D25KS & D245S

(Caterpillar C15, C16 & C18 Engine (Tier 2 or Tier 3)

High or Low Pressure Compressor)

MAINTENANCE MANUAL

March 2002
Serial Number 732596 & Up
(Rev. 7-09)

SANDVIK MINING and CONSTRUCTION

BLASTHOLE

1814 kg / 4,000 lb

SANDVIK MINING and CONSTRUCTION

13500 NW County Road 235
Alachua, Florida 32615 - USA
Tel. (386) 462-4100
Fax. (386) 462-3247
 The following three hazard signal words are used throughout this manual to emphasize
important instructions. For the purpose of this manual, these signal words are defined as follows:

Indicates an hazardous situation which,

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

Indicates a hazardous situation which,

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

Indicates a situation which, if not avoided,

NOTICE may result damage to machinery or components.

Indicates a situation which, if not avoided,

CAUTION may result damage to machinery or components.

California Proposition 65
WARNING:
This Product Contains And, When Used, Produces Chemicals Known
To The State Of California To Cause Cancer, And Birth Defects Or
Other Reproductive Harm.
 TABLE OF CONTENTS
SAFE OPERATING PRACTICES FOR DRILLERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii
Management's Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
The Operator’s Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Operator's Safety Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
Planning the Job 0vi
Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
General Maintenance Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
Fire Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ix

INCLEMENT WEATHER and SAFE DRILLING PRACTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi

GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi

MANAGEMENT’S RESPOSIBILITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi

RAINFALL AND FLOODING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi

THUNDERSTORMS AND LIGHTNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii

Exceptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii

MACHINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii

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

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

FILL WATER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 1
Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Coolant Conditioner Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

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

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

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

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

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

AIR COMPRESSOR LUBRICANT RECOMMENDATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 8

Table of Contents
SECTION 2 PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 1

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Replace Ether Starting Aid Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A- 1

Check Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1
Check the Cooler Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1

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

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

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

Change Air Conditioner/Heater Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-5
DUST COLLECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2A- 5
Change the Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-5

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Check Central Lubricator Grease Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-6
Drain Water and Check Pump Oiler Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-6

MISCEALLANEOUS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2B- 7
Inspect Winch Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-7
Check Bit/Hammer Lubricator Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-7
Check Feed Chain Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-7

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

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

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

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

Table of Contents
EVERY 250 HOURS OR MONTHLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2D- 1

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

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

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

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

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

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

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D- 5

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

COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D- 6
Change Main Oil Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-6
Clean Oil Return (Scavenge) Line Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-7
Change or Sample Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-7

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

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

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

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

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

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

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

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

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

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

UNDERCARRIAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D- 12
Check Track Tension and Adjust if Necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-12
Adjusting Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-13
Check Final Drive Gearbox Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-13

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

Replace Primary Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-14
CENTRAL LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2D- 14
Clean Water Trap Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-14
Check System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-15

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

ROTARY HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2F- 4

Replace Gearbox Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2F-4

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

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

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

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

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

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

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

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

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

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

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

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

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Preparation for Long Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Removal From Long Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
11-06

SAFE OPERATING PRACTICES FOR DRILLERS

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

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

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

Management's Responsibilities

It is the responsibility of management to:

• See that all operators of this equipment are thoroughly trained (with special emphasis on safety), competent, physi-
cally fit and if required, licensed.

• Assign specific crew members specific safety responsibilities and instruct them how to report any unsafe conditions.

• Enforce the use of protective clothing, eye and hearing equipment.

• See that the operation and maintenance of this drill is in compliance with all Federal, State and local codes, regula-
tions and standards.

• Ensure that the work area is appropriately illuminated when drilling is performed at night.

• Maintain a complete first aid kit at the drill site. At least two members of the drilling crew or personnel in the area
where the drill is operated should be familiar with first aid and Cardiac Pulmonary Resuscitation.

• Contact the utility companies for the exact location of underground transmission lines in the drilling area.

The Operator’s Responsibilities

Safety must always be the operator's most important concern. The operator must refuse to operate the drill if an unsafe

Safe Operating Practices for Drillers iii

 11-06

condition exists. It is the responsibility of the drill operator to ensure that the drill is properly equipped, safe to operate
and that the site conditions make it possible for safe operation:

• The operator must see that all emergency stops, "operational aids" and "warning signals" are functional before oper-
ating.

• The operator must be alert, physically fit, and free from the
influences of drugs, alcohol and medications that might
impair eyesight, hearing or reactions

• The operator should not attempt to start, operate or service the drill unless he has been properly trained and read this
manual.

• The operator should not operate this equipment if any

of it's controls display a "lockout" tag.

• If an unsafe condition exists, the operator must place a

tag, identifying this condition, on the starting controls
and alert other potential users of the drill.

iv
11-06

• The operator should not operate the drill without first

checking that all personnel protection devices and
machinery guards are in place.

Operator's Safety Check

The operator must make a safety check before starting to work to ensure that the machine is in proper order for accident
free operation. Somethings to check are:

• Check that there are no "lockouts" or "tagouts" attached to the

controls.

• Check the machine log book to see that periodic maintenance

and inspections have been performed, and that all necessary
repairs have been made.

• After starting the engine, check all indicators, emergency stop,

trip devices and gauges for serviceability.

• Check the fire extinguisher(s) for charge and accessibility.

• Clean the cab interior windows if necessary.

• Test all controls for proper operation.

• Check access ladders and decking for damage and slipping hazards such as mud, oil or ice.

• At the end of the shift, the operator must properly secure the drill to prevent the machine from being operated by
unauthorized individuals.

• The operator must never permit personnel to ride on the machine except in the passenger compartment.

• The operator should treat all power lines as live.

Safe Operating Practices for Drillers v

 11-06

Planning the Job

The person in charge must have a clear understanding of the work to be done and consider all the hazards at the site.
He must develop a plan to do the job safely and explain the plan to the crew members involved. Factors such as these
should be considered:

• Will the drilling take place in wet formations?

• Are there utility lines or structures that must be moved or avoided?

• Are there unusual or extreme weather conditions expected?

• Will drilling be done in night hours?

• Will the machine be propelled on inclines?

• Will drilling be done into difficult formations?

• Has a drilling pattern been developed?

• What is the required depth of the drilling pattern?

• Will special drilling tools be required to complete the job?

• Will vertical or angle drilling be required?

vi
11-06

Operating Precautions

• Operating near or contacting a power line with any part of the

machine can result in electrocution.
Do not raise the drilling mast or operate the machine in the
vicinity of electrical power lines without checking the mini-
mum safe operating perimeter set by local, state or federal
regulations.

• Raising or lowering the mast, and drilling with an unsupported or unleveled machine can result in excessive structural
stress to the machine frames or can cause the machine to overturn.
Do not raise or lower the mast or attempt to drill until the machine is fully supported and leveled by the lev-
eling jacks.

• Drilling with an unlocked mast can result in excessive pressure at the mast raising cylinders causing the mast to fall.
Do not attempt to drill until the mast locking pins are fully engaged.
.

• Before leaving the operator's station, all controls must be in the

neutral position with all locking and safety devices engaged.
Do not allow the drill to operate unattended.

• Do not park or position the machine on grades that exceed the tilt
ratings.
Park or position the machine on level ground or across (hori-
zontal) grade

• Park or position the machine to allow the wind to carry engine exhaust fumes away from the operator.
Exhaust fumes from diesel engines are lethal.

Safe Operating Practices for Drillers vii

 11-06

• Drill pipe that is free to slide through the opening in the top plate
could be released from the loader while traveling.
Before lowering the mast, index the loader to a position
such that the top plate of the loader prevents all drill pipe
from moving past the top plate

General Maintenance Safety Practices

While operating and servicing this machine be aware of the following:

• The sudden release of a pressurized lid or hose can spray hot

oil.
Do not open hydraulic tanks, air reservoirs or hydraulic
connections while the machine is running or the sys-
tems are under pressure.

• Before entering any enclosure, be sure that the door is secured open. Avoid entrapment, be sure that no one is
inside any enclosure before closing and latching the doors.
Enclosures can cause suffocation.

• Before starting any service or maintenance work, always perform a safety/risk analysis of the task.
Performing maintenance work without the proper tools and personal protection equipment can cause seri-
ous injury or death.

• Climbing the mast is a crushing and falling hazard.

Climbing the mast may cause serious injury or death. Stay off the mast at all times.

• Hydraulic oil under extreme pressure from a small opening

can penetrate the skin and inject oil into the body.
Do not attempt to locate a hydraulic leak by using your
hand.

• Pressure in hydraulic systems can be retained for long peri-

ods of time. If not properly released before maintenance
people attempt to work on the hydraulic system, this pres-
sure can let components move or cause hot oil to spray
and hose ends to shoot out at high speed.
Release system pressure before attempting to make
adjustments or repairs.

viii
11-06

• Carelessness in getting on and off equipment can result in seri-

ous injuries.
Always wait until the machine has completely stopped. Do
not jump on or off. Always use both hands and feet and
use the 3-point contact rule.

• Riding the rotary head up and down the mast is a crushing hazard.
Never ride the rotary head for any reason!!! It was not designed to be an elevator.

When there is a need for an operator or helper to work on the rig in the working area or danger zone and this work
involves activation of one or several machine functions, this work shall only be done under the following conditions:

a. There must be two safety trained people present, one should supervise the safety of the other doing the servicing.
Supervision should be done from the operator’s station to ensure immediate access to an emergency stop at all
times.

b. The area where the service work is to be done should be properly illuminated.

c. A reliable mode of communication should be establish between the servicing person and the supervisor.

d. The rig must be completely shut down and all methods of starting disabled before servicing work begins.

