush is worn down to approx. 3 mm in the thinnest place, the
carbon brush must be replaced. It is recommended to replace all carbon
brushes at the same time.

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If necessary, clean the collector on the inside. The slip rings must be dry,
clean and free from oil or other covering stains. Use a vacuum cleaner,
brush and/or lint-free cloth for cleaning.
Note! Do not use water for cleaning the collector, its parts or its housing.
If a part is damaged, it must be replaced immediately. After cleaning the

rings remount the collector housing ensuring that the drainage holes are
downwards. Also make sure the rubber gasket is in place with its joint
downwards as well. This will ensure a good sealing.
5.11 Drilling hydraulics

5.11.1 Replacing the breather filter of the hydraulic oil receiver
1. Carefully clean the top of the hydraulic oil receiver so that any dirt doesn’t
get into the receiver.
2. Replace the breather filter of the hydraulic oil receiver.

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5.11.2 Replacing the pressure filter

The filter is equipped with an electric service indicator (optional). The
indicator light (H611) on the indicator panel goes on if the pressure filter has
become so dirty that it must be replaced.
1. Ensure that the hydraulic system is not pressurised.
2. Clean the filter.

3. Open the filter housing and remove the old filter cartridge and seal.
4. Install the new filter cartridge and seal.
5. Close the filter housing by twisting.
Ensure the tightness of the filter housing upon the next start-up.

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5.11.3 Replacing the return oil filter

The filter is located inside the receiver.
2. Open the return filter cover on top of the receiver.

3. Replace the return filter cartridge. Make sure that the filter cartridge’s
seals are undamaged and fit their grooves well. Replace the seals if
necessary.
4. Replace the covers’ O-ring seals if necessary.
5. Install the return filter cover.

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5.11.4 Changing the hydraulic oil

RISK OF DAMAGE TO THE HYDRAULIC SYSTEM!
NOTICE Contaminated oil is a major cause of premature component failure.
Observe strict cleanliness when filling oil.
1. Position the rig on level surface.

2. Retract all hydraulic cylinders and set the boom(s) to a tramming
position.
4. Remove the tank breather.
5. Empty the oil receiver to the receptacle using the drain valve (1).
6. Remove the service hatch (2) at the top of the receiver to facilitate
cleaning the receiver internally.
7. Clean, rinse, and dry the receiver thoroughly.
Before filling the receiver, ensure that it is free of impurities.
8. Fill the hydraulic oil receiver with fresh oil. Use oil as specified in the
chapter "Lubricants and capacities". DO NOT OVERFILL!
• When using rig's electric filling pump, pump automatically stops filling
when the correct level is reached.
• When filling the receiver manually, observe the correct oil level from
the sight glass on the tank.
9. Install the service hatch and correctly tighten the hatch’s fastening nuts.
10. Start the power packs and check the correct oil level (3) after the
hydraulic motors have been running for a few minutes. Add oil if
necessary. In case of need to bleed the hydraulic system, drive the
relevant function a few times from extreme position to another.

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Note! Make sure that used oil is correctly disposed.
5.12 Water circuit

5.12.1 Checking the operation of the water valve FV-70
The valve needs attention only if water or oil comes out of the overflow duct
(arrow), or if the flushing water flow does not stop although the valve is
closed.
All seals that affect the operation of the valve are sealing rings on the
spool. They all come out with the spool when it is pulled out of the valve
block.
5.12.2 Checking the operation of the water valve FV-100
The valve needs attention only if water or oil comes out of the overflow duct
(arrow), or if the flushing water flow does not stop although the valve is
closed.
All seals that affect the operation of the valve are sealing rings on the
spool. They all come out with the spool when it is pulled out of the valve
block.

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5.12.3 Checking the operation of the pressure switch

Close the water circuit using the shut-off valve. When the water pressure
drops below 2.8 bar, the pressure switch engages and lights the warning
indicator H601 (water pressure low) on the QN panel. Now press button
S505 (pressure switch reset). The pressure switch is operating properly if
the warning indicator does not go off. Open the shut-off valve. The pressure
switch is operating properly if the warning indicator H601 goes off as the
pressure exceeds 2.8 bar.
H601
S505

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5.12.4 Cleaning the oil cooler

If the oil temperature increases or the pressure of the flushing valves falls, it
may be a sign that the oil cooler needs cleaning. There may also be other
reasons for a decrease in the pressure, so the cause for it must always be
clarified.
If it has been ascertained that the cooler is blocked and if the cooler model
is dismountable, drain both the water and the oil from the cooler unit and
detach the hoses before cleaning.
The best way to clean the water circuit-side surfaces of the tubing (the
inner surfaces of the tubes) is pushing a 3 mm steel rod into the tube in the
opposite direction of the water flow during cooling.
After cleaning, remove all impurities carefully from both surfaces of the
tubing. This can be done for example by first washing the unit carefully and
then blowing any loose materials and the water off the tube surfaces with
compressed air.
Note! Be careful not to over-tighten the bolts. The tightening torque (37
Nm) of the cooler end fastening bolts should be complied with so
that the ends do not bend and get damaged by excessive tightness.
Note! If the cooler hoses are detached, make sure that they are
reconnected in the correct order. The inflowing oil must be directed
through the upper way, for the reason that then the running direction
of the oil is natural with respect to the cooling. For the same reason
the water must be directed into the cooler through the bottom way.
Note! Observe the given pressure limits! For example, if the pressure in the
water circuit exceeds the specified limit, the oil cooler is in danger of
getting damaged. The damaged cooler may let water into the
hydraulic oil and the damages can be very serious.
Note! New seals should be used when assembling the cooler.

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5.12.5 Changing the mud separator strainer and O-ring

Note! The mud separator does not operate effectively if it reuses water
already used for flushing.
Restricted water flow causes flushing and cooling problems. The most
common reason for the drop of pressure is a blocked mud separator.
The strainer (4) is located inside of the mud separator (2). Dismantle the
mud separator fittings to pull the old strainer and O-ring out and replace
them with new ones.
2
3

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5.13 Air circuit

5.13.1 Checking the condition of the air receiver (optional)
WARNING
Make sure that the system is unpressurized before doing any
maintenance.
604
604.01
Visually check the fastening and external condition of the receiver (604):
• There must not be any cracks or dents in the receiver's structure.
• If cracks or dents at the outer surface are noticed, replace the receiver.
• Surveillance and periodical checks must be executed according to
country laws.

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5.14 Compressor CTN

5.14.1 Procedures prior to compressor maintenance
Hot surfaces of the equipment could cause burns.
Let the compressor cool down before starting any maintenance
work!
• Stop the compressor and check that the oil separator unit is not
pressurized. After the compressor is stopped, the oil separator unit is
drained by the out-blow unit – wait approximately 2 minutes.
• Turn the power off and make sure the compressor cannot be started.
• Ensure that the drill rig is detached from an external pneumatic network.
• Close the shut-off valve between the network and the compressor.
• Open the safety valve cap 4–5 turns.
Note! Make sure that the system is non-pressurized.

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5.14.2 Changing the compressor oil
3 2
1. Run the compressor until the oil temperature is approximately +40–

50 °C.
2. Stop the compressor.
3. Loosen the safety valve (2) 4–5 turns.
4. Open the oil filler plug (1) and drain valve (3) and let the oil drain into the
recovery tank.
5. Close the drain valve (3)
6. Replace the oil filter (refer to section Replacing the compressor oil filter).
7. Fill with fresh oil up to the max. indicator.
8. Replace and close the oil filler plug (1).
9. Close the safety valve (2).
Note! Follow the local regulations for oil disposal.

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5.14.3 Replacing the compressor oil filter
Note! Dispose of the oil in accordance with local regulations.
1. Place a protective cloth under the filter. While the filter is being replaced,
oil runs from the filter housing.
2. Remove the filter by turning it counterclockwise using a tightening belt.
3. Apply oil to the seal of the new filter.
4. Fasten the new filter by manually turning it clockwise.
5.14.4 Checking and retightening main motor cables
Check and retighten main motor cables in every 500h.
5.14.5 Cleaning the compressor externally with a cloth
Clean the compressor in every 500 h and in a dirty environment as needed.

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5.14.6 Replacing the compressor air filters

Note! The filters are disposable and cannot be cleaned.
1 2 3
1. Remove the air filter cover (3).

2. Remove the old primary and secondary filters (2).
3. Clean the air filter housing (1).
4. Install new filters (2).
5. Reinstall the cover (3).
Note! Check that the particle remover hole (4) points downward.
5.14.7 Replacing the compressor belts
1. Untighten the screw (1) counterclockwise until the belts are loose
enough. (The screw pushes the motor up so that belts loosen.)
2. Change the belts.
3. Return the screw (1) to its original position.
5.14.8 Cleaning the cooler externally

Clean the cooler with pressurized air. For a more effective cleaning, brush
the cooler from underneath. Note! Do not use a metal wire brush.
Refer to the compressor manufacturer's instructions.

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5.14.9 Replacing the compressor oil separator cartridge, discharge valve, valve nest,
wing nut and O-rings
8 5
1 3
Note! Dispose of the used separator element in accordance with local

regulations.
1. Close the shut-off valve between the network and the compressor.
2. Open the safety valve cap 4–5 turns.
3. Remove the oil separator cartridge cover (1).
4. Remove the separator cartridge (2).
5. Remove the discharge valve (6) by turning.
6. Remove the valve nest (7).
7. Replace the discharge valve (6) and the valve nest (7).
8. Clean the orifices (3) at the ends of the hose.
9. Replace the filter strainer (4) and clean the oil separator housing.
10. Lubricate the separator O-ring and install the new separator cartridge.
11. Replace and lubricate the O-ring (5) between the oil separator unit and
the discharge valve (6).
12. Install new separator cartridge (2) by hand.
13. Install the cover (1).
14. Tighten the screws alternately.

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15. Replace the wing nut and O-ring (8).

16. Close the safety valve.
17. Open the shut-off valve between the network and the compressor.
5.14.10 Cleaning the oil return line
Clean the return hose line and orifice plate.
5.14.11 Replacing the screen for oil return, fittings and gasket
Refer to the manufacturer's instructions.
5.14.12 Checking the operation of the compressor relief valve
The operation must be checked at least once a year, as recommended by
the manufacturer.
Note! All safety valve adjustment and repair tasks must be performed by
trained professionals (take into consideration local regulations).
The opening pressure of the safety valve must be tested in a separate

compressed air circuit.
The valve operation can be tested by turning the safety valve cap (1) 1–2
turns counterclockwise until you can hear the air bleeding out between the
cap and the body. Close the cap by hands to original position.
5.14.13 Lubricating the electric motor bearings
Lubricate the electric motor bearings once a year / in every 1000h.