Fire Prevention

• Keep the machine clean of vegetation, coal dust and oily rags.

• Clean-up any oil and fuel spills particularly around hot surfaces
and heat producing components.

• Check the Fire Suppression System (FSS), if fitted, for damaged hoses or cylinders.

• Check all electrical lines and connections including battery terminals for a tight fit, wear, abrasion, and corrosion.

• Do not use the drilling machine in oil, gas or waterwell operations unless the well head is properly equipped with blow-
out preventers and safety equipment required by law or as recommended in the American Petroleum Institute's doc-
ument API 54.

Safe Operating Practices for Drillers ix

 11-06

• Check all machine ignition points (engine block, exhaust manifolds, mufflers, turbo-chargers, etc...) to make sure they
are not in contact with any hoses.

• Keep the batteries secured in their compartment and covered.

• Never inject ether or other starting aids into the engine and compressor intake filter(s). Ether or other aids drawn into
the compressor can cause an explosion.

• Do not store flammable fluids on or in the immediate vicinity of the machine.

• Engine oil, hydraulic fluid and compressor oil are flammable. Do not operate a machine with leaking or worn hoses or
lines.

• Do not clean washable filter elements with flammable solvents, diesel fuel, kerosene, or gasoline.

• Do not attempt to perform welding repairs until all flammable materials including oil and fuel spills oily rags, and rock
and coal dust, have been isolated or removed from the machine.

• Disconnect the battery cables before welding on the machine.

• Keep tools away from exposed live electrical parts such as terminals, to avoid arching.

• If charging the batteries, always turn the charger off before making or breaking connections to the battery.

• The compound (ethyl ether) used in the engine starting aid system is extremely flammable. Changing the cylinders
and servicing this system should be done in a well ventilated area. Do not store or install the cylinders in tempera-
tures above 160° F (71° C).

• The anti-freeze compound (methanol) used in the air line anti-ice systems is flammable. Refill the system with com-
pound only in well ventilated areas, away from heat, open flames and sparks. Do not store or expose this system or
the compound to temperatures above 150° F (65° C), or in direct sunlight.

x
11-06

INCLEMENT WEATHER and SAFE DRILLING PRACTICES

GENERAL

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

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

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

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

MANAGEMENT’S RESPOSIBILITIES

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

It is the responsibility of management to:

• Be aware of daily weather conditions within a 100 mile (161 Km) radius of the mine property.

• Determine a plan of action relating to expected bad or unexpected weather conditions.

• Notify equipment operators of impending storms. Communication to equipment operators may be given via two way
radio and/or in person.

• Consider that drill operators need ample time:

a. to retrieve drill pipe from blastholes and well bottom.

b. lower masts to a horizontal position or position feed rails into feed supports.

c. give the drill engine an adequate cool down period prior to shutting machine down.

d. leave machine cabin or operator platform and transport to central meeting location.

• Give equipment operators an all clear signal after the storm has cleared the area.

Note To Supervisors!

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

RAINFALL AND FLOODING

When notified of an impending storm, machine operators should:

Safe Operating Practices for Drillers xi

 11-06

•Move the drill machine to higher ground conditions.

Never leave a drill machine at the lowest floor position of
a mine or quarry or in a low lying ditch that could trap
water runoff.

•Move the drill machine to stable ground and away from

unstable crests or the face.
Never leave a drill machine on the front face of the drill
pattern while rain and severe weather pose a threat of
loose ground falls or washouts.

•When operating machines in a construction application, equipment operators shall move the drill machine to higher
stable ground.
Never leave a drill machine in any construction zone roadway, river bed or drainage ditch.

•Move the drill machine to stable ground away from high walls and any threat where rock or water erosion may
allow unstable ground to fall or slide.

THUNDERSTORMS AND LIGHTNING

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

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

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

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

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

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

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

• Equipment operators shall move the machine to secure ground as noted in the rainfall and flooding description.

• Equipment operators shall give adequate engine cool down period prior to shutting machine down. Adequate
engine cool down periods range between 3 to 5 minutes.
Follow engine manufacture specifications as a standard.

xii
11-06

• Equipment operators shall secure the machine, close doors and windows, leave the machine cabin and dismount
the machine in a proper 3 point contact with the boarding ladder.

• Equipment operators shall drive or be transported to a central meeting location away from bad weather and storm
conditions.

There are exceptions to the rules when bad weather develops and time does not permit adequate machine preparation
- shutdown principals.

Exceptions

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

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

• all windows are closed

• all doors closed

• do not touch metal parts

• do not use two way radio communication

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

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

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

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

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

Lightning detectors are available aftermarket as a measuring instrument to determine lightning proximity. Blasting crews
are aware of lightning hazards and may have a lightning detector on site.

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

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

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

MACHINE MAINTENANCE

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

Safe Operating Practices for Drillers xiii

 11-06

Electrical charge should dissipate immediately after impact.

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

Reference material

MSHA Holmes Safety Association Bulletin April 2001

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

National weather service (www.noaa.gov)

xiv
 SECTION 1

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

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

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

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

Refer to the engine manufacturer for detailed

specifications, or Caterpillar® form SEBD0518.
Coolant Conditioner Elements

FILL WATER Coolant conditioner elements should be used to

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

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

detailed summary of preferred fuels and their
specifications.
Antifreeze

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

Coolant, Fuel and Lubricant Specifications - Page 1-1
Cetane Requirement NOTE !
The minmum Total Base Number (TBN) of the
The cetane number of the fuel has an effect on oil used must be 20 times the percentage of fuel
the ability of the engine to start. Also, the cetane sulphur (TBN as measured by the ASTM
number has an effect on the interval of time ‘D2896’ method). If the sulphur content is
before the engine runs smoothly. The minimum greater than 1.5%, choose and oil with the high-
fuel cetane number recommended for this est TBN that meets one of these classifications:
engine is 40. API CF, API CF-4, API CG-4, API CH-4, or API
CI-4 . Consult your Caterpillar® dealer or form
SEBU6251 for correct engine oil recommenda-
Fuel Cloud Point tions.

The cloud point of the fuel is the temperature

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

The percentage of fuel sulphur content will

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

Only use oils that meet Engine Service Classifi-

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

At the factory, this machine was filled with BP

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

SAE 5W-40 -30°C (-22°F) 50°C (122°F)

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

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

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

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

NOTE! HYDRAULIC TANK 135 511

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

Hydraulic Oils (HYDO) BIT LUBRICATOR TANK 10 38

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

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

with Citgo 32 AW hydraulic oil. WATER INJECTION 230 870

TANK(WO/DUST COLLECTOR

WATER INJECTION TANK(W/ 120 454

Multipurpose - Type Gear Lubricant (MPL) DUST COLLECTOR

WATER INJECTION PUMP 1 qt. 1

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

Coolant, Fuel and Lubricant Specifications - Page 1-3

 6-05

RECOMMENDED LUBRICANT VISCOSITIES

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

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

-40°F ISO 32
COMPRESSOR
ISO 46

COMP ISO68
Note oil change intervals

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

32AW
HYDRAULIC SYSTEM 46AW
HYDO 68AW
100AW

WATER INJ. PUMP - CH SAE 30

SAE 10W-30

ROTARY HEAD, WINCH and GL-5 EP 90

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

HAMMER OIL ISO 46-100

RDO ISO 100-220
220-460

Page 1-4
 996
EQUIVALENT HYDRAULIC OILS

LUBRICANT ISO ISO ISO ISO

MANUFACTURER
BRAND NAME 22 32-46-68 100 150

ACCITE HIDRAULICO MH PETROLEOS MEXICANOS X X

AMOCO AW OIL AMOCO OIL CO. X

AMOCO RYDON OIL MV AMOCO OIL CO. X X

ANTECH EXXON/ESSO X

ASHLAND VG ASHLAND OIL CO. 32

BARTRAN HV BP OIL CO. 46 & 68

BRESLUBE VG BRESLUBE LTD.-CANADA X X

CANADIAN OIL MOXY T OIL CANADA X X X

CANVIS AW BP OIL CO. X X

CHAMPION SUPER GRADE LOWE OIL X

CHEVRON AW CHEVRON X

CITGO AW CITGO X X X

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

DECOL ANTI-WEAR SHELL CANADA X X X

DTE 24-25-26 MOBIL OIL CORP. X

DURO AW ARCO X X

EAL SYNDRAULIC MOBIL OIL CO. X

ELF OLNA DS ELF/ANTAR X

ENERGOL HLP-HD SERIES BP OIL CO. X X

EPPCO UNIVIVERSAL GP EPPERT OIL CO. X

GULF HARMONY AW GULF R&D X

GULF SYNFLUID SL H__AW GULF USA X

HIDRALUB EP MARAVAN S.A. X X

HARMONY AW GULF CANADA LTD. X X

HYDRAFLOW PETRO CANADA X X X

HYDRALUBE AW LUSCON IND. X X

HYDRELF DS ELF 46 & 68

HYSPIN AWS-AD CASTROL INC. X

HYTAC DISTAC LUBRICANTS X X

KENOIL R&O AW KENDALL REFINING CO. X X

LUSCON HD LUSCON IND. X X

MARATHON MULTI. VG MARATHON PETROLEUM X X

MOBIL HYD. OIL NZ MOBIL OIL CO. X

MOBIL HYD. OIL ZF MOBIL OIL CO. X

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

(Page 1 of 2)

Coolant, Fuel and Lubricant Specifications - Page 1-5

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

NERVOL FLUID SH2 NERVOL X X X

NUTO-H EXXON/ESSO X X X

NUTO-HP EXXON/ESSO 32 & 46

NUTO-H PLUS EXXON/ESSO X

NYCO HYD. OIL NYCO LUBRICANT CORP. X X

ORLY AGENA ORLY INTERNATIONAL X

ORLY GALA ORLY INTERNATIONAL X

ORLY HYDRO ORLY INTERNATIONAL X

PACER POWER V PACER LUBRICANT INC. X X X

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

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

PEN PREMIUM EP PENTAGON CORP. 32 & 68 X

PENNZBELL AW PENNZOIL PROD. CO. X X

PENNZOIL AW PENNZOIL PROD. CO. X X X

PENNZOIL AWX PENNZOIL PROD. CO. X X

RANDO OIL HD TEXACO INC. - USA X X

ROL ANTELITTERAM HVI ROL RAFFINERIA X

ROYAL AW EPPERT OIL CO. X

ROYAL PREMIUM VG EPPERT OIL CO. X

RYKON OIL AMOCO OIL CO. X

SELCO SF 330 SELCO X X X

SHARLU HYDROFLUIDS AW SHARJAH NATIONAL LUBE OIL X

CO. LTD.

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

STAR PREMIUM VG EPPERT OIL CO. X

SUNVIS 8__ WR SUNCOR or SUNTECK X X X

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

SUPER HYD. OIL VG CONOCO X X

TELLUS SHELL CANADA LTD. X X X

TELLUS SHELL CO. - USA X X

TERRAPIN IND. OIL AUTOLINE OIL CO. X X X

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

TRC HYD. OILS VG TEXACO REFINERY X

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

UNIVIS N EXXON/ESSO X X

UNIVIS N PLUS EXXON/ESSO X X

UNIVIS SHP EXXON/ESSO 32 & 46

YUKONG SUPERVIS YUKONG LTD. X

(Page 2 of 2)

Page 1-6
 MINIMUM PERFORMANCE STANDARDS FOR HYDRAULIC OILS

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

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

ASTM Viscosity Grade No.

(Saybolt) 150 215 315 465

Gravity: API 31.1 30.3 29.5 28.9

Viscosity, Kinematic: cSt

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

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

Viscosity Index,
ASTM D 2270 106 105 104 99

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

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

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

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

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

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

Carbon Residue,
Ramsbottom:% 0.30 0.30 0.36 0.37

Rust Preventive Test,

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

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

Oxidation Test, ASTM D 943

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

Emulsion, FTMS 791 3201,

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

Aniline Point, ASTM

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

Coolant, Fuel and Lubricant Specifications - Page 1-7

 AIR COMPRESSOR LUBRICANT RECOMMENDATIONS

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

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

AMBIENT CHANGE LUBRICANT

ISO
TEMPERATURE INTERVAL DESCRIPTION

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Low and High Pressure Compressors

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

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

* 500 Hours for High Pressure Compressors

Page 1-8
 SECTION 2 follow list items according to the service interval.
Use the hourmeter to determine when each ser-
PREVENTIVE MAINTENANCE vice is due. Calendar intervals (daily, weekly,
monthly, etc.) may be used if they allow for
more convenient maintenance scheduling, pro-
GENERAL
vided they approximate the hourmeter readings.
This section of the manual provides a step-by-
When performing scheduled maintenance, all
step guide to performing scheduled lubrication
services due at more frequent intervals should
and maintenance for your drill. A thorough study
also be performed. For example, at “Every 250
of this manual is recommended before mainte-
Hours or Monthly” service, also perform the
nance of the machine is attempted.
items listed at “Every 50 Hours or Weekly” and
“Every 8 Hours or Shift Change.”
Careful attention should be given to the service
and maintenance instructions for the various
The recommended maintenance schedule is
components and systems of the machine.
designed for average conditions. When operat-
Experience indicates that the procedures
ing in temperature extremes, dusty or wet con-
described herein are preferred practices and
ditions, the period between maintenance
that failure to comply with them can materially
operations should be shortened. For example,
shorten the useful life of the equipment and/or
check fluid levels more frequently than the rec-
reduce its standard performance.
ommended intervals if leaking is suspected or
observed.
Some photographs in this section may show
details or attachments that are different from
A number of services may need to be per-
your unit, due to optional equipment and/or
formed on a “When Required” basis, as deter-
advancement of product design. Contact your
mined by service indicators on the machine
Sandvik Mining And Construction dealer for
details of lubrication or maintenance not cov-
ered in this publication.
MAINTENANCE RECOMMENDATIONS
The parts manual should be referred to when it
Wipe grease fittings clean and ensure that
is necessary to order repair parts. For prompt
grease gun nozzles are clean before injecting
and efficient parts service, contact your
grease.
Sandvik Mining and Construction dealer, giving
the model and serial number of the machine,
Always keep caps, plugs, dipstick tubes and
along with the part number and description of
their surroundings clean before removing for
the items required, as their personnel are fully
servicing.
qualified to assist and advise you on any ser-
vice or operational problems that may be
When servicing, watch for:
encountered. Sandvik Mining and Construction
• Leaks
Field Representatives are also available to you
• Fire hazards (accumulated fuel, oil, grease,
for advice and assistance on special problems.
debris)
• Loose or missing hardware
• Signs of wear
SERVICE AND OIL CHANGE INTERVALS
• Damage
The Lubrication and Maintenance Charts that
Preventive Maintenance - Page 2-1
USE OF CORRECT TOOLS AND PROCE- THE DRILL MONITOR SYSTEM (DMS)
DURES
The optional DMS control panel in the opera-
When servicing the drill, use the correct tools tor’s cab is the Drill Monitor System. This panel
and tensioning procedures outlined in this man- provides warning signals to the operator or
ual. Overtighting plugs, filter, adaptors, etc. will automatically shuts down the machine (for criti-
cause undue stress on components and may cal out-of-limit conditions) in the event that the
weaken or fracture the component under pres- monitored conditions are not within safe limits.
sure. Remember, if you are unsure as to the Several of the “When Required” maintenance
correct procedure in performing a job, DO NOT checks are dictated by the signalling from the
attempt to start it. DMS. For more information on the functions of
this system refer to section 2 of the Operation
When filling the hydraulic reservoir, always Guide.
check the oil level with the cylinders fully
retracted. If oil is added when the cylinders are
extended, the increase in volume of oil to the COMPRESSOR AND HYDRAULIC SYSTEMS
tank may cause the tank to overfill and rupture
when the cylinders are retracted.
Cleanliness

OIL SAMPLE ANALYSIS Cleanliness is an important factor when per-

forming even the most routine service proce-
Sandvik Mining and Construction encourages dure. You can reduce the possibility of dirt
the user to participate in an oil analysis program entering a system by:
with an oil supplier or engine manufacturer. • Ensuring that all containers used for dis-
Periodically analyzing the oil monitors the con- pensing oil are clean.
ditions of both the machine components and the • Ensure that the areas around filler caps and
oil itself. Also, using an oil analysis program plugs are clean before removing them.
could result in oil change intervals differing from Never leave plugs or caps off any longer
those stated in this manual. than necessary.
• Keep disconnected hoses plugged to pre-
Following the instructions of your program coor- vent entry of dirt.
dinator, we recommend taking samples when • Repair leaking cylinder rod wiper seals
the oil is hot and mixed from the following loca- immediately.
tions: • Change filters and breathers regularly in
• Engine crankcase accordance with maintenance recommenda-
• Hydraulic tank tions.
• Main pump drive gearbox • Ensure that all gaskets, seals and protective
• Final drive gearbox covers are tight and properly fitted.
• Compressor air/oil receiver tank

Oil Contamination
WIGGINS SERVICE STATION
Water or air in a hydraulic system can cause
If your machine is equipped with a Wiggins ser- pump failure. If hydraulic oil appears cloudy,
vice station it should be used whenever replen- water or air is entering the system and the oil
ishing fluids to reduce the risk of contamination should be drained, the system flushed and
and the chance of mixing fluids. cleaned, and refilled with new oil. Points of
entry for air or water such as suction hoses or
loose clamps, faulty seals or gaskets, and areas
2-2
where water may pool and be drawn into the • Component bearing failure
system should be checked and remedied. • Acid formation
• Overheating

Leaks
Initial Start-Up
If a leak has developed in a system, it is
because there is a fault which may not be On the initial start-up of the machine, the
noticeable or immediately evident. A leak is hydraulic actuators may move without notice or
generally a symptom of a fault such as: without any control input signal due to air
• Overheating. entrapment in the circuits. Ensure that all per-
• Overpressure sonnel are clear prior to starting. Normally,
• Excessive vibration through a mechanical cycling the component several times will cause
component fault. the air to bleed off. However, if the condition
• Incorrect operating procedure. continues it will require technical assistance.
• Poor maintenance procedure.