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5.14.14 Replacing the seal kits of the inlet and the discharge valve
Note! CTN compressor discharge valve seals do not require replacement.
Instead the replacing occurs simultaneously with the complete
discharge valve replacement, see "Replacing the discharge valve".
Remove the Inlet valve from the air end before maintenance and protect
the air end inlet while the inlet valve is separated from the air end.

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Disassembling the inlet valve
WARNING!
Opening the valve releases a loaded spring.
Use safety glasses when disassembling the valve.
1. Remove the retaining ring with pointed pliers.
2. Remove the plug and o-ring.

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3. Remove the retaining ring from the top of the valve and push the cover
down.
4. Remove the cover and the spring.

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5. Open the screw and remove bushing, spring and plate.

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6. Remove the piston from the frame.
7. Clean the parts and check for possible wearing marks.
Disassembled inlet valve

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8. Replace the seals. Lubricate the o-rings with heat resistant grease. Note
that one of the o-rings is inside the frame. Typically only seals require
replacement, but in case of worn parts, replacement is recommended.

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Reassembling the inlet valve

1. Before reassembling the valve, grind all sharp edges with sand paper.
2. Assemble the valve in reverse order; put the plate, spring and bushing to
the correct position and tighten the screw.
3. Assemble the spring and cover.

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4. Push the retaining ring to the groove.
5. Assemble the plug and the o-ring.

6. Mount retaining ring with pointed pliers.
7. Reassemble the inlet valve to the air end.

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5.14.15 Checking the function of the thermometer safety limits

Thermometer´s functionality is tested by using a heater (operation range
0-120 °C) to heat the sensor to the temperature limits. Do not use fire.
• Remove the sensor from the compressor's body.
• Start the power packs, compressor and water pump.
• Heat the sensor and monitor the temperature gauge.
• When temperature reaches 100 ºC, check that the red indicator light
H604 in the QN-panel goes on.
H604 is still on and power pack, compressor and water pumps stop.
5.14.16 Checking the condition of the compressor hoses
Visually check the hoses. If visible damage is detected or the hose leaks,
replace it with a new one.
5.14.17 Replacing the blow-down valve
The blow-down valve is attached to a flange below the inlet valve.
1. Disassemble the hosing to the blow-down valve (1).
2. Replace the blow-down valve (1).

3. Reassemble the hosing.

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5.14.18 Replacing the seal kit of the pilot valve

1. Undo the screws (1) and disassemble the valve.
1
2
2. Replace the membrane (2).

3. Reassemble the valve in reverse order.
5.14.19 Replacing the oil thermostat
1. Undo the lock ring (1) to open the cover.

2. Replace the thermostat (2) and the o-ring (3).
3. Reattach the cover with the lock ring.
5.14.20 Replacing the motor bearings
Replace the motor bearings in every 5 years / 10 000h.
5.14.21 Replacing the shaft seal kit
Replace the shaft seal kit in every 5 years / 10 000h.

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5.14.22 Replacing the air end

Replace the air end in every 10 years / 20 000h.
5.15 Compressor CT
5.15.1 Procedures prior to compressor maintenance
Hot surfaces of the equipment could cause burns.
Let the compressor cool down before starting any maintenance
work!
• Stop the compressor and check that the oil separator unit is not
pressurized. After the compressor is stopped, the oil separator unit is
drained by the out-blow unit – wait approximately 2 minutes.
• Turn the power off and make sure the compressor cannot be started.
• Ensure that the drill rig is detached from an external pneumatic network.
• Close the shut-off valve between the network and the compressor.
• Open the safety valve cap 4–5 turns.
Note! Make sure that the system is non-pressurized.

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5.15.2 Changing the compressor oil
1 3
1. Run the compressor until the oil temperature is approximately +40–

50 °C.
2. Stop the compressor.
3. Loosen the safety valve (2) 4–5 turns.
4. Open the oil filler plug (1) and drain valve (3) and let the oil drain into the
recovery tank.
5. Close the drain valve (3).
6. Replace the oil filter (refer to section Replacing the compressor oil filter).
7. Fill with fresh oil up to the max. indicator.
8. Replace and close the oil filler plug (1).
9. Close the safety valve (2).
Note! Follow the local regulations for oil disposal.

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5.15.3 Replacing the compressor oil filter
1. Place a protective cloth under the filter. While the filter is being replaced,
oil runs from the filter housing.
2. Use a tightening belt and turn the filter counterclockwise to remove it.
3. Apply oil to the seal of the new filter.
4. Turn the filter manually clockwise to fasten it.
Note! Dispose of the oil in accordance with local regulations.
5.15.4 Checking and retightening main motor cables

Check and retighten main motor cables in every 500h.
5.15.5 Cleaning the compressor externally with a cloth
Clean the compressor in every 500 h and in a dirty environment as needed.

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5.15.6 Replacing the compressor air filters

Note! The filters are disposable and cannot be cleaned.
1 2 3
1. Remove the air filter cover (3).

2. Remove the old primary and secondary filters (2).
3. Clean the air filter housing (1).
4. Install new filters (2).
5. Reinstall the cover (3).
Note! Check that the particle remover hole (4) points downward.
5.15.7 Replacing the compressor belts
1. Untighten the screw (1) counterclockwise until the belts are loose
enough. (The screw pushes the motor up so that belts loosen.)
2. Change the belts.
3. Return the screw (1) to its original position.
5.15.8 Cleaning the cooler externally

Clean the cooler with pressurized air. For a more effective cleaning, brush
the cooler from underneath. Note! Do not use a metal wire brush.
Refer to the compressor manufacturer's instructions.

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5.15.9 Replacing the compressor oil separator cartridge, wing nut and discharge valve
seals
3 4 7
1. Close the shut-off valve between the network and the compressor.
2. Open the safety valve cap 4–5 turns.
3. Remove the discharge valve (1).
4. Remove the separator cartridge (2).
5. Clean the sealing surfaces on the receiver and on the discharge valve (1)
of the oil separator unit.
6. Clean the orifices (3) at the ends of the hose.
7. Replace the strainer (4) and clean the oil separator unit.
8. Lubricate the separator O-ring and install the new separator cartridge.
9. Replace and lubricate the O-ring (5) between the oil separator unit and
the discharge valve.
10. Replace the discharge valve seals if needed. After the discharge valve
assembly, leave the nut (6) on the cover approximately 2 mm free of the
cover.
11. Install the discharge valve (1).
12. Tighten the screws alternately.
13. Replace the wing nut and O-ring (7).
14. Close the safety valve.
15. Open the shut-off valve between the network and the compressor.

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Note! Dispose of the used separator cartridge in accordance with local

regulations.
5.15.10 Cleaning the oil return line

Clean the return hose line and orifice plate.
5.15.11 Replacing the screen for oil return, fittings and gasket
Refer to the manufacturer's instructions.
5.15.12 Checking the operation of the compressor relief valve
The operation must be checked at least once a year, as recommended by
the manufacturer.
Note! All safety valve adjustment and repair tasks must be performed by
trained professionals (take into consideration local regulations).
The opening pressure of the safety valve must be tested in a separate

compressed air circuit.
The valve operation can be tested by turning the safety valve cap (1) 1–2
turns counterclockwise until you can hear the air bleeding out between the
cap and the body. Close the cap by hands to original position.
5.15.13 Lubricating the electric motor bearings
Lubricate the electric motor bearings once a year / in every 1000h.

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5.15.14 Replacing the seal kit of the inlet valve

1. Remove the inlet valve housing by opening the nut.
2. Disassemble the valve cover by opening the bolt. A spring is released
when the cover is opened. Wear safety glasses.
3. Replace the seals (1-8).
4
3
5
7 2
4. Reassemble the valve in reverse order.

5.15.15 Checking the function of the thermometer safety limits
Thermometer´s functionality is tested by using a heater (operation range
0-120 °C) to heat the sensor to the temperature limits. Do not use fire.
• Remove the sensor from the compressor's body.
• Start the power packs, compressor and water pump.
• Heat the sensor and monitor the temperature gauge.
H604 in the QN-panel goes on.
H604 is still on and power pack, compressor and water pumps stop.
5.15.16 Checking the condition of the compressor hoses
Visually check the hoses. If visible damage is detected or the hose leaks,
replace it with a new one.

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5.15.17 Replacing the blow-down valve

The blow-down valve is attached to a flange below the inlet valve.
1. Disassemble the hosing to the blow-down valve (1).
2. Replace the blow-down valve (1).

3. Reassemble the hosing.
5.15.18 Replacing the oil thermostat
1. Undo the lock ring (1) to open the cover.

2. Replace the thermostat (2) and the o-ring (3).
3. Reattach the cover with the lock ring.

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5.15.19 Replacing the motor bearings

Replace the motor bearings in every 5 years / 10 000h.
5.15.20 Replacing the shaft seal kit
Replace the shaft seal kit in every 5 years / 10 000h.
5.15.21 Replacing the air end
Replace the air end in every 10 years / 20 000h.
5.16 SLU
5.16.1 Draining the condensed water
1. Drain the condensation water from the oil tank to the receptacle using the
drain valve.

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5.16.2 Checking the condition of the water separator
When mechanical service indicator (1) shows approximately all red, the
filter element (2) inside the water separator should be changed. Refer to
section "Changing the water separator filter element".

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5.16.3 Changing the water separator filter element
Disassembly
1. Water separator filter element (4) can be disassembled without removal
from air line.
2. Shut off inlet pressure. Reduce pressure in inlet and outlet lines to zero.
3. Remove bowl (8) - push into body and turn counterclockwise.
4. Disassemble in general accordance shown on the exploded view. Do not
remove the drains or the service indicator (1) unless replacement is
necessary. Remove and replace only if they malfunction.
9
1 1
2
6
3 8
11
4
7
5
10
Assembly
1. Lubricate o-rings, the portion of the manual drain body (6) that contacts
the bowl, and the hole in the manual drain body that accommodates the
stem of drain valve (7) with o-ring grease.
2. Assemble the filter as shown on the exploded view.
3. Arrows on the indicator (1) and the body (2) must point in the same
direction. Screw the baffle (5) onto the center-post (3) until contact is
made with the filter element (4), then tighten an additional 1/4 turn. Push
bowl (8), or bowl with guard, into body (2) and turn fully clockwise.
4. Torques in Nm:
3 2,0 - 2,7 Nm (center-post)
9 2,8 - 3,9 Nm (screw)
10 2,3 - 2,8 Nm (nut)
11 1,7 - 2,3 Nm (screw)

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5.16.4 Cleaning the tank

1. Empty the oil tank into the receptacle using the drain valve.
2. Clean the receiver from the inside.

5.16.5 Replacing the breather
1. Replace the breather.
Replace the breather at the intervals specified in the maintenance

instructions or earlier as required e.g. in the event that breather has
become wet.

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5.16.6 Checking the function of the monitoring system
CT5
CT1
Check the operation of the monitoring unit as follows:

• Disconnect the directional valve (CT5) plug: the alarm must activate after
four operational cycles.
• Disconnect the flow monitoring cable from the monitoring unit (CT1): the
alarm must activate after four operational cycles.
• Short-circuit the flow monitoring cable to the pump body: the alarm must
activate after four operational cycles.
5.17 Electric system

5.17.1 Electric system maintenance - Safety instructions
DANGER
ELECTRICAL HAZARD!
Failure to strictly follow instructions will lead to severe injury and/or
death and/or property damage.
Work on electrical equipment or devices is to be performed only by
persons with the expertise and qualifications required by the
authorities, or under the supervision of a person meeting these
requirements.
Make sure that the instructions set forth below are read and
understood before any electric system maintenance.

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Performing maintenance on electrical components

Failure to follow these instructions could lead to death or severe
injury.
Isolate the machine by turning off the main switch and removing the
power plug from the electrical network before any work on electrical
components.
Ensure that nobody connects the power on during the maintenance
or repair work!
Electrical safety tests and measurements must be done before
operating the machine.
• The work must be carried out according to local electric safety

regulations.
• Always use approved, correct and certified electrical testing equipment
and personal protective equipment.
• When performing electrical work, always ensure that the machine is
disconnected from the supply network before any service, repair or
maintenance. Ensure that the components in question are not live, and
then lock the main switch or arrange appropriate grounding.
• When the electrical cabinet main switch is switched off, always be aware
that this does not normally isolate the electrical supply going into the
machine’s electrical cabinet. Hence, the trailing cable, cable reel and
cable going to the live side of the main switch remain live!
(This is the case unless a separate Pilot core electrical system has been
adopted at the work site and the pilot core is wired through the machine’s
main switch!)
• Do not open live junctions or terminal boxes on electric motors, cable
reel, electrical cabinets, light fittings, HID gas discharge lamp fittings or
the like.
• Check the condition of the drill rig's electrical devices regularly.
• Check the operation of the earth leakage control system from the gate
end panel weekly. If the control does not switch the power off, the control
system must be repaired or replaced before any device connected to it is
started.
• Fuses and the circuit breakers are protecting the wires and electrical
components against overheat and fire in case of overload and short
circuit.
• Breaker tripping or fuse burn is a sign of failure. Before resetting the
breaker or replacing the fuse the failure must be repaired. The original
fuse size and type must be used. Never replace the fuse with a fuse
having higher ampere value than the original.

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Modifications to electrical systems

Electrical modifications to the drill rig require written permission
from Sandvik Mining and Construction Oy's electrical design
department to ensure the correct operation of the modified device.
• When replacing any electrical components or wiring, always use original

parts of original equipment manufacturer and use the correct installation
and testing procedure before operating the machine. All changes or
corrections should be documented for future reference.
• Use the original cable routing and clamping when replacing cables.
• Current settings of circuit devices such as overloads, circuit breakers and
other protective devices shall only be set to the specifications of original
equipment manufacturer.
Replacing the light bulbs

WARNING! ELECTRIC SHOCK HAZARD!
Failure to follow these procedures could result in severe injury!
Cut the supply voltage to the light using the main switches before
replacing the bulbs of the working and driving lights.
Exercise extreme caution when performing work on HID gas
discharge lamps. The light components include high voltage parts.
• Note that parts of the light may be hot after use, so allow it to cool before
commencing repair work.
• The bulbs of gas-discharge lamps are gas-filled, so handle with care.
Use gloves and safety glasses.
• Do not touch the lamp holder or the glass part of the bulb when carrying
out the replacement.
• Use proper servicing stands when changing the light bulbs.
5.17.2 Checking the operation of the fault current protector switch
Check the operation of the fault current protector switch in the main
switchgear door. Repair/replace the switch if necessary.
5.17.3 Checking the condition of the power supply cable
Pull the power supply cable out and check it for wear, cuts and overheating/
ageing.
The use of machine is prohibited if the cable is damaged. Replace
damaged cable immediately.

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5.17.4 Checking the water drainage holes
Check that the water drainage holes are open. Open the drainage holes if
necessary.
5.17.5 Checking the seal bushings
Check the seal bushings condition and tightness. Replace/tighten the

bushings if necessary.
5.17.6 Checking connections and contacts (110 VAC - 1000 VAC)
Components:
• slip ring unit
• main cabinet (main switch, motor contactors and breakers, transformers)
• electric motors
• sockets
• cabin heater
Check:
1. Component wire connections for overheating and corrosion.
2. Tightness of component wire connections (bolts and nuts) using tools.
3. Sealing and insulations for signs of overheating/ageing.
Apply corrosion prevention grease (ID 86742989) to all connections to
ensure conductivity.
5.17.7 Checking connections and contacts (24 VDC, battery system)
Components:
• battery
• battery isolation switch and breaker
• diesel engine starter motor and generator
• tramming panel.
Check:

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5.17.8 Checking control system

Components:
• solenoid valve connections.
Check:

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5.17.9 Cleaning electric devices
DANGER
ELECTRICAL HAZARD!
Electric shock will cause death or severe injury.
Ensure that all the devices are in proper condition before cleaning.
Do not clean damaged or broken devices.
1. Switch off the main power and unplug the machine from a power source
before cleaning.
2. Clean devices more frequently than at the specified interval, if required.
Devices cleaned using water:
• cables and harnesses
• solenoid valve connections
When cleaning using water, flush components with water. Do not use
high-pressure washer.
Devices cleaned using compressed air or anti-static (ESD) brush:
• slip ring unit
• main cabinet (main switch, motor contactors and breakers)
• electric motors
• sockets
• cabin heater
• battery
• battery isolation switch and breaker
• diesel engine starter motor and generator
• glow plugs
When cleaning using compressed air or anti-static (ESD) brush, blow or
brush dust and debris off the components carefully.
Devices cleaned using cleaning cloth (or compressed air).
WARNING! HAZARD OF UNEXPECTED MACHINE MOVEMENT!
Ensure that the main power is switched off when cleaning cabin/
canopy controls and panels to avoid unexpected movement of the
machine.
• cabin/canopy controls and panels

Wipe surfaces clean with a damp cloth.
5.17.10 Checking the motor terminals
Check the tightness of the motor terminals and other screw-mounting

terminals in the main switchgear and in the control system. Tighten the
terminals if necessary.

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5.18 Safety cabin

5.18.1 Cleaning or replacing the filters
Fresh (atmospheric) air filter

The fresh-air filter on the outer wall of the cabin removes dust from the
incoming air.
4
3
2
1
1 Detachable cover
2 Coarse filter
3 Fastening plate
4 Two separate fine filters
5 Housing
The air filter must be cleaned with compressed air (the coarse filter may
also be washed in soap solution). Replace the filter every 12 months or
more often if necessary. The maintenance interval depends on the quality
of the external air.
Air filter for internal air circulation (metal)
Removes impurities from the air circulating in the cabin. Located in front of
the air conditioner air intake, inside the cabin. The filter must be cleaned
regularly by washing or by blowing with compressed air. Replace the filter
every 12 months or more often if necessary.

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5.18.2 Checking the operation of the heating and air conditioning

1. Check the operation of the heating and air conditioning. Refer to the
heating and air conditioning instructions.
5.18.3 Lubricating the cabin door hinges
1. Lubricate the cabin door hinges (1) on both sides.
1
5.19 Other components

5.19.1 Checking the grease unit
• Check that there is no excess grease at the pressure-reducing valve of
the central lubrication system's pump element.
Accumulation of grease indicates a blockage; remove the blockage.
• Check all valves and connections.
• Check the pipes for holes and cracks; replace if necessary.

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6 Lubricants and capacities

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6.1 General
WARNING! HEALTH AND ENVIRONMENTAL HAZARD!
Skin contact and inhalation of vapours when handling fluids could
cause damage to human health.
Incorrect disposal of fluids and greases could cause damage to the
environment.
Use personal protective equipment when handling fluids and
greases, and dispose of all fluids and greases in accordance with
local regulations.
Choosing the oil according to its properties

The following issues must be considered:
• viscosity
• stability of properties throughout the oil’s service life
• water separation ability
• anti-oxidation and anti-foaming properties
• health effects
• environmental effects
Note! Check the original oil type from the machine card or the maintenance
instructions.
Note! Refer to the parts manual Section 3 for ordering information on

Sandvik Performance Fluids.
Choosing the oil according to the application

The following issues must be considered:
• Sandvik's oil recommendation
• the component manufacturer's oil recommendation (e.g. diesel engine,
transmission)
• environmental/site-specific/safety requirements
- biodegradable oils
- less flammable fluids
Mistakes in choosing and using oil

Components may be damaged if
• a wrong oil type has been chosen
• a wrong oil viscosity has been chosen
• the recommended oil change interval is exceeded.
Oils must be changed at certain intervals because the properties of the oil
and its additives deteriorate and are lost as the oil ages. Sandvik fluid
analysis helps to find the optimized oil change interval by determining the
condition of the oil. Refer to the section "Fluid analysis service".

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Oil viscosity
Too low viscosity causes:
• breaking of the lubrication film between contact surfaces. The resulting
metal-to-metal contact between surfaces causes rapid wear and
increases the need for maintenance.
• internal leaks in components, which reduces efficiency and causes
overheating.
Too high viscosity causes:
• flow losses in the system, which also reduces efficiency
• increase in the load on the seals due to increased return line pressure
• for certain rock drills, wear of the rotation shaft and thrust bearing due to
increased return line pressure
• too thick oil increases the risk of cavitation in pumps.

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Oil contamination
Oil contamination is the primary cause for hydraulic system failures.
70...80% of the hydraulic systems failures are caused by oil contamination!
Contaminants can be liquids, solid particles, or even gaseous materials and
not all are visible to the eye. Fibrous material typically originates from poor
quality oil filters or e.g. rags used during the maintenance. Rubber and
plastic particles in hydraulic system are usually deposited from worn seals
or uncleaned replacement hoses. Hard metallic and non-metallic particles
in oil usually result from poor maintenance practices and poorly maintained
or low quality components (e.g. cylinder rod seals, breathers, etc).
Particles cannot be seen with a human eye
A B
A Oil cleanliness, class requirement

B Barrel oil cleanliness
When water is present in hydraulic oil, it can be a result of improper storage

(condensation, temperature changes) conditions. Component malfunctions,
e.g. leaking seals, can also be the source of water in hydraulic oil. When air
is present in the hydraulic oil, typical sources are leaking pump shafts and
cylinder rod seals, or even a wrong oil type that has caused foaming. When
water and/or air is present in the hydraulic oil, resulting aspects affecting
equipment performance are cavitation, rusting, excessive wear and
premature failing of components and oil aging.