When fixing a leak, try to identify the real cause. Hose Replacement

If a hose is frayed or damaged, it must be

Mixing Hydraulic Oils replaced. When replacing a hose, be sure that
the correct hose type and diameter is used.
The hydraulic oils used in your machine have Replacing a hose with a smaller diameter hose
been selected to perform specific roles with will increase the velocity of fluid through the
respect to the following properties: hose and result in severe overheating. Also be
• Viscosity (thickness). sure to route and clamp the hose as originally
• Viscosity Index (change in thickness through designed.
temperature variation).
• Anti-wear performance.
• Heat dissipating performance. HEATING, CUTTING AND WELDING EQUIP-
• Compatibility with the internal materials used MENT USAGE
in components.

Incompatibility (an adverse reaction of one or ! DANGER

more of the preceding properties) is to be
Welding on a pressure vessel or near batter-
avoided at all costs. Never top off or fill a res-
ies could cause an explosion resulting in
ervoir with an incompatible fluid. Use only
injury or death.
the oils specified in the “COOLANT, FUEL and
LUBRICANT SPECIFICATION” table in this
All welding should be in accordance with Ameri-
manual.
can Welding Society D1.1 ‘Structural Welding
Code’ in conjunction with AWS D14.3-82R spe-
Problems caused by incompatible fluids are:
cific for welding earth moving and construction
• Sludging
equipment.
• Oxidation
• Reduced lubrication effectiveness
Never use oxy heating or cutting equipment on
• Seal damage
or around hydraulic components. Apart from
• Metallic erosion
fire hazard the heat can damage components.
• Corrosion
Heating or welding on hydraulic pipes or fittings
• Foaming/aeration
will cause a scale to develop on the inside. This
• Solidification/emulsification
Preventive Maintenance - Page 2-3
scale may enter the system and cause severe and replace these cartridges with maintenance
component damage. cartridges at 250 hour intervals.

Always disconnect the ground terminals from Use only the water and coolants specified in the
the batteries before welding on the machine to “COOLANT, FUEL and LUBRICANT SPECIFI-
prevent damage to electronic controls. CATION” topic in this manual and refer to Cater-
pillar® bulletin SEBD 0518-06.
The ground cable of the welding machine must
be connected to the work piece, as close as If the engine is to be operated or stored in an
possible to the area being welded. The ground area with temperatures below 32°F (0°C), the
cable should not be connected in such a way to cooling system must be protected to the lowest
allow current to flow through a bearing, joint expected ambient temperature.
coupling, sealing surface, lever or control cable.
Clean the cooling system if scale is present or
If welding is performed near pins or in places there is evidence of oil contamination. In either
where flexing may cause shanges in the align- case, overheating may result.
ment of bushings, remove the pins and check
the alignment after welding. When refilling the cooling system, add coolant
no faster than 20 qts (20 l) per minute to prevent
air pockets from developing.
AIR INTAKE SYSTEM
After refilling the system, run the engine with the
The engine and compressor air intake filters radiator cap(s) removed until the coolant level
should be serviced when the service indicates stabilizes. Top off the radiator if necessary.
to do so or the Drill Monitoring System (DMS)
indicator illuminates.
FUEL SYSTEM
Observe the limits on the number of times the
filter elements can be cleaned and when the Use only the fuels specified in the “COOLANT,
safety element should be replaced. FUEL and LUBRICANT SPECIFICATION” topic
in this manual.

ELECTRICAL SYSTEM Have your fuel supplier drain water and sedi-
ment from his fuel storage tanks at weekly inter-
When jump-starting the machine, follow the vals to prevent contamination from being
instructions in the Operators Manual to avoid pumped into the machine’s tank.
equipment damage or injury to personnel.
Always fill the tank at the end of the shift to drive
Always disconnect the batteries before welding out moisture laden air from the tank but do not
on the machine or alternator damage will result. fill the tank to the brim as fuel will expand as it
warms and may overflow
Keep all electrical compartments closed and
properly sealed during machine operation. Allow fuel to settle for a few minutes after filling
before draining water and sediment..

COOLING SYSTEM After changing fuel filters, bleed the fuel circuit
to remove air.
All water is corrosive at engine operating tem-
perature. Always use coolant conditioner pre-
charge cartridges when changing the coolant,
2-4
RECOMMENDED TORQUE VALUES FOR STANDARD HARDWARE - UNC

This table applies to part numbers:

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

Coarse Thread (UNC) Torque Torque

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

1/4 6 (.8) 9 (1.2)

5/16 12-14 (1.5) 17-19 (2)

3/8 22-24 (3) 31-34 (4.5)

7/16 36-39 (5) 50-55 (7)

1/2 54-59 (8) 76-84 (11)

9/16 77-85 (11) 110-120 (15-16.5)

5/8 107-118 (15-16) 153-166 (21-23)

3/4 190-210 (26-29) 270-292 (37-40)

7/8 280-310 (38-43) 437-475 (60-66)

1 425-460 (59-63) 650-710 (90-98)

1-1/8 570-620 (79-86) 930-1000 (128-138)

1-1/4 810-870 (112-120) 1310-1410 (181-195)

1-3/8 1060-1140 (146-157) 1730-1850 (239-256)

1-1/2 1410-1510 (195-209) 2290-2460 (316-340)

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

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

Preventive Maintenance - Page 2-5

RECOMMENDED TORQUE VALUES FOR STANDARD HARDWARE - UNF

This table applies to part numbers:

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

Fine Thread (UNF) Torque Torque

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

1/4 7 (1) 10-11 (1.5)

5/16 14-16 (2) 20-22 (3)

3/8 25-28 (3.5) 35-39 (5)

7/16 39-43 (6) 55-61 (8)

1/2 63-69 (9) 86-94 (12)

9/16 87-95 (12-13) 123-134 (17-18.5)

5/8 126-138 (17-19) 171-187 (24-26)

3/4 213-233 (30-32) 300-328 (42-45)

7/8 312-338 (43-46) 480-520 (66-72)

1 466-504 (64-70) 715-770 (99-106)

1-1/8 640-695 (89-96) 1040-1120 (144-155)

1-1/4 900-960 (124-133) 1460-1560 (202-216)

1-3/8 1210-1300 (167-180) 1970-2100 (272-290)

1-1/2 1585-1700 (167-180) 2570-2750 (272-290)

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

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

2-6
 WHEN REQUIRED MAINTENANCE CHECKS

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

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

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

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

Maintenance Point Serviced By

Replace Starting Aid Cylinder

Coolant Condition

Check Cooler Cores for Obstructions

Change Air Cleaner Elements

Change Cab Air Conditioner/Heater Air Cleaner Element

Change Dust Collector Elements

Page 2A
8 HOUR or SHIFT CHANGE MAINTENANCE CHECKS

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

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

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

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

Maintenance Point Serviced By

Perform “Operator’s Safety Check”

Check Engine Oil Level

Drain Primary Fuel Filter Water

Check Engine Coolant Level

Check Air Compressor Oil Level

Drain Condensation from Air/Oil Receiver Tank

Check Compressor Oil Return Line Sightglass

Check Air/Oil Separator Element Indicator

Check Hydraulic Tank Oil Level

Drain Water from Hydraulic Reservoir Tank

Check Hydraulic Tank Air Pressure Regulator Gauge

Check Hydraulic Filter Service Alarm Indicators

Lubricate Pump Driveshaft

Check Oil Level in Pump Drive Gearbox

Check Undercarriage for Debris

Check Air Cleaner Element Indicators

Inspect Air Cleaner Vacuator Valves

Check Central Lubricator System Grease Level

Drain Central Lubricator Water

Check Central Lubricator Pump Oiler Level

Visually Inspect Winch Wire Rope

Check Air Lubricator Oil Level

Check Feed Chain Adjustment

Page 2B
 50 HOUR or WEEKLY MAINTENANCE CHECKS

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

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

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

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

Maintenance Point Serviced By

Perform the 8 Hour Maintenance Checks

Lubricate Air Swivel

* Replace Hydraulic Feed Circuit Filter Elements

* Replace Compressor Main Oil Filter Elements

* Replace Hydraulic Return Filter Elements

* Replace Servo Replenshing Filter Elements

* Change Winch Oil

* Initial 50 Hours or Operation Only

Page 2C
 250 HOUR or MONTHLY MAINTENANCE CHECKS

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

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

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

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

Maintenance Point Serviced By

Perform the 50 Hour Maintenance Checks

Check Engine Mounts for Tightness

Change Engine Oil and Replace Filter

Inspect Alternator and Air Conditioner Compressor V-Belts

Check Battery Condition and Electrolyte Level

Replace Secondary Fuel Filters

Replace Coolant Conditioner Cartridge

Check Fan Mountings, Blade, Guards and Hose Condition

Replace Compressor Main Oil Filter Elements

Clean Compressor Oil Scavenge Line Strainer

Sample Compressor Oil

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

sors Only)

Replace Hydraulic Servo Replenishing Filter Elements

Replace Hydraulic Feed Circuit Filter Elements

Clean Hydraulic Tank In-Line Air Strainer

Clean Hydraulic Tank Water Trap Filter

Replace Hydraulic Tank Breather

Check Hydraulic Tank Mounting Bolts

Clean Pump Drive Breather

Check Water Injection Pump V-Belt Tension

Page 2D
 250 HOUR or MONTHLY MAINTENANCE CHECKS
CONTINUED

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

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

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

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

Maintenance Point Serviced By

Change Water Injection Pump Oil

Check Rotary Head Oil Level

Check Feed Chain Tension

Lubricate Feed Chains

Inspect and Lubricate Chain Sprockets

Check Crawler Track Tension Adjustment

Check Oil Level - Crawler Final Drives

Replace Engine & Compressor Primary Air Cleaner Elements

Clean Central Lubrication Water Trap Filter

Check Central Lubrication Operation

Check Electrical Wiring Condition

Check Air Intake and Exhaust System

Check Dust Collector Hoses and Components

Check Decals and Nameplates

* Adjust Engine Valve Lash

* Change Oil - Crawler Final Drives

* Initial 250 Hours or Operation Only

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

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

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

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

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

Maintenance Point Serviced By

Perform the 250 Hour Maintenance Checks

Clean Engine Crankcase Breather

Change Primary Fuel Filter Element

Change Pump Drive Gearbox Oil

Replace Hydraulic Return Filter Elements

Change Rotary Head Gearbox Oil

Clean Water Injection Suction Strainer

Check Winch Oil Level

Replace Engine & Compressor Safety Air Cleaner Elements

Inspect Drill Pipe Safety Hoop

Inspect Mast Pedestal Welds

Page 2E
 1000 HOUR or 6 MONTH MAINTENANCE CHECKS

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

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

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

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

Maintenance Point Serviced By

Perform the 500 Hour Maintenance Checks

Change Hydraulic Oil

Check Compressor Mounting Hardware Torque

Change Compressor Oil

Change Air/Oil Separator Filter Element

Change Winch Oil and Clean Breather

Replace Rotary Head Gearbox Breather

Check Torque of Mast Pivot Block Bolts

Page 2F
 2000 HOUR or 1 YEAR MAINTENANCE CHECKS

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

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

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

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

Maintenance Point Serviced By

Perform the 1000 Hour Maintenance Checks

Change Engine Coolant

Check Cooler Mounting Hardware Torque

Change Crawler Final Drive Oil

Test Mast Pedestal Welds

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

Page 2G
 WHEN REQUIRED

FUEL SYSTEM
c40-53
Replace Ether Starting Aid Cylinder

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

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

When Required Maintenance Checks - Page 2A-1

AIR CLEANERS - ENGINE & COMPRESSOR 4. If the filter is dented or bunched it must be
replaced. Never rap or hit the element to
remove dirt. The primary element can be
Changing Elements cleaned with compressed air, pressurized water
or washed with detergent. If cleaning the pri-
mary element with proceed as follows:
General
Proper air cleaner servicing will result in maxi-
mum protection against dust. Proper servicing COMPRESSED AIR
can also save time and money by increasing fil-
ter life and dust cleaning efficiency. Two of the
most common servicing problems are: Over
! WARNING
Servicing and Improper Servicing. Replace or Always use a face shield and protective
clean elements only when the restriction indica- clothing when using compressed air. Fail-
tor on the filter or the warning light on the instru- ure to do so can cause eye damage or
ment panel indicate to do so. Don’t be fooled by blindness.
filter appearance, the filter should look dirty.
Careless servicing procedures can cause con- NOTICE
tamination. Use the following procedures as a Using compressed air above 30 psi (205
guide to air cleaner maintenance. kPa) can damage the filter element.

A. Blow air ALONG (not across) the pleats

SAFETY inside and outside of the element as shown.
ELEMENT

PRIMARY
ELEMENT

SERVICE
INDICATOR/NUT COMPRESSED AIR
VACUATOR
VALVE

B. After cleaning, inspect the element with a

light bulb as shown. Replace the element if
necessary.
Primary Element

1. Loosen the wing nut and gently slide the pri- PRESSURIZED WATER
mary element out of the air cleaner assembly.

2. Inspect the service indicator for the safety

NOTICE
element. Remove and replace the element if Using compressed water above 40 psi (with-
the indicator is in the red zone. out nozzle) (280 kPa) can damage the filter
element.
3. Inspect the inside of the filter housing and if A. Direct water ALONG (not across) the pleats
cleaning is required remove the safety element. inside and outside the element.
Be careful not to allow dust to enter the intake
duct. B. Air dry the element Do Not dry with a light
bulb.
Page 2A-2
C. After drying, inspect the element with a light element and tighten the wingnut.
bulb as shown. Replace the element if neces-
sary. 7. Inspect all air cleaner and air duct connec-
tions for leakage before starting the engine.

Safety Element

The safety element should be replaced every

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

1. Remove the primary element as described

earlier.

WASHING WITH DETERGENT 2. Remove the split pin and nut that hold the
A. Remove excess dust with compressed air safety element in place.
or water as described earlier.
B. Wash the element in warm water with a 3. Remove and discard the safety element.
non-sudsing household detergent or Donaldson The safety element should not be cleaned.
D-1400 Washing Compound.
C. Rise the element with clean water from both 4. Clean the inside of the filter housing espe-
sides if necessary. cially around the areas of the element sealing
D. Let dry in warm circulating air of less than surfaces.
160°F (71°C).
E. After drying, inspect the element with a light 5. Install a new safety element.
bulb as shown. Replace the element if neces-
sary. 6. Install the primary element.

INSPECTION
‘T’ STYLE AIR CLEANER

Primary Element

1. Unlatch the filter cover and remove the

cover and gasket.

2. Loosen the wing nut and gently slide the pri-

mary element out of the housing.

3. Inspect the service indicator/nut for the

5. Before installing the cleaned or new element safety element. Remove and replace the ele-
press the element gasket to ensure that it has ment if the indicator is in the red zone.
not gotten brittle.
4. Inspect the inside of the filter housing and if
6. Slide the primary element over the safety cleaning is required remove the safety element.

When Required Maintenance Checks - Page 2A-3

Be careful not to allow dust to enter the intake
duct.
COVER
LATCHES

SAFETY
ELEMENT
21237s1 SPLIT PIN

PRIMARY
ELEMENT

SERVICE
INDICATOR/NUT

BODY & TUBE

ASSEMBLY GASKET

COVER
COVER
GASKET

CUP CLAMP

DUST CUP ‘T’ Style Air Cleaner

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

Page 2A-4
not steam clean!
AIR CONDITIONER/
HEATER AIR CLEANER
Inspect Dust Cup PRE-CLEANER
ELEMENT

The dust cup at the base of each air cleaner

should be removed and emptied. Turn the
thumb screw and loosen the cup clamp.When c245-2
installing the cup, be sure the cup is fully sealed
by the gasket.

DUST COLLECTOR
C40-

Change the Filter Elements

Routine inspection of door gaskets, suction

hose, dump hoses, dusthood seals and other
wear items is necessary to ensure that there are
no leaks to the system.

THUMB SCREWS
FILTER ELEMENT

OPERATOR’S CAB

Change Air Conditioner/Heater Filter Ele-

ment

Remove and replace the filter element as

described in the previous topic.

WING NUT

When Required Maintenance Checks - Page 2A-5

Inspect the filter elements through the access
doors provided. Remove the elements by
unthreading the wingnuts. Be sure to tighten
the wingnuts after the elements have been
replaced or cleaned.

Compressed air must be clean and filtered to

ensure that there is no contamination of the
valve seats.

Filters can be ruined by operating under wet

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

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

Page 2A-6
 EVERY 8 SERVICE HOURS
OR DAILY

ENGINE

c25-3
Measure Crankcase Oil Level

1. Measure engine oil level. Maintain oil level

to FULL mark on the ENGINE STOPPED side
of dipstick.

2. Add oil if necessary through fill point. WATER

DRAIN PRIMARY
VALVE FUEL
FILTER

COOLING SYSTEM

c25-1 Check Coolant Level

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

FILLER
FILLER
CAP

Drain Fuel Water Separator Bowl COOLANT

SIGHT
GAUGE
1. Locate the water separator bowl at the base
of the primary fuel filter.

2. Open the drain valve to allow the accumu-

lated water to drain.
Adding Coolant
3. Close the drain.

! WARNING
Steam can burn. At operating temperature,
engine coolant is hot and under pressure.

8 Hour Maintenance Checks - Page 2B-1

Remove the filler cap only when the engine Check Oil Level
is stopped. Open the filler cap slowly only
when cap is cool to the touch. Check the oil level at least 10 minutes after
shutdown, with the unit level and separator
NOTICE pressure zero.

If filling the radiator via the Wiggins station, 1. Observe the oil level in the air/oil receiver
leave the radiator cap off to prevent pres- tank sightglasses.
sure from building up during filling.

1. Remove the radiator filler cap slowly. 1

! WARNING 2
40-60 OIL LEVEL
Cooling System Conditioner contains alkali. SIGHTGLASS
Avoid contact with skin and eyes to prevent
personal injury.

2. Inspect the condition of the cap gasket.

Replace if necessary.

3. Maintain the coolant level to the bottom of

the filler tube.

4. Replace the cap and tighten.

NOTE !
• Inspect for coolant leaks, damaged or deteri- The oil level should be maintained so that it
orated hoses and obstructed radiator cores. is visible in the center sightglass.
• Any of these may cause damage to the
engine through overheating. NOTICE
Do not mix compressor oils. Incompatible
fluids may cause compressor damage or
COMPRESSOR
reduced oil change intervals.

! WARNING 2. Add oil if necessary, through the fill point (1)

or Wiggins station. Do not overfill; the oil level
• Do not remove caps, plugs, or other com- must not rise above the upper sightglass (2).
ponents while the compressor system is
running or pressurized.

• Stop the engine and allow time for the Drain Condensate From Air/Oil Receiver
system to relieve all internal pressure Tank
before servicing. Check the air pressure
gauge in the cab to ensure pressure is Remove the plug from the valve and open the
zero. valve and drain off water until oil appears.