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To prevent oil contamination:

• Pre-filter all oil that is used for hydraulic systems
Unfiltered oil allows particles enter the system

• Use good quality oil that is meant for the application and make sure the
viscosity is correct
• Store oil carefully in proper facilities
• Handle oil so that entering of contaminants is minimized
• Do not leave tanks or other entry points to the hydraulic system open
during maintenance and plug the hoses
• Replace leaking cylinder rod seals

• Use good quality filters and breathers

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• Clean replacement hoses before installation
Fluid analysis service

Contaminants like dirt, sand, water and metallic particles can cause
premature component wear and component failures, even if present only in
microscopic quantities.
Monitoring the condition of the fluids will help in determining the required
maintenance intervals and reduce total lifecycle cost of the equipment.
Sandvik offers comprehensive analysis for all fluids used in the equipment
including engine, gear and transmission oils, hydraulic, cooling and AdBlue
exhaust fluids and diesel fuel. Sandvik fluid analysis includes e.g. number
of particles found in the oil, total amount of water in the oil, issues related to
oil aging etc.
The results of the fluid analysis can provide early warning signs on
unexpected failures, help in planning of maintenance, improve equipment
efficiency and reduce waste.
Contact your local Sandvik representative for more information on the fluid
analysis.
SAE classification (engine oils)

(SAE = Society of Automotive Engineers)
Viscosity indicates the oil's ability to flow. Viscosity is measured at a high
and low temperature and is indicated as an SAE grade, e.g. SAE 40. For
multigrade oils, e.g. 5W-40, the first value (5W) indicates the oil’s viscosity
at low temperatures, and the second value (40) indicates the oil’s viscosity
when it is hot.
ISO classification (industrial oils)

(ISO = International Organization for Standardization)
The viscosity of industrial oils is determined by the ISO-VG standard (ISO
3448). The ISO grade number indicates the oil’s viscosity at +40°C,
expressed in centistokes (cSt, kinematic viscosity). For example, oil graded
as ISO-VG 68 has a viscosity of 68 cSt at +40°C.

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Choosing the fuel

Fuel is chosen according to the properties of the fuel and the application.
When choosing the fuel, at least the following issues must be considered:
• Sandvik's fuel recommendation
• the engine manufacturer's fuel recommendation
• environmental/site-specific/safety requirements
• fuel sulfur content
Compressor oil and refrigerant for the air conditioning unit

Refer to the manual for the air conditioning unit.
6.2 Hydraulic system

Oil viscosity recommendations are based on the operating temperature of
the oil.
Note! Never mix different types of hydraulic system oils. Mixing can
damage the hydraulic components.
The selected hydraulic oil must be high quality and must retain its
properties in fluctuating temperature conditions. Furthermore, it should
contain additives typical of high performance hydraulic oils.
When choosing the viscosity of the oil to be used, the temperature of the
drilling environment is important. Pay attention to temperature fluctuation.
When choosing the oil, consider the following:
1. Check or estimate the operating temperature of the oil.
2. The viscosity of oils at their operating temperature should be close to 60
cSt, and any variation in continuous use should remain within the range
50–110 cSt.
The following variation limits are permitted temporarily (but not
constantly):
• 110–200 cSt as a result of a low temperature peak, or
• 30–50 cSt as a result of a high temperature peak.
The values indicated in the tables should be considered first and
foremost. In each case you must always make sure that the product in
question has the required properties.
3. If the drilling environment temperature does not vary greatly, we
recommend that you use single-grade oils which undergo minimal
viscosity variation during use.
4. If the drilling conditions are such that single-grade oils do not remain
within the given viscosity limits, choose a multigrade oil.
5. The oil should be changed once a year unless heavy use requires more
frequent changes. This change interval recommendation is based on the
extent that the oil ages and gathers moisture over a one-year period.

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For arctic conditions (temperatures below –20°C), we recommend synthetic

oils.
Maximum permissible degree of contamination of the hydraulic fluid;
cleanliness class 20/15/12 according to the ISO 4406 (c).
A recommended water content for the hydraulic oils is <300 ppm.
Engine oils in the hydraulic system

Only use high-quality oils.
Viscosity/temperature table
Classification
Operating temperature
(SAE)
Multigrade oil
°C -30 -20 -10 0 +10 +20 +30 +40 +50 +60 +70
°F -22 -4 +14 +32 +50 +68 +86 +104 +122 +140 +158
5W--20
5W--30
10W--30
10W--40
Single-grade
oil
10W
20W--20
SAE 30
SAE 40
Synthetic oil
5W--30
Recommended temperature range
Temporarily allowed temperature range
Lowest permitted starting temperature

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Hydraulic oils
DIN 51524 part 2 HLP, ISO 6743-4 HM, DIN 51524 part 3 HVLP, ISO
6743-4 HV
Viscosity cSt
(40°C)
°C -30 -20 -10 0 +10 +20 +30 +40 +50 +60 +70
°F -22 -4 +14 +32 +50 +68 +86 +104 +122 +140 +158
32
46
68
100
150

ID: BG00471036 en-US C.001.1 2018-05-28
Biodegradable hydraulic oils

Sandvik sets the same high technical quality requirements for
biodegradable oils as are set for conventional mineral oils. In addition, the
oils must be environmentally friendly in terms of the following quality
requirements:
• biodegradability
• toxicity
• use and disposal.
The international standard ISO 15380 specifies the requirements for
environmentally acceptable hydraulic fluids.
Viscosity cSt
(40°C)
°C -30 -20 -10 0 +10 +20 +30 +40 +50 +60 +70
°F -22 -4 +14 +32 +50 +68 +86 +104 +122 +140 +158
46
68
Instructions for changing biodegradable oils are provided in the manual

"Biodegradable hydraulic oils – change instructions".
Note! When biodegradable oils (optional) are used, Sandvik factory fill oils
are Fuchs Hydraway Bio SE 46 or Fuchs Hydraway Bio SE 68
(synthetic ester). The guarantee is valid only when these oils are
used.
A recommended water content for the biodegradable hydraulic oils is <1000

ppm.

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Fire retardant hydraulic fluids

Sandvik sets the same high technical quality requirements for less
flammable hydraulic fluids as are set for conventional mineral oils. In
addition, the oils must be non-flammable, with self-extinguishing properties.
A range of fire retardant fluids are available on the market, the properties of
which differ greatly.
In risk-prone conditions, Sandvik recommends the use of fluids that comply
with the ISO 6743-4 HFD standard for synthetic fluids.
Note! For safety, performance and environmental reasons, Sandvik does
not allow mixing of different hydraulic oils/fluids.
These fluids must be compatible with the majority of metals and seal
materials.
Sandvik uses fire retardant and biodegradable HFD fluids as factory-fill oils:
Fuchs Plantoflux 68-AT-S (Tampere plant) and Condat D68 (Lyon plant).
Sandvik recommends these fluids for use in drilling rigs. Since the
availability of these fluids can be limited in certain market areas, Sandvik
also approves the following alternative:
• Quintolubric 888-68 (Quaker Chemicals)
Sandvik factory fill oils are totally miscible with the fluid mentioned above.
Thus, the factory filled oil can be changed as necessary in connection with
the rig start-up inspection without flushing the hydraulic system. Sandvik
does not approve continuous mixing of hydraulic fluids.
Note! The guarantee is valid only if the recommended fluids are used.
Oils and fluids suitable for hydraulic systems are, e.g.

• Fuchs Plantoflux 68-AT-S (less flammable hydraulic fluid)

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6.3 Rock drill shank lubrication

Shank lubrication with oil
Note! Use only recommended shank lubrication oils. Using water-based
lubricants for this purpose is forbidden.
The oil recommendations are based on the ambient temperature.

Viscosity cSt
Ambient temperature
(40 °C)
°C -30 -20 -10 0 +10 +20 +30 +40 +50 +60 +70
°F -22 -4 +14 +32 +50 +68 +86 +104 +122 +140 +158
32
68
100
150
220
320
Examples of rock drill oils

Oil type Manufacturer
OS SANDVIK
Air Tool Oil S2 SHELL
Arox ESSO (EXXON)
Gulf Rock Drill Oil GULF
Almo MOBIL
Energol RD-E BP
Rock drill lube TEXACO

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Shank lubrication with grease

The grease used must provide sufficient lubrication properties at high
temperatures.
Recommendations
Property Value
NLGI grade 2
Penetration, beaten, 25 ºC, ASTM D 217, 0.1 mm 265–295
Operating temperature range, °C –40...+150
Dropping point, ASTM D 2265, °C > +260
Corrosion protection, ASTM D 1743, SKF EMCOR, classifica-
Approved
tion
Water flushing test, ASTM D 1264, 79ºC, % wt. loss <3
Oxidation, ASTM D 942, psi decrease / 100 hours <5
Evaporation, ASTM D 2595, 100 ºC, wt % <2
High mechanical durability.

Suitable for heavy shock loads as well as high vibration and oscillatory
conditions.
Recommended greases
Grease type Manufacturer
OG220-H SANDVIK
VISO 808-2 VISO
MOBILITH SHC220 MOBIL
ALMAGARD 3752 LUBRICATION ENGINEERS
GADUS S5 V220 2 SHELL
SYNTEC GREASE TEBOIL
6.4 Diesel engine

API engine oil classification
The API (American Petroleum Institute) diesel engine oil classification has
two-letter designations, the first letter being “C”. The current classification
designations for four-stroke diesel engines are API CG-4, API CH-4, API
CI-4 ja API CJ-4. The higher the second letter in the alphabet, the higher
the oil quality.

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Fuel sulphur content, Mercedes-Benz

A fuel sulphur content exceeding 0.5 % can affect the oil selection and the
length of oil change intervals. For more information, refer to the engine
manufacturer’s maintenance instructions.
Note! For the engine oil selection, refer to the engine manufacturer’s
maintenance instructions.
For a list of oil types, refer to the engine manufacturer's maintenance

instructions.
• 228.1, 228.3, and 228.5
Classification
Ambient temperature
(SAE)
6.5 Compressor
Gardner Denver compressor
Mineral-based engine oil or synthetic compressor oil can be used in the
compressor.
Note! Never mix different types of oil. Mixing may damage the compressor.
When changing the oil type, the compressor circuit must be flushed with
new oil:
1. Drain the oil from the compressor circuit.
2. Fill the compressor circuit with new oil and run the compressor to warm it
up.
3. Drain the oil from the compressor circuit.
4. Replace the oil filter and oil separators.
5. Fill the compressor circuit with new oil.