NOTE!
Water can cause compressor failure. If the oil

Page 2B-2
appears cloudy, water is entering the system. Some models do not have a dirt alarm indicator
Determine the point of entry and rectify the on the filter housing. In this case the filter con-
problem, then drain, flush and refill the system. dition is monitored by a warning lamp on the
instrument panel.
.

25- 51
ELEMENT
INDICATOR
245-8

RECEIVER TANK RECEIVER

DRAIN TANK

BATTERY
BOX

HYDRAULIC SYSTEM

Check Oil Return Line Sightglass Check Oil Level in Reservoir Tank

When the engine is running, inspect the sight- 1. Fully retract all hydraulic cylinders and shut-
glass (1) to ensure that oil is visibly flowing. If down the engine.
oil is not visible, clean the in line strainer (2).
2. Look at the sight gauge. The oil level must
1 be maintained to the decal line. Add oil if
necessary.

245-30

HYDRAULIC
OIL
245-9 SIGHT
GAUGE

2 COMPRESSOR FILTER
HYDRAULIC
TANK

Check Air/Oil Separator Element Indicator

When the engine is running, ensure the indica-

tor is not showing its red band. If the red band
is fully visible, change the separator element.

8 Hour Maintenance Checks - Page 2B-3

Adding Oil
HYDRAULIC
TANK
DRAIN
! WARNING
• Before filling, shutdown the engine and
relieve all pressure from the tank by 245-11
opening the tank vent ball valve.

• Double check that all hydraulic cylinders

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

Add oil only via the Wiggins station or the hand

pump.

Check Hydraulic Tank Air Pressure Regula-

NOTICE tor Gauge
• Do not mix hydraulic oils.
The tank is pressurized to prevent entry of con-
• Incompatible fluids may cause pump tamination and to prime the hydraulic pumps.
damage and reduce oil change intervals.
Inspect the air pressure gauge while the engine
is running. It should read between 3 and 5 p.s.i.

REGULATOR
GAUGE Check Servo Replenishing Filters Dirt
Alarms

The indicators should be checked to ensure that

245-12 they are not seized and for oil bypassing the fil-
ter.

1. With the engine stopped, turn the indicator

HYDRAULIC HAND (1) through its range of movement. It should
TANK PUMP
turn freely.

2. With the engine and pumps running,

observe the position of the indicator. It should
point to the green sector. If it points to either the
Drain Water From Reservoir Tank
yellow or red sectors, the filter element should
be changed, as it is clogged and oil is bypassing
Open the valve and drain off water until oil
the element.
appears.

NOTE !
Water can cause pump failure. If the oil
appears cloudy, water is entering the system.
Determine the point of entry and rectify the
problem, then drain, flush and refill the system.

Page 2B-4
 NOTICE
• Do not overlubricate the universal joints.
1
• Seal rupture can occur and allow ingress
245-34 of dirt.

• Do not use a pressurized grease gun.

PUMP DRIVE GEARBOX

SERVO
FILTERS
Check Oil Level

1. Locate the dipstick on the pump drive gear-

box.

FILL PLUG

DRIVESHAFT

PUMP DRIVE
GEARBOX 245-16
Lubricate Pump Driveshaft

Ensure the fittings and grease gun are clean DIPSTICK

before servicing.

1. Remove the wingnut and open the access

door.

2. The oil level should be between the LOW

WINGNUT and FULL marks on the dipstick. If necessary
add oil of the type specified in the “Coolant,
Fuel and Lubricant Specification” section of this
245-34 manual through the fill opening.
ACCESS
DOOR

UNDERCARRIAGE

Check for Debris

2. Clean the grease fitting in each universal Visually inspect the undercarriage for rocks,
joint and lubricate with two strokes from a hand debris and built-up dirt. Clean idlers and
grease gun. sprockets as necessary.

8 Hour Maintenance Checks - Page 2B-5

AIR INLET CENTRAL LUBE SYSTEM

Check Air Cleaner Element Indicator Check Central Lubricator Grease Level

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

CLIP

245-36

Drain Water and Check Pump Oiler Level

ELEMENT INDICATORS
1. Unscrew tap (1) under the bowl to drain the
water. Close the tap after draining.

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

SAFETY
ELEMENT

PRIMARY 245-37
ELEMENT

SERVICE 1 2
INDICATOR/NUT

VACUATOR
VALVE

Page 2B-6
MISCEALLANEOUS

FILLER
CAP
Inspect Winch Wire Rope

Visually inspect the winch wire rope for kinking,

twisting and general wear, lubricate if required.
Replace as necessary and discard in accor-
dance with 3.5 of ISO 4309:1990. 245-17

LEVEL
Check Bit/Hammer Lubricator Oil SIGHTGAUGE

Locate the lubricator tank sight gauge and fill as

required through the filler port.

Check Feed Chain Adjustment

With the mast lowered and the rotary head at

the top of it’s travel, check the sag of the chain
as shown.

TABLE ROTARY HEAD

3mm (1/8”)

245-41

FEED CHAIN
ADJUSTMENT
HOIST CHAIN
ADJUSTMENT

8 Hour Maintenance Checks - Page 2B-7

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

WEEKLY Replace Air Compressor Main Oil Filter Ele-

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

Replace Feed Circuit Filter Element

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

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

3. Replace the protective cap.

LUBRICATION
FITTING

245-46 AIR SWIVEL

50 Hour Maintenance Checks - Page 2C-1

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

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

1. With the oil warm and the engine stopped,

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

c40-65

OIL PAN

c25-10
PLUG

2. Install the plug when draining is completed.

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

MOUNTS
(REAR)

c40-66
OIL FILTER

c25-11 REMOVE
TO ACCESS
FRONT MOUNTS

4. Clean the filter base to ensure that all traces

of the old seal are removed.

5. Coat the seal on the new filter cartridge with

clean engine oil.

250 Hour Maintenance Checks - Page 2D-1

6. Install the new filters by hand. When the fil- ALTERNATOR and AIR CONDITIONER COM-
ter seal contacts the base, tighten the filter 3/4 PRESSOR V-BELTS
turn more.

NOTE ! Inspect
Do not overtighten the filter.
Inspect the belts for wear. Replace the belts if
7. Refill the crankcase. See the “Refill Capaci- worn, cracked or frayed.
ties” and “Fuel, Coolant and Lubricant Specifi-
cations” tables.
Check Belt Adjustment
8. Start the engine and run long enough to
ensure that the lube system cavities and filter 1. Remove the capscrews securing the belt
have oil. cover and remove the cover to access the
belts..

DIPSTICK BELT
COVER

C25-11

REMOVE
TO ACCESS
c40-63 BELTS

OIL FILLER

C40-63

9. Stop the engine and allow the oil to drain 2. Apply a 12 kg (25 lb.) force perpendicular to
back to the sump for a minimum of five minutes. the belt, midway between the driving and driven
The oil level reading should indicate FULL on pulley. Measure the belt deflection. Proper belt
the ENGINE STOPPED side of the dipstick. deflection is 15 to 20 mm (9/16 to 7/8 inch).
Adjust the belt tension as required.

Engine Valve Lash (Initial)

Adjust Belt
ADJUST
1. Loosen the alternator pivot bolt and the lock-
Adjust valve lash (clearance) at the first oil nut on the belt tensioner rod.
change. All subsequent adjustments are to be
performed at the “Every 3000 Service Hour”
interval.

Refer to Engine Valve Lash in the Caterpillar®

Maintenance Manual for the procedure.

Page 2D-2
 • Battery electrolyte contains sulfuric acid.
It will cause severe personal injury if it
contacts skin or eyes.

• Always wear protective glasses when

working with batteries.

C25-3 1. Open the battery box access door.

LOCKNUT

C25-51
ALTERNATOR
BELT
TENSIONER

2. Turn the adjustment bolt until correct belt

deflection is obtained.

3. Tighten the locknut.

BATTERY
ACCESS
4. If new belts are installed, check the belt DOOR
adjustment after 30 minutes of engine opera-
tion.
2. Clean the tops of the batteries with a clean
5. Secure the belt cover. cloth. Check for corrosion or looseness of the
terminals and cable clamps. If necessary,
replace, clean or tighten cable clamps.
BATTERIES 3. Clean the cable clamps and terminals with a
wire brush, then coat them with petroleum jelly.
Check Battery Electrolyte Level and Clean
Batteries ! WARNING
DO NOT top off batteries with acid.
Locate the battery box located at the left front of
the machine. 4. Remove the battery fill caps. Maintain the
electrolyte level to the bottom of the filler tube.
If the level is low, top up with distilled or dem-
! DANGER ineralized water.

• Batteries give off explosive hydrogen 5. Replace the fill caps and close the cover.
gas.

• Do not smoke or allow any other ignition

source near the batteries.

250 Hour Maintenance Checks - Page 2D-3

FUEL SYSTEM 7. Open the fuel supply valve.

8. Prime the fuel system. See the topic “Prim-

! WARNING ing the Fuel System”.

• Fuel leaked or spilled onto hot surfaces 9. Start the engine and inspect for leaks.
or electrical components can cause a
fire.

• Disconnect the battery when changing Priming the Fuel System

fuel filters.
Priming the fuel system fills the fuel filters and
removes air from the fuel system after the filters
Change Secondary Fuel Filters have been changed. Refer to the Caterpillar®
engine Operation and Maintenance manual if
1. Stop the engine. the engine fuel supply has run dry.

2. Close the fuel supply line valve (if fitted). 1. Turn the priming pump plunger counter-
clockwise and pull out the plunger.
3. Use a strap wrench to remove the fuel filters.

FUEL
PRIMING
PUMP
PLUNGER

C40-61

SECONDARY
FUEL
FILTERS
2. Pump the plunger to fill the new filter ele-
ment. Continue pumping until resistance is felt,
4. Clean the filter base. Be sure to remove all indicating that the filter is full.
of the old seal.
3. Turn the pump handle knob clockwise to
5. Apply a light coat of clean fuel to the new fil- lock the plunger.
ter seals.
4. Start the engine and check for fuel leaks.
6. Install the new filters by hand. When the
seal contacts the base, tighten 3/4 turn more.

NOTE !
Do not overtighten the filters.

Page 2D-4
COOLING SYSTEM

Change Coolant Conditioner Cartridge

COOLANT
CONDITIONER
Check the cooling system only after the engine CARTIDGE
is stopped and cool to the touch. Refer to the
engine manufacturer’s Operation and Mainte-
nance Manual for coolant testing and additional
specifications.

NOTE !
Ensure that a MAINTENANCE (not a PRE-
CHARGE) conditioner cartridge is used for this
service, unless the coolant is also being OPTIONAL CARTRIDGE LOCATION
changed.

1. Close the coolant inlet and outlet valves. NOTE !

Do not overtighten the cartridge.
2. Use a strap wrench to remove the cartridge.
5. Open the shutoff valves on the coolant lines

! WARNING 6. Check for leaks with the engine running.

Engine coolant contains alkali - avoid con-
tact with skin and eyes.

3. Clean the filter base. Check Radiator Mounting Hardware Torque

Using a torque wrench and the torque table
4. Install the new cartridge by hand. When the listed in this manual, check the radiator mount-
seal contacts the base, tighten 3/4 turn more. ing hardware.

STANDARD CARTRIDGE LOCATION

Check Cooler Fan Finger Guards and Radia-
tor Blade Condition

SHUTOFF
VALVES c40-61 245-23
FINGER
GUARD
HARDWARE

COOLANT
CONDITIONER
CARTIDGE

250 Hour Maintenance Checks - Page 2D-5

Check the tightness of the fan guards and
inspect the fan blades for cracks. Replace if
necessary. 1

COMPRESSOR 2

Change Main Oil Filter Elements

3 GROMMET

The filters should be changed every 250 hours

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

COMPRESSOR 7
MAIN OIL FILTER
c25-8 4

BASE

SHOWN
WITH MANUAL INDICATOR
ing to prevent dirty oil from the elements from
dripping into the housing.

NOTICE
! WARNING Be sure to inspect the inside of the filter
base to ensure that the element grommet
Ensure the engine is shutdown and the
was removed at the time the lower element
internal pressure relieved.
was removed.
1. Unscrew the filter housing cap (1).
4. Replace the ‘O’ ring and backup rings on the
cap and base if necessary.
2. Remove the cap (1), spring (2) and washer
(3).
5. Install two new elements, ensuring they are
joined with the plastic connector.
3. Quickly remove the two filters from the hous-
6. Install the washer, spring and cap.
Page 2D-6
7. Check the oil level and replenish if neces- 2. Wash the screen clean with a non-flamma-
sary. ble solvent and dry with compressed air.

8. Start the engine and inspect for leaks. 3. Reinstall the strainer and plug.

NOTE !
Only Schroeder elements are authorized for use
in the compressor system. Use of any other Change or Sample Compressor Oil
brand must be authorized by the Sandvik Engi-
neering Department. NOTE !
The oil change interval depends on the type of
oil and whether or not oil analysis is being used.
See the ‘Recommended Lubrication Viscosity
Clean Oil Return (Scavenge) Line Strainer Chart’ in section 1 of this manual for details.

The oil line strainer should be cleaned every NOTE !

250 hours or when oil is not visible in the sight- The oil should be warm when changed.
glass.

! WARNING ! WARNING
Avoid touching hot oil or components -
Be sure the engine is shutdown and pres- these can cause burns.
sure relieved before proceeding.

1. Unthread the plug and remove the screen ! WARNING

from the housing. Ensure the engine is shutdown and internal
pressure relieved.

Locate the drain valve and take an oil sample

for analysis. If required, change the oil as
described in the 1000 Hour Maintenance Sec-
tion.
C25-8

25- 51

RECEIVER TANK
DRAIN

BATTERY
BOX

PLUG

250 Hour Maintenance Checks - Page 2D-7

HYDRAULIC SYSTEM
4

Change the Servo Replenishing Filter Ele-

ments

The filter elements should be changed after the

first 50 hours of operation and at each 250
hours thereafter, or as indicated by the dirt 5
alarm indicator.

3
245-34 1
SERVO 2
REPLENISHING
FILTERS

3. Remove the element (2) together with grom-

met (3).

4. Thoroughly clean the element housing and

inspect the bypass mechanism (4) on the filter
base and O-ring (5) for damage. Replace if
necessary.

5. Install a new element and replace the ele-

ment housing. Tighten the housing firmly but do
! WARNING not overtighten.
Avoid skin contact with hot oil or compo-
nents - burns will result. 6. Start the engine and inspect for leaks.

1. Ensure the engine is stopped, and the

hydraulic tank pressure relieved.
Change Feed Cylinder Circuit Filter Element
2. Unthread the filter housing (1).
The filter elements should be changed after the
first 50 hours of operation and at each 250
hours thereafter, or as indicated by the DMS.

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

1. Relieve the hydraulic tank pressure by open-

ing the ball valve on the hydraulic tank as
shown.
Page 2D-8
 8. Start the machine and inspect for leaks.
BALL VALVE
NOTE!
Only Schroeder elements are authorized for use
in the hydraulic system. Use of any other brand
must be authorized by the Sandvik Engineering
Department.

1190e-35
Clean Hydraulic Reservoir In-Line Air
Strainer

! WARNING
The air line to the hydraulic tank may be
pressurized. Vent air pressure by opening
2. Locate the filter assembly located between
the air vent ball valve.
the hydraulic tank and the mast pedestal
Unthread the bolts and remove the element
1. Shut down the engine and vent air pressure
housing to expose the elements.
by opening ball valve (1).

2. Remove strainer (2) from the air line.

3. Clean the strainer in a non-flammable sol-

MOUNTING vent and dry with compressed air.
BOLTS

4. Replace the strainer.

Clean the Water Trap Filter

1. Unscrew the water trap filter housing (3).

2. Remove the filter element.

3. Clean the element in a non-flammable sol-

vent and dry with compressed air.
3. Remove the filter from the housing and drain
the oil into an appropriate container. 4. Replace the element and screw the housing
on hand tight.
4. Inspect the housing for contaminents. Clean
the housings.

5. Install a new element. Replace the Breather/Filter

6. Replace the O-ring on the cover. 1. Unscrew breather/filter assembly (4) and
discard.
7. Check the oil level and replenish if neces-
sary.
250 Hour Maintenance Checks - Page 2D-9
 PUMP DRIVE GEARBOX
Breather/Filter
4

Check Clean Breather

Valve
5
Regulator 1. Remove the breather.
7 Ball
Valve
(Vent) 2. Clean in a non-flammable solvent and dry
1 with compressed air.
Pressure 3. Install the breather.
Relief
Valve
6
BREATHER
Water Trap
3 245-16
Air Strainer
2

PUMP
DRIVE

NOTE !
Ensure that the check valve assembly (5) has
been retained in the fitting and not removed with
the breather/filter assembly.

2. Clean the contact area of breather/filter (4)

ensuring all traces of the old seal are removed. WATER INJECTION PUMP

3. Apply a thin film of clean oil to the seal sur-

face on the new breather/filter assembly. Check Belt Tension

NOTICE ! WARNING
Do not overtighten the filter/breather Ensure the keys are removed and the
assembly. machine has been tagged-out before
proceeding.
4. Screw the new filter assembly onto the
check valve fitting by hand. 1. Undo the four bolts (1) and remove belt drive
guard (2).

2. Inspect the condition of drive belts. Replace

Check Hydraulic Tank Mounting Hardware as a pair if cracked or frayed.

Inspect the mounts at the four corners of the 3. Measure the belt deflection using thumb
tank for signs of cracks or movement and re- pressure (approximately 12 kg (25 lbs) midway
torque the mounting bolts. between the pulleys. Deflection should be 13 to
19 mm (1/2 to 3/4 inch).
Page 2D-10
 2. Replace the drain plug.

3. Refill the compartment.

2 4. Replace fill plug (1).

1
1

2
To adjust:

1. Loosen 4 bolts (5).

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

tighten the belts and then retighten bolts (). ROTARY HEAD

3. Replace belt drive guard (2).

Check Gearbox Oil Level

7 1. With the mast raised, lower the rotary head

to access the fill plug.

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

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

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

this manual if necessary.

6 4. Clean and install the fill plug when finished.

BELT ADJUSTMENT
5

Change Oil ROTARY

HEAD
MOTOR

! WARNING 245-45
Use caution and avoid touching hot oil or
components - these can cause burns.

NOTE !
The oil should be warm when changed. FILL/LEVEL
PLUG

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

allow the oil to drain into a suitable container.