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Mineral-based engine oil

Mineral-based engine oil can be used in the compressor. The flash point of
the oil must be over 180 °C. The lowest allowable viscosity at the operating
temperature is 7 cSt.
The mineral-based engine oil recommendations are based on the ambient
temperature.
Classification
Ambient temperature
(SAE)
SAE SW - 20
SAE 10W
SAE 20W - 20
SAE 10 - 30
Mineral-based compressor oil

The mineral-based compressor oil recommendations are based on the
ambient temperature.
ISO VG
Viscosity cSt Ambient temperature
(40 °C)
°C -40 -30 -20 -10 0 +10 +20 +30 +40 +50 +60
°F -40 -22 -4 +14 +32 +50 +68 +86 +104 +122 +140
32
46
Recommended mineral-based compressor oils:

• Shell Corena S3 R 46

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Synthetic compressor oil

Note! If the operating temperature is continuously over 100 °C (ambient
temperature over 40 °C) or below –20 °C (in arctic conditions),
synthetic compressor oil must be used.
The synthetic compressor oil recommendations are based on the ambient

temperature.
ISO VG
Viscosity cSt Ambient temperature
(40 °C)
°C -40 -30 -20 -10 0 +10 +20 +30 +40 +50 +60
°F -40 -22 -4 +14 +32 +50 +68 +86 +104 +122 +140
32
46
Recommended synthetic oils:

• Sandvik OC10-H
• Shell Corena S4 R 46
• Mobil Rarus SHC 1025
• Esso Cetus Pao 46
• BP Enersyn RC-S46
6.6 Transmission and driveline oils

API quality classification
The API (American Petroleum Institute) transmission oil recommendations

are API GL-1...API GL-5. The higher the last digit, the higher the EP
additive level is.
For example, API-GL-5 is an EP oil with a high additive level, suitable for
hypoid gears.
ISO 12925-1 quality classification

ISO (International Organization for Standardization) industrial transmission
oil recommendations are ISO 12925-1 type CKB... ISO 12925-1 type CKD.
The higher the third letter, the more additives there are in the oil.
For example, ISO 12925-1 type CKD. Lubricants with oxidation resistance,
anti-corrosion, anti-foam, pressure resistance, and anti-wear properties.
Improved thermal/oxidation resistance properties enable use at high
temperatures.

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SAE viscosity classification (transmission)

SAE (Society of Automotive Engineers) Viscosity indicates the oil's ability to
flow. Viscosity is measured at a high and low temperature and is indicated
as an SAE grade, e.g. SAE 90. For multigrade oils, e.g. 75W-90, the first
value 75W indicates the viscosity at low temperatures, and the second
value 90 indicates the oil viscosity when it is hot.
ISO viscosity classification (industrial oils)

( ISO = International Organization for Standardization) The viscosity of
industrial lubricants is determined by the ISO-VG standard (ISO 3448). The
ISO grade number indicates the oil viscosity at +40 °C, expressed in
centistokes (cSt, kinematic viscosity). For example, oil graded as ISO-VG
150 has a viscosity of 150 cSt at + 40 °C.
Carriers with wet brakes
Carriers TC6, NC7-TC9, C400, C900 front and rear axles, TC11-TC12
rear axle
Carriers TC11-TC12 front axle
Oils that meet the classification API GL-5, e.g., Fuchs Titan Gear LS SAE
90
Note! Oils used in axles must be suitable for wet brakes.
Hydrodynamic transmission
Oils that meet the following requirements are to be used in the

transmission:
GM Allison C-4, GM A SUFFIX A, e.g., Sandvik OT3000

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Rotation mechanisms
Oils that meet the classification API GL-5, e.g., Titan Gear HYP LD SAE
80W-90
6.7 Drill steel thread grease

Recommended lubrication grease:
Sandvik Coromant thread grease
6.8 Lubrication grease

The hardness of greases is indicated by the NLGI grade, which indicates
the grease’s penetration value as determined in laboratory tests. The NLGI
grade can be 000, 00, 0, 1, 2, 3, 4, 5, or 6. Number 2 indicates the so-
called normal hardness for a bearing grease. The higher the figure, the
harder the grease. The hardness grade of a grease is usually indicated
after the product name.
Greases for Lincoln central lubrication system

Operating temperature NLGI grade Example
Below 0 °C 0-1 Sandvik OG220-H
Above 0 °C 1-2 Sandvik OG220-H
Note! Mixing different grease types is strictly prohibited. Verify the grease
type from the greasing system instructions.

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6.9 Engine coolant

Mercedes-Benz engines
Engine coolant is a mixture of water and corrosion prevention agents / anti-
freeze agent. To prevent corrosion and to elevate the boiling point of the
coolant, the mixture must be used in the cooling system throughout the
year.
When choosing the corrosion preventing agents / anti-freeze agent for the
engine coolant, refer to the engine manufacturer's manual.
Engine coolant must be changed at certain intervals. The characteristics of
the coolant and its additives weaken and are lost as the coolant ages.
Refer to the engine manufacturer's manual.
Mixing different type of coolants can lead to clogging the radiator's
NOTICE ducts and seriously damage the engine.
Do not mix different type of coolants.
The engine cooling system is filled at the factory with a mixture of 50%
water and 50% Maintain Fricofin V anti-freeze, which is a pink-violet
monoethylene glycol-based fluid. Only this same Maintain Fricofin V anti-
freeze or pure water may be added to the cooling system.
Coolant mixing ratio
Anti-freezing to temperature Water percentage of vol- Maintain Fricofin V anti-freeze
°C / °F ume (%) percentage of volume (%)
–37 °C / –34 °F 50 50
about –45 °C / –49 °F 45 max. 55
6.10 Filling capacities
For further information and fluid specific environmental, safety and health
instructions, refer to technical data and material safety data sheets in the
appendix Factory filled oils, lubricants and coolants for underground rigs
(only on electronic publication).
CLASSIFICA-
FIRST FILLING
ITEM CAPACITY TION RECOM- NOTE!
OIL/FLUID
MENDATION
Diesel engine CF, CF-4, CG-4, Sandvik First filling with oil
15 L
(MB 904 LA) ACEA E3 OE10W40-LA filter
Diesel engine CF, CF-4, CG-4, Sandvik First filling with oil
28 L
(MB 906 LA) ACEA E3 OE10W40-LA filter
Diesel engine Sandvik First filling with oil
14 L CF, CF-4, CG-4
(Deutz D914L04) OE10W40-LA filter

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CLASSIFICA-
FIRST FILLING
OIL/FLUID
MENDATION
Diesel engine
(Cummins QSB CES 20081 API Sandvik First filling with oil
11 L
4.5, Tier3/Tier4i/ CJ-4/SL OE10W40-LA filter
Tier4F)
Diesel engine
CES 20081 API Sandvik First filling with oil
(Cummins QSB 18 L
CJ-4/SL OE10W40-LA filter
6.7)
Driveline gear-
box
22 L GM Allison C-4 Sandvik OT3000
(T20000) (MB
904 LA)
Driveline gear-
box
(HR32000) (MB
906 LA)
Driveline gear-
box
(T20000) (Cum-
mins QSB 4.5)
Driveline gear-
box
(HR32000) 34 L GM Allison C-4 Sandvik OT3000
(Cummins QSB
6.7)
Transfer gearbox SAE 75 W / 90
(Stiebel 4382) API GL5 Renolin Unisyn
5.2 L
(Cummins QSB SAE 80 W / 90 CLP 150
6.7) API GL5
1.7 L / planetary
Front/rear axle
gear Sandvik
(Axle 123, wet API GL-4
8 L / differential OA10W30-KS
brake)
gear
1.6 L / planetary
Front/rear axle
gear Sandvik
14 L / differential OA10W30-KS
brake)
gear
2.3 L / planetary
Front/rear axle
gear Sandvik
16 L/ differential OA10W30-KS
brake)
gear

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CLASSIFICA-
FIRST FILLING
OIL/FLUID
MENDATION
4.7 L / planetary
Front axle
gear Sandvik
21 L/ differential OA10W30-KS
brake)
gear
Front/rear axle
Titan Gear LS SAE
(Axle 37R/43R, 45 L API GL-5
90
wet brake)
Front/rear axle
2-5% from axles
(Axle 37R/43R,
oil capacity (45 Lubrizol 6178LZ
wet brake)
L)
admixture
Sandvik OH46 for
cold ambitient tem-
peratures
Sandvik OH68 for
normal ambitient
Hydraulic oil DIN 51524 part 2 Sandvik OH46 temperatures
tank, drilling 160 L (HLP), ISO Sandvik OH68 Sandvik OH100 for
(NC4) 6743-4 (HM) Sandvik OH100 high ambitient tem-
peratures
Viscosity class is
chosen according
to operating condi-
tions
Sandvik OH46 for
cold ambitient tem-
peratures
Sandvik OH68 for
normal ambitient
Hydraulic oil
DIN 51524 part 2 Sandvik OH46 temperatures
tank, drilling
210 L (HLP), ISO Sandvik OH68 Sandvik OH100 for
TC7/TC8 (DS
6743-4 (HM) Sandvik OH100 high ambitient tem-
rigs)
peratures
Viscosity class is
chosen according
to operating condi-
tions

ID: BG00471036 en-US C.001.1 2018-05-28
CLASSIFICA-
FIRST FILLING
OIL/FLUID
MENDATION
Sandvik OH46 for
cold ambitient tem-
peratures
Sandvik OH68 for
normal ambitient
Hydraulic oil
tank, drilling
(TC8 and NC7-
series)
peratures
Viscosity class is
chosen according
to operating condi-
tions
Sandvik OH46 for
cold ambitient tem-
peratures
Sandvik OH68 for
normal ambitient
(TC9) 6743-4 (HM) Sandvik OH100 high ambitient tem-
peratures
Viscosity class is
chosen according
to operating condi-
tions
Sandvik OH46 for
cold ambitient tem-
peratures
Sandvik OH68 for
normal ambitient
(TC11–TC12) 6743-4 (HM) Sandvik OH100 high ambitient tem-
peratures
Viscosity class is
chosen according
to operating condi-
tions

ID: BG00471036 en-US C.001.1 2018-05-28
CLASSIFICA-
FIRST FILLING
OIL/FLUID
MENDATION
Sandvik OH46 for
cold ambitient tem-
peratures
Sandvik OH68 for
normal ambitient
tank, tramming 50 L (HLP), ISO Sandvik OH68 Sandvik OH100 for
(NC4) 6743-4 (HM) Sandvik OH100 high ambitient tem-
peratures
Viscosity class is
chosen according
to operating condi-
tions
Sandvik OH46 for
cold ambitient tem-
peratures
Sandvik OH68 for
normal ambitient
Hydraulic oil tank
(C400, C900)
peratures
Viscosity class is
chosen according
to operating condi-
tions
SAE 75 W / 90
Drive gears,
API GL5 Renolin Unisyn
transmission 2.4 L
SAE 80 W / 90 CLP 150
(NC4)
API GL5
SAE 75 W / 90
Gearbox, trans-
API GL5
mission 2.4 L Sandvik OT30
SAE 80 W / 90
(C400, C900)
API GL5
Gearbox, trans-
mission 11 L Sandvik OT30
(C400E)
SAE 75 W / 90
Cable reel gear- API GL5 Mobil Mobilube
2.7 L
box SAE 80 W / 90 80W-90
API GL5

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CLASSIFICA-
FIRST FILLING
OIL/FLUID
MENDATION
Titan Supergear
HYP 75W-90 cold
ambitient tempera-
SAE 75 W / 90 Titan Supergear
tures
Rotation mecha- API GL5 HYP 75W-90
1.8 L Titan Gear HYP LD
nism SAE 80 W / 90 Titan Gear HYP LD
SAE 80W-90 for
API GL5 SAE 80W-90
normal and high
ambitient tempera-
tures
Compressor
3L API CE/CF Sandvik OC10-H
(CTN9)
Compressor
(CT10/16)
Compressor
10 L API CE/CF Sandvik OC10-H
(CTN10/16)
Compressor
(CT28)
Compressor
(CT40)
Compressor 20 L
Compressor
OW cooler 3,6 L API CE/CF Sandvik OC10-H
(CT80)
OA cooler 10,8 L
Compressor
(Enduro 12)
Booster com-
pressor
Water pump
Sandvik
(Hydra-Cell D/ 0.95 L API CF
OE10W40-LA
G-03 Series)
Water pump
Sandvik
(Hydra-Cell D/ 1.05 L API CF
OE10W40-LA
G-10)
Sandvik OS32 for
Shank lubrica- cold ambitient tem-
tion Sandvik OS32 peratures
14 L Sandvik
(Rig with 1 or 2 Sandvik OS100 Sandvik OS100 for
booms) high ambitient tem-
peratures

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CLASSIFICA-
FIRST FILLING
OIL/FLUID
MENDATION
Sandvik OS32 for
Shank lubrica- cold ambitient tem-
tion Sandvik OS32 peratures
22 L Sandvik
(Rig with 3 Sandvik OS100 Sandvik OS100 for
booms) high ambitient tem-
peratures
Oil: Sandvik
Hammer lubrica- OS100
45 L
tion Grease: Arox NM
000
Sandvik OG100-H
for cold ambitient
temperatures
Sandvik OG100-H
Boom grease Sandvik OG220-H
Sandvik OG220-H
for normal and high
ambitient tempera-
tures
Air conditioner
refrigerant 1500 g Sandvik R-134a
(NC4 carrier)
Air conditioner
refrigerant DS511 / DS520 ->
1950 g Sandvik R-134a
(TC8 and NC7- 2000g
series carriers)
Air conditioner
refrigerant 1950 g Sandvik R-134a
(TC9–12 carrier)
Air conditioner
refrigerant
1800 g Sandvik R-134a
(C400-C900 car-
rier)
Refer to separate
ISO-100 (high vis-
Air conditioner air conditioner Reniso PAG 46 /
cosity) or ISO-46
oil manual for the Reniso PAG 100
(low viscosity)
capacities.
Gear Lube SAE
140 (high temp.),
Top drive 6L
SAE 80W-90 (low
temp.)
Fuel, diesel en-
Thermoshell Win-
gine 55 L EN 590
ter 1202
(Deutz D914L04)

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CLASSIFICA-
FIRST FILLING
OIL/FLUID
MENDATION
Fuel, diesel en-
gine
Thermoshell Win-
(MB 904/906 LA, 150 L EN 590
ter 1202
Cummins QSB
4.5/6.7)
Fuel, diesel en-
gine
Thermoshell Win-
(Cummins QSB 100 / 155 L EN 590
ter 1202
4.5, Tier3/
Tier4F)
Fuel, diesel en-
gine
Thermoshell Win-
(Cummins QSB 410 L EN 590
ter 1202
6.7, Tier4F)
(C900DH carrier)
Diesel engine
BS 6580, AFNOR,
coolant 22 L Maintain Fricofin V
ASTM D 3306
(MB 904 LA)
Diesel engine
BS 6580, AFNOR,
coolant 27 L Maintain Fricofin V
ASTM D 3306
(MB 906 LA)
Diesel engine
coolant BS 6580, AFNOR,
32 L Maintain Fricofin V
(Cummins QSB ASTM D 3306
4.5, Tier4i)
Diesel engine
coolant
25 L (Tier3) BS 6580, AFNOR,
(Cummins QSB Maintain Fricofin V
27 L (Tier4F) ASTM D 3306
4.5, Tier3,
Tier4F)
Diesel engine
coolant
35 L (Tier4F) BS 6580, AFNOR,
(Cummins QSB Maintain Fricofin V
45 L (Tier4i) ASTM D 3306
6.7, Tier4F,
Tier4i)

ID: BG00471036 en-US C.001.1 2018-05-28
CLASSIFICA-
FIRST FILLING
OIL/FLUID
MENDATION
Diesel exhaust
fluid
19 L ISO 22241 DEF/AdBlueR
(Cummins QSB
4.5, Tier4F)
Diesel exhaust
fluid
(Cummins QSB 38 L ISO 22241 DEF/AdBlueR
6.7, Tier4F)
(C900DH carrier)

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7 Additional instructions

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7.1 Towing
Pay attention to following when towing:
• The rig must not be used for towing.
• Make sure that the towing vehicle's brakes are in good condition, and
powerful enough to stop both vehicles in all conditions.
• Due to the structure of the transmission system, the engine cannot be
started by pushing or towing.
WARNING
RISK OF LOSING THE CONTROL OF THE VEHICLE!
Uncontrolled machine movements during towing could cause death,
severe injury or property damage.
The rigidity of the steering limits the towing speed. If hydraulic
pressure is not available, steering will be extremely stiff and slow.
The towing speed should be slower than 10 km/h and the towing
distance less than 10 km.
7.1.1 Towing with the engine in operating condition

If the engine/pump combination is in working order, towing does not require
any special measures. Start the engine and adjust the running speed so
that the feed pressure is normal.

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7.1.2 Towing with a faulty engine

If the engine/pump combination is out of order and the engine cannot be
started, the steering will not work either, and the following measures will be
required for towing.
If the engine is not in working order and the brake system is not
pressurized, the brakes can be released mechanically.
Attach a towing rod between the towed and the towing vehicles
before releasing the brakes and uncoupling the driveline.
1. Uncouple the front and rear drivelines.

2. Attach the uncoupled axles to the support so that they do not get damage
during towing.

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7.1.3 Releasing the parking brakes

The parking brakes (both sides [A]) can also be released mechanically.
1. Release the parking brake by loosening the nuts (1) of the screws (2),
which are intended for mechanical and manual releasing of brake units,
and by moving the nuts backwards about 8 mm.
1 2
2. Tighten the screws (2) against the pressure plate.

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3. Tighten the screws (2) alternately by 1/4 turns with a key until the spring
washers are pressed and the brake discs come off.
NOTE! Tighten no more than one turn.

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7.1.4 After towing

Adjust the parking brake as follows:
1. Detach the screws, nuts, and seals.
2. Replace the seals, apply Tecno Lube 101 silicone grease (or similar) to
the screws, and install all parts on the frame.
3. Adjust the screws (2) so that the distance to the frame is 30 mm.
4. Lock in position with nuts (1).

NOTE! Hold the screws (2) in position when you lock the nuts (1).
Recheck the distance of screws (2) after you have locked the nuts.
1 2
5. Test the operation of the brakes.

ID: BG00471036 en-US C.001.1 2018-05-28
If hydraulic pressure is not available, steering will be extremely stiff

and slow.
Remember to adjust the parking brake before tramming the rig.
When releasing the brakes, make sure that the brakeless rig does not
roll away. Because there are no brakes, a stiff towing rod must be
used when towing.
7.2 Transport
WARNING! TIP OVER HAZARD!
Machine tip over could cause death or severe injury.
Before tramming the machine onto a transport platform or onto a
ship, make sure that the machine is in tramming position. Never
exceed the maximum inclination angles.
• When tramming the machine onto/from a transport platform or onto/from

a ship, use ramps. This should always be done on level ground.
• Make sure that the transport platform endures the rig's weight.
• Always use low speed and observe special caution when coming from
the ramps to the platform or from platform to ramps.
• Before transportation:
a) Engage the parking brake.
b) Remove the extension pieces and retract the jacks.
c) Lower the jacks against the transport platform.

ID: BG00471036 en-US C.001.1 2018-05-28
d) Move the boom(s) as low as possible and fasten them gently to the
platform. Use supports beneath the boom(s).
e) Secure the feed(s) to the platform with boom. Use supports
beneath the feed(s).
f) Lower the safety canopy/cabin (if the machine is equipped with a
safety canopy or lowering cabin).
g) Anchor the machine to the platform with straps or chains and wheel
chocks so that it cannot move during transportation.
h) Make sure there are no machine components outside the platform
area.
• Always bear in mind the maximum height and width of the load.
Note! When fastening the machine to transport platform, use covered
fastening devices or install protective covers under the straps or
chains to prevent damage to the machine’s paintwork.
7.3 Lifting
WARNING
Incorrect lifting methods could result in death or severe injury.
The hazard zone must be clear of people during lifting. Do not lift the
load over anyone. Follow the applicable local laws and regulations
as well as the safety instructions below.
• Before lifting the drill rig, move the booms, the boom supports, the feeds
and cabin/canopy into the driving position.
• Make sure that all the doors and covers are locked/secured in order to
prevent unexpected opening during lifting.
• Make sure that there are no movable or loose objects on the unit
surfaces which could fall down during lifting.
• Use only marked lifting points for lifting.
Lifting points are marked with hook symbols.

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ID: BG00471036 en-US C.001.1 2018-05-28
• Consider the drill rig's total weight, which is indicated on the drill rig's type
plate and/or in the technical specification.
• Use only an appropriate type of lifting device, with sufficient lifting
capacity. Neither the drill rig nor its components may be lifted with
devices other than those designed for lifting purposes. Do not use, for
instance, a loader for lifting.
• The weight of the load must be known, and the capacity of the lifting
device, as specified by the manufacturer, must not be exceeded.
• Check that the lifting device is in good condition.
• The lifting wires and chains must be checked regularly. Damaged wires
and chains must be marked clearly and removed from use immediately.
• Never wrap the lifting wires or chains around the lifting hook. Always
fasten wires or chains according to the manufacturer's instructions.

ID: BG00471036 en-US C.001.1 2018-05-28
• Make sure that the load is properly attached and balanced. To check the
fastening and balance, lift the load by just a few centimeters initially. Do
not continue lifting until you are certain that the fastening and balance are
good.
• Lifting routes should be chosen so that the load is not moved over
persons or locations where persons could be present.
RIGHT
WRONG
7.3.1 Lowering and raising equipment through a mine shaft
WARNING
Incorrect lifting methods could result in death or severe injury.
Contact your local Sandvik representative for the correct
disassembling and lifting procedures, before lowering or raising
equipment through a mine shaft.
Gather the following information for the Sandvik representative:

• The model(s) and serial number(s) of the equipment to be lowered /
raised.
• The maximum possible weight and dimensions of a single object that
could be lowered / raised through the shaft in question.

ID: BG00471036 en-US C.001.1 2018-05-28
7.4 Storage
Storage conditions:
C F
30 86
20 68
10 50
0 32
max 90 %
The temperature of the storage location should be between 0 °C and 35 °C.

The drill rig must be protected against direct sunlight and rain.
Note! The relative humidity of the air in the storage space must be below
90%.

ID: BG00471036 en-US C.001.1 2018-05-28
Drill rig
• Wash the drill rig if it has been in use or has been transported by sea.
Use a high-pressure steam washer.
• Empty the water circuit and blow some anti-freeze agent into it (an anti-
corrosive agent).
• Lubricate the drill rig (all greasing points).
• Lift the drill rig with the jacks (if the drill rig is equipped with jacks).
• Tilt the feed's front end downward.
• Empty the rock drill's pressure accumulators and prominently hang a sign
informing other personnel of this (the pressure accumulators must be
filled before the drilling rig is used).
• Protect all hydraulic cylinder piston rods with grease.
• Empty the water separator/s.
• Replace all lubricants and fluids, which may have deteriorated in use.
• Protect all electrical devices from corrosion so that there will be no
contact failures.
• Charge 24 VDC batteries full and turn the battery main switch (S1) to the
position 0.
RISK OF DAMAGING THE DRILL RIG!
Too high a humidity level in the storage location could damage the
drill rig.
Ensure that the storage space does not collect water, that the
NOTICE humidity will not become too high, and that the location is otherwise
protected from the elements.
Protect the electrical connections in accordance with the
instructions set: “Protecting electrical and electronic components
and connectors with protective agents”.
Proceed as specified in instructions set, and use a suitable protective agent

to protect, for example, the following points:
• coupling box connections
• screw terminals of the multi-pole switches
• battery terminals
• multi-pole switch coupling contacts
• contacts of the connecting caps of magnetic valves, pressure switches,
and corresponding parts (fill the caps with grease)

ID: BG00471036 en-US C.001.1 2018-05-28
7.5 Washing
WARNING
HIGH PRESSURE FLUID HAZARD!
High pressure fluid spray could cause severe injury.
Never point the nozzle on anybody. Use eye-protector.
Before washing the drill rig with water, high-pressure cleaner, steam
cleaner, or any other method, protect any components that are susceptible
to damage from the cleaning method or due to exposure to water. Pay
special attention to the protection of electric motors, boxes, and cabinets.
Before washing cylinders, protect load control valve breathers. Painted
surfaces of the cylinders can be washed as any other painted surface
(pressure/steam cleaner), but do not spray the water/steam directly into the
piston rods. Detergents and hot water/steam will destroy waxing which is
essential for the functioning of the cylinders. After washing, the rods must
be protected with oil by either wiping oil onto the piston rods or by
extracting and detracting the cylinders.
In addition to washing the drilling module and the front part of the machine
daily, the complete machine should be washed according to the interval
stated in the maintenance cards in the maintenance manual or at least
once a week. The washing interval should be adjusted to surrounding
conditions, i.e. in a dirty environment the complete machine can be washed
more frequently. Accumulated debris on the machine structures promotes
corrosion and component wear.

ID: BG00471036 en-US C.001.1 2018-05-28
Pressure cleaning system with reel (optional)
Water starts to flow when the washing nozzle is turned open. The washer
functions at water distribution system pressure. Washing pressure can be
seen from the pressure gauge connected to the cleaner. The normal water
pressure is 5...20 bar. Stop the washer by turning the nozzle.
High pressure cleaning system with reel (optional)
The high pressure cleaner is hydraulically operated. The high pressure

washing can be started by pulling the handle of the washing pistol. The
pump starts to idle.
The water flow is controlled by the handle of the washing pistol. The
washing pressure can be seen from the pressure gauge connected to the
cleaner. The normal water pressure is 140...170 bar.

ID: BG00471036 en-US C.001.1 2018-05-28

ID: BG00471036 en-US C.001.1 2018-05-28
8 Maintenance cards

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Maintenance program
8.1
452 (476)
Maintenance card hours
Maintenance hours
250 500 1000 2000 4000
250 4250 8250 12250 16250 20250 24250 28250 32250 36250 X
500 4500 8500 12500 16500 20500 24500 28500 32500 36500 X X
750 4750 8750 12750 16750 20750 24750 28750 32750 36750 X
1000 5000 9000 13000 17000 21000 25000 29000 33000 37000 X X X
Maintenance Manual
1250 5250 9250 13250 17250 21250 25250 29250 33250 37250 X
1500 5500 9500 13500 17500 21500 25500 29500 33500 37500 X X
Maintenance program
1750 5750 9750 13750 17750 21750 25750 29750 33750 37750 X
2000 6000 10000 14000 18000 22000 26000 30000 34000 38000 X X X X
2250 6250 10250 14250 18250 22250 26250 30250 34250 38250 X
2500 6500 10500 14500 18500 22500 26500 30500 34500 38500 X X
2750 6750 10750 14750 18750 22750 26750 30750 34750 38750 X
3000 7000 11000 15000 19000 23000 27000 31000 35000 39000 X X X
ID: BG00471036 en-US C.001.1 2018-05-28

3250 7250 11250 15250 19250 23250 27250 31250 35250 39250 X
3500 7500 11500 15500 19500 23500 27500 31500 35500 39500 X X
3750 7750 11750 15750 19750 23750 27750 31750 35750 39750 X
4000 8000 12000 16000 20000 24000 28000 32000 36000 40000 X X X X X
The daily checks and the 50 h maintenance interval are excluded from this table for readability. The daily checks must
be done daily. The 50 h maintenance must be done every 50 hours.
DT820
8.2 Instructions for reading maintenance cards

1 2 3 4 5 6
1 Maintenance card heading Hour type and amount

2 Maintenance procedure column Maintenance procedure to be performed
3 Symbol column Symbol representing the maintenance procedure
Maintenance manual page for additional information on
4 Page number column
the maintenance procedure
Check the box when the maintenance procedure is com-
5 Check column
pleted
6 Notes column Enter any notes on the maintenance procedure here
Maintenance card symbol descriptions
Adjust Check
Change/Replace Lubricate
Drain Measure
Service Clean
The maintenance schedule is based on applicable OEM service schedules

and Sandvik standards for machine maintenance. Some intervals may
need to be adjusted based on mine-specific applications and/or
environments. Be aware that adjusting service intervals will void warranties
on specific components. Contact your local Sandvik representative before
adjusting service intervals.

ID: BG00471036 en-US C.001.1 2018-05-28
8.3 Maintenance performed according to rock drill percussion hours
Note! Also remember to perform daily checks which are listed in the
Operator's manual.
Perform 50 hour maintenance procedures every fifty hours, i.e. at 50 h, 100

h, 150 h, 200 h, etc.
Perform 250 hour maintenance procedures every 250 hours, i.e. at 250 h,
500 h, 750 h, 1000 h, etc.
1000 h, 1500 h, 2000 h, etc.
1500 h, 2250 h, 3000 h, etc.
Perform 1000 hour maintenance procedures every 1000 hours, i.e. at 1000
h, 2000 h, 3000 h, 4000 h, etc.
h, 4000 h, 6000 h, 8000 h, etc.

ID: BG00471036 en-US C.001.1 2018-05-28
8.3.1 Every 50 hours
Percussion hours – 50 HOURS
Maintenance procedure Notes
Perform the maintenance procedures

See the instructions for reading
of all relevant shorter intervals at the
maintenance cards.
same time.
GENERAL 238
Wash the rig 238
Check the steel structures 238
HYDRAULIC ROCK DRILL HLX5 239
Check the front end parts 240
Check the tightness of the rock drill

243
bolts
Check the pressure of the pressure
246
accumulators
HYDRAULIC ROCK DRILL HLX 5T,
248
HFX 5T
Check the condition of the stabilizer
249
pins
Check the condition of the flushing
249
housing bushings
Check the condition of the rotation
250
bushing bearings
Check the condition of the rotation
250
bushing
Check the condition of the chuck bear-
251
ing
Check the condition of the coupling 252
Check the chuck 253
Check the shank 253
Check the condition of the guide rings 254
Check the accumulator filling valve

261
and cover plug condition
Check the accumulator pressure.
262
Change the diaphragm if necessary.

ID: BG00471036 en-US C.001.1 2018-05-28
HYDRAULIC ROCK DRILL RD520/

268
RD525
Check the piston head, stabilizer long
movement piston head and chuck 269
bearing
270
housing bushings
Check the condition of the coupling 270
Check the condition of the chuck 271
Check the condition of the shank 272

273
housing parts, change if necessary
Check the accumulator filling valve
280
and cover plug condition
Check the accumulator pressure.
281
Change the diaphragm if necessary.
Check the tightness of the rock drill
281
bolts
BOOM TB/SB 287
Lubricate the greasing points 288
Check the bearing bushings and axle

289
pins
Check the tightness of bolts and nuts 290
Check the slide pieces of the cradle 291
Check the slide plates and slide

293
pieces
SUB UTILITY BOOM 299
Lubricate the pins and bearings of the
299
boom
Inspect the cylinder joint pins, pin
300
lockings and bearings
FEED TF/TFX 303
Check the tightness of bolts and nuts 303

ID: BG00471036 en-US C.001.1 2018-05-28
Check the condition and mounting of

the impulse cylinders / inductive sen- 303
sors
Check the front centralizer 304
Lubricate the hose reel 304
Check and adjust the slide pieces

305
(TF500)
Check and adjust the slide pieces
306
(TFX500)
Check the tightness and condition of
306
the feed wires
Check the tension of the hoses 308
WATER CIRCUIT 365

Check the operation of the water valve
365
FV-70
Check the operation of the water valve
365
FV-100
Check the operation of the pressure
366
switch
Clean the oil cooler 367
AIR CIRCUIT 369

Check the condition of the air receiver
369
(optional)
SLU 394
Drain the condensed water 394
Check the condition of the water sepa-

395
rator
OTHER COMPONENTS 405
Check the condition of the grease unit 405
When completed:
Date .............................................................. Percussion hours ..........................................
Approved .......................................................

ID: BG00471036 en-US C.001.1 2018-05-28

maintenance cards.
same time.
BOOM TB/SB 287
Check boom clearances 293
Adjust the boom extension clearance 301
WATER CIRCUIT 365

Change the mud separator strainer
368
and O-ring
ELECTRIC SYSTEM 398
Check the operation of the fault cur-
400
rent protector switch
Check the condition of the power sup-
400
ply cable
Check the water drainage holes 401
Check the seal bushings 401
When completed:
Approved .......................................................

ID: BG00471036 en-US C.001.1 2018-05-28

maintenance cards.
same time.
HYDRAULIC ROCK DRILL HLX5 239
Rock drill overhaul. Check the condi-
247
tion of the rock drill
HYDRAULIC ROCK DRILL HLX 5T,
248
HFX 5T
Change the flushing housing bearing
255
and shank bushings
267
HYDRAULIC ROCK DRILL RD520/
268
RD525
Change the flushing housing bearing
274
and shank bushings
287
BOOM TB/SB 287
Check the cylinder pins 294
Check the sensor boxes 295
Lubricate the electric box connections 295
Check the angle restriction function 296
Test the lift/swing cylinder seals 297
Check hydraulic pressures 302
Inspect the turning joint lug welding

and the basket tilt cylinder fixing lug 303
welding
Inspect the condition of the boom
303
beams

ID: BG00471036 en-US C.001.1 2018-05-28
FEED TF/TFX 303
Check the condition of the steel strips 309
DRILLING HYDRAULICS 361

Replace the breather filter of the hy-
361
draulic oil receiver
Replace the pressure filter 362
Replace the return oil filter 363
Change the hydraulic oil 364
ELECTRIC SYSTEM 398
Check connections and contacts 401
Check battery system connections

401
and contacts
Check control system 402
Clean electric devices 403
When completed:
Approved .......................................................

ID: BG00471036 en-US C.001.1 2018-05-28

maintenance cards.
same time.
BOOM TB/SB 287
Lift/swing cylinders overhaul 298

Change the tilting cylinder joint pin
303
and bearing
FEED TF/TFX 303
Check the condition of the hose reel
310
components
SLU 394
Change the water separator filter ele-
396
ment
Clean the tank 397
Replace the breather 397
Check the function of the monitoring

398
system
When completed:
Approved .......................................................

ID: BG00471036 en-US C.001.1 2018-05-28

maintenance cards.
same time.
ELECTRIC SYSTEM 398
Check the motor terminals 403
When completed:
Approved .......................................................
8.4 Maintenance performed according to diesel engine hours
Operator's manual.
Perform 50 hour maintenance procedures every fifty hours, i.e. at 50 h, 100

h, 150 h, 200 h, etc.
500 h, 750 h, 1000 h, etc.
1000 h, 1500 h, 2000 h, etc.
1500 h, 2250 h, 3000 h, etc.
h, 2000 h, 3000 h, 4000 h, etc.
h, 4000 h, 6000 h, 8000 h, etc.

ID: BG00471036 en-US C.001.1 2018-05-28
Diesel hours – 50 HOURS

maintenance cards.
same time.
CARRIER 311
Grease machine greasing points 311
Check the oil level of the planetary

312
gears
Check the differential oil level 312
Check the battery electrolyte level 313
CABLE AND WATER HOSE REEL 355
Lubricate the cable spooling system 355
Check the guide rollers of the cable

356
reel
Check the guide rollers of the water
356
hose reel
When completed:
Date .............................................................. Diesel hours ..................................................
Approved .......................................................

ID: BG00471036 en-US C.001.1 2018-05-28

maintenance cards.
same time.
CARRIER 311
Check the pressure of the brake accu-
313
mulators
Bleed the brakes 317
Check the steering wheel and control

320
arm
Lubricate the chain of the cable reel 356
Lubricate the chain of the water hose

357
reel
Check the tightness of the chain of the
357
cable reel
Check the tightness of the chain of the
358
water hose reel
Check the cable fastening to the reel 358
Check the operation of the cable reel

358
limit switch
Change the gear box oil of the cable
359
reel
Check the cable reel slip rings and
carbon brushes. Clean the collector. 360
Check the thickness of the carbon.
SAFETY CABIN 404
Clean or replace the air conditioner fil-
404
ters
Check the operation of the heating
405
and air conditioning
Lubricate the cabin door hinges 405

ID: BG00471036 en-US C.001.1 2018-05-28
When completed:
Approved .......................................................

ID: BG00471036 en-US C.001.1 2018-05-28

maintenance cards.
same time.
CARRIER 311
Check the tightness of boom support
321
bolts
Replace the transmission oil filter 324
Change the differential gear oil 325
Check the brake discs for wear 326
DIESEL ENGINE MB 336

Change the engine oil and replace the
336
filter
Replace the fuel filter 339
Replace the fuel water separator filter 340
Check the condition of poly V-belt 341
Check the engine for leaks and gener-

345
al condition
Check the lines and hoses of the en-
345
gine
Check the intake pipe between air
345
cleaner and engine
Check the engine cooling system 346
Replace the intake air cleaner filter 347
When completed:
Approved .......................................................

ID: BG00471036 en-US C.001.1 2018-05-28

maintenance cards.
same time.
CARRIER 311
Check the middle-joint bearings 328
Check the oscillation axle bearings 328
Replace the safety cartridge of the air

328
filter
Change the transmission oil 329
Change the planetary gear oil 330
Check the specific gravity of the elec-

331
trolyte and clean the battery terminals
Do the servicing of Ansul fire suppres-
331
sion system (optional)
Adjust the valve clearances 348
Clean the fuel pre-filter 352

Change the gear box oil of the cable
359
reel
When completed:
Approved .......................................................

ID: BG00471036 en-US C.001.1 2018-05-28

maintenance cards.
same time.
Check the general condition of cooling
353
and heating system
Renew the coolant 354
Replace the poly V-belt 355
When completed:
Approved .......................................................
8.5 Maintenance performed according to compressor operating

hours
Operator's manual.
1000 h, 1500 h, 2000 h, etc.
h, 2000 h, 3000 h, 4000 h, etc.
h, 4000 h, 6000 h, 8000 h, etc.
h, 8000 h, 12000 h, 16000 h, etc.

ID: BG00471036 en-US C.001.1 2018-05-28
Compressor hours – 500 HOURS

maintenance cards.
same time.
COMPRESSOR CTN 370
Change the compressor oil and the oil
371
filling plug
Replace the compressor oil filter 372
Check and retighten main motor ca-

372
bles
Clean the compressor externally with
372
a cloth
Replace the compressor primary and
373
secondary air filters
Clean the cooler externally 373
COMPRESSOR CT 386
Change the compressor oil and the oil
387
filling plug
Replace the compressor oil filter 388
Check and retighten main motor ca-

388
bles
Clean the compressor externally with
388
a cloth
Replace the compressor primary and
389
secondary air filters
Clean the cooler externally 389
When completed:
Date .............................................................. Compressor hours ........................................
Approved .......................................................

ID: BG00471036 en-US C.001.1 2018-05-28

maintenance cards.
same time.
COMPRESSOR CTN 370
Replace the compressor belts 373
Replace the compressor oil separator

element, discharge valve, valve nest, 374
wing nut and O-rings
Clean the oil return line 375
Replace the screen for oil return, fit-

375
tings and gasket
Check the operation of the compres-
375
sor relief valve
Lubricate the electric motor bearings 375
Replace the seal kits of the inlet and

376
the discharge valve
Check functioning of the thermometer
384
safety limits
COMPRESSOR CT 386
Replace the compressor belts 389
Replace the compressor oil separator

element, wing nut and discharge valve 390
seals
Clean the oil return line 391
Replace the screen for oil return, fit-

391
tings and gasket
Check the operation of the compres-
391
sor relief valve
Lubricate the electric motor bearings 391
Replace the seal kit of the inlet valve 392
Check functioning of the thermometer

392
safety limits

ID: BG00471036 en-US C.001.1 2018-05-28
When completed:
Approved .......................................................

ID: BG00471036 en-US C.001.1 2018-05-28

maintenance cards.
same time.
COMPRESSOR CTN 370
Check the condition of the compressor
384
hoses
COMPRESSOR CT 386
Check the condition of the compressor
392
hoses
When completed:
Approved .......................................................

ID: BG00471036 en-US C.001.1 2018-05-28

maintenance cards.
same time.
COMPRESSOR CTN 370
Replace the blow-down valve 384
Replace the seal kit of the pilot valve 385
Replace the oil thermostat 385
COMPRESSOR CT 386
Replace the blow-down valve 393
Replace the oil thermostat 393
When completed:
Approved .......................................................

ID: BG00471036 en-US C.001.1 2018-05-28

ID: BG00471036 en-US C.001.1 2018-05-28
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Original instructions

BG00471036 en-US C.001.1 2018-05-28

This page is intentionally left blank

2 Safety and environmental instructions .......................23

2.6.3 Safe access to machine and three-point support ........................ 79

3 Machine description ..................................................... 107

3.3.9 Reversing camera monitor (optional) .......................................... 177

4 Periodic maintenance ................................................... 221

5 Maintenance instructions .............................................237

5.2.6 After rock drill service .................................................................. 247

5.5.6 Checking boom clearances ......................................................... 293

5.11.4 Changing the hydraulic oil ........................................................... 364

6 Lubricants and capacities ............................................ 407

6.3 Rock drill shank lubrication .................................................................418

7 Additional instructions ................................................. 435

8 Maintenance cards ........................................................451

This page is intentionally left blank

Copyright © Sandvik 15 (476)

1.1 The purpose of these instructions

16 (476) Copyright © Sandvik

1.2 Identification of the product

Product name: Drill rig

European Economic Area (EEA) Eurasian Economic Union

Identification plate location

1.2.2 Product manufacturer

Copyright © Sandvik 17 (476)

Location of manuals on the product

18 (476) Copyright © Sandvik

1 Document box for the tramming instructions

1.2.4 How to identify the correct manual for the product

1.3 Copyright notice

Copyright © Sandvik 19 (476)

20 (476) Copyright © Sandvik

• ROPS: Roll-Over Protective Structure. Structure that has been designed

Copyright © Sandvik 21 (476)

This page is intentionally left blank

22 (476) Copyright © Sandvik

2 Safety and environmental instructions

Copyright © Sandvik 23 (476)

2.1 Safety labels, safety messages and signals

The signal word, "DANGER", indicates a hazardous situation which, if not

The signal word, “WARNING”, indicates a hazardous situation which, if not

The signal word, “NOTICE”, indicates a situation which, if not avoided,

This general hazard symbol identifies important safety messages in this

24 (476) Copyright © Sandvik

2.1.3 Mandatory action symbols

Wear protective gloves Wear eye-protector Wear safety helmet

Wear safety harness Wear hearing protectors Wear safety footwear

Wear protective clothing Wear high visibility Wear respirator

General mandatory ac-

Copyright © Sandvik 25 (476)

2.1.4 Prohibited action symbols

No climbing No smoking No open flames

Do not touch Limit or restrict access Do not weld

Do not remove safety Do not modify General prohibited ac-

26 (476) Copyright © Sandvik

2.1.5 Hazard symbols

Mechanical hazard symbols

Falling load hazard Crushing hazard Flying material hazard

Crushing hazard - feet Crushing hazard - Cutting hazard

Entanglement hazard Entanglement hazard Entanglement hazard

Entanglement hazard - Slipping hazard Tripping hazard

Falling hazard Skin injection hazard High pressure injection

Hanging load hazard Run over hazard Sideways tipping haz-