250 Hour Maintenance Checks - Page 2D-11

FEED SYSTEM wear because of the accumulation of drilling
dirt.

Check Feed Chain Adjustment UPPER SPROCKETS

With the mast lowered and the rotary head at 245-43

the top of it’s travel, check the sag of the chain
as shown.

Lubricate Feed Chain

1. Clean the chain with 30 psi compressed air

or with a brush. Do Not Pressure Wash or
Steam Clean the Feed Chains!

2. Brush or spray a light penetrating oil (such

as WD-40) onto the chains to lubricate internal UNDERCARRIAGE
surfaces of the chain and drive out water.

3. Brush SAE 40, or heavier, on all chain sur- Check Track Tension and Adjust if Neces-
faces. to provide a barrier against dirt and sary
moisture, and prevent corrosion.
1. Propel the machine backwards for a dis-
tance of 20 meters on level ground. Bring the
machine to a SLOW STOP and shutdown the
Inspect and Lubricate Chain Sprockets engine.

Inspect all sprockets for wear and lubrication 2. Place a straightedge, long enough to reach
even if an auto-lubrication system is used. The from the idler to the upper roller, on top of the
lower sprockets are particularly susceptible to track.

TABLE ROTARY HEAD

3mm (1/8”)

245-41

FEED CHAIN
ADJUSTMENT
HOIST CHAIN
ADJUSTMENT

Page 2D-12
 TRACK LOOSENING

! WARNING
• Grease may vent from the valve at high
pressure.
• Never look at the valve to see if grease is
coming out of it - watch the idler and
track chain for movement.
• Loosen the relief valve one turn only.
GROUSER
• If the track does not loosen, close the
relief valve and contact your Caterpillar®
3. Where the track sags the most, measure the dealer.
distance between the top of the track grouser
and the bottom of the straight edge. When the 1. To slacken the chain, undo the relief valve
track is adjusted correctly, the distance should (2), NO MORE than one turn.
be 40 to 55 mm (1-5/8 to 2-1/8 inches).
2. Tighten relief valve (2) to 34 Nm (25 ft lbs)
when the desired track tension is reached.

Adjusting Track Tension 3. Propel the machine back and forth to equal-
ize the pressure.

TRACK TIGHTENING 4. Check the track tension as described earlier.

1. Clean the grease fitting (1) on the track

adjuster.
Check Final Drive Gearbox Oil Level

Check the crawler final drive gearbox oil level

as follows:
1
1. Position the machine on a level surface.

2. Position one of the final drives so that the

TRACK ADJUSTMENTS 2 drain plug is at the bottom.

FILL/
LEVEL
PLUG

2. To tighten the track chain, pump grease into

the fitting until correct track tension is reached.

3. Propel the machine back and forth to equal-

ize the pressure.

4. Check the track tension as described earlier. DRAIN PLUG

3. Remove the level/fill plug. The oil should be

250 Hour Maintenance Checks - Page 2D-13

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

5. Clean and replace the plug. 3. Inspect the service indicator/nut for the
safety element. Remove and replace the ele-
6. Repeat the procedure for the other final ment if the indicator is in the red zone.
drive.
4. Inspect the inside of the filter housing and if
cleaning is required remove the safety element.
Be careful not to allow dust to enter the intake
AIR INLET - ENGINE & COMPRESSOR duct.

COVER
Replace Primary Elements LATCHES
SAFETY
ELEMENT
1. Loosen the wing nut and gently slide the pri-
SPLIT PIN
mary element out of the air cleaner assembly.
PRIMARY
21237s1 ELEMENT
2. Inspect the service indicator for the safety
element. Remove and replace the element if
the indicator is in the red zone.

3. Inspect the inside of the filter housing and if SERVICE

cleaning is required remove the safety element. INDICATOR/NUT
Be careful not to allow dust to enter the intake
duct.
GASKET
4. If the filter is dented or bunched it must be COVER
replaced. Never rap or hit the element to ‘T’ Style Air Cleaner
remove dirt.
5. If the element is dented or bunched it must
be replaced. Never rap or hit the element to
SAFETY
ELEMENT
remove dirt.
PRIMARY
ELEMENT

CENTRAL LUBRICATION SYSTEM

Clean Water Trap Filter

SERVICE
INDICATOR/NUT
VACUATOR 1. Disassemble the filter and clean the parts in
VALVE
a non-flammable solvent.

2. Dry with filtered compressed air and re-

‘T’ STYLE AIR CLEANER assemble.

Page 2D-14
 Check Decals and Nameplates

Walk around the machine and check the condi-

245-37 tion of the safety and information decals. Refer
to the parts manual for decal locations and
ordering information.

WATER TRAP
FILTER

Check System Operation

Inspect all lubrication points serviced by the

central lubrication system to ensure that ade-
quate lubricant is being delivered. Check the
following areas:
• Undercarriage Pivot Points
• Feed Chain Sprockets and Winch
Sheaves
• Loader Pivots
• Mast Lock Pivots

MISCELLANEOUS

Check Electrical Wiring

Visually inspect the electrical wiring for wear

particularly near areas of high heat.

Check Intake and Exhaust Systems

Visually inspect the intake and exhaust system

pipe connections.
Inspect the engine exhaust muffler for wear.

Check Dust Collector Hoses

Visually inspect the condition of the dust collec-

tor hoses. Replace as necessary.

250 Hour Maintenance Checks - Page 2D-15

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

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

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

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

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

3

4. Remove the breather element from cover (3)

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

5. Apply clean petroleum jelly to rubber parts

and install the seal.

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

in place with clamp (2).

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

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

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

• Disconnect the battery when changing

fuel filters.

Replace Primary Fuel Filter/Water Separator

1. Stop the engine.

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

500 Hour Maintenance Checks - Page 2E-1

 FUEL
PRIMING
PUMP
PLUNGER
40-61
c25-3
BASE

ELEMENT

BOWL
DRAIN VALVE

4. Clean the filter base of any gasket material.

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

8. Open the fuel supply line valve.

PUMP DRIVE GEARBOX
9. Prime the fuel system. See the topic “Prim-
ing the Fuel System”.
Change Oil

The oil should be changed at 500 hour intervals,

or whenever the oil shows traces of dirt, water,
Priming the Fuel System
or the effects of overheating (discoloration or
strong odor).
Priming the fuel system fills the fuel filters and
removes air from the fuel system after the filters
NOTE !
have been changed. Refer to the Caterpillar®
The oil should be warm when changed.
engine Operation and Maintenance manual if
the engine fuel supply has run dry.
! WARNING
1. Turn the priming pump plunger counter- Use caution and avoid touching hot oil or
clockwise and pull out the plunger. components - these can cause burns.

Take an oil sample for analysis.

1. While the unit is still warm, remove the drain

Page 2E-2
 1. Relieve the hydraulic tank pressure by open-
FILL PORT
245-16 ing the ball valve on the hydraulic tank.

COVER
PUMP DRIVE SCREWS BALL VALVE

DIPSTICK

245-49

plug located at the base of the dipstick and

allow the oil to drain into a suitable container.
Examine the oil for contamination or metal parti-
cles.

2. Inspect and clean the drain plug. HYDRAULIC TANK

3. Install the drain plug. 2. Slowly unthread the filter cover screws and
remove the spring loaded filter cover to expose
4. Refill the housing through the fill port, the elements.
located on top of the housing, and replace the
fill plug. See the “Recommended Lubricant Vis-
cosities” table. Check the oil level using the dip- 3. Quickly remove the elements from the hous-
stick provided. ing and drain the oil into an appropriate con-
tainer.
NOTICE 4. Inspect the housing for contaminents. Clean
Overfilling the gearbox can cause overheat-
the housings.
ing and damage will result.
5. Install two new elements, ensuring they are
5. Start the engine and inspect for leaks.
joined with the plastic element connector.

6. Replace the O-ring on the cover and install

the cover.
HYDRAULIC SYSTEM
7. Check the oil level and replenish if neces-
sary.
Change Return Filter Elements
8. Start the engine and inspect for leaks.
The filter elements should be changed after the
first 50 hours of operation and at each 500
hours thereafter, or as indicated by the DMS.
NOTE!
Only Schroeder elements are authorized for use
! WARNING in the hydraulic system. Use of any other brand
must be authorized by the Sandvik Engineering
Avoid skin contact with hot oil or compo-
Department.
nents - burns will result.

500 Hour Maintenance Checks - Page 2E-3

 COVER
SCREWS DRAIN PLUGS

245-50

2. inspect, clean and replace the plugs.

3. Refill the gearbox through the fill/level port

with the type of oil specified in Section 1.

1471-S 245-45

FILL/LEVEL
PLUG

4. Replace the fill/level plug. Operate the

ELEMENT rotary head and check for leaks.
CONNECTOR

ROTARY HEAD WATER INJECTION

Change Gearbox Oil Clean Suction Strainer

1. with the mast raised and the rotary head 1. Drain the water tank by removing the drain
lowered to a working height, remove the two plug and opening the valve.
drain plugs from the gearbox and allow the oil to
drain into a suitable container. 2. Unscrew the fitting and remove the strainer
from the tank.

Page 2E-4
 AIR INLET - ENGINE & COMPRESSOR

Replace Safety Elements

The safety element should be replaced every

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

1. Remove the primary element as described

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

Check Oil Level 6. Install the primary element.

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

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

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

fill to the port opening with the type of lubricant

specified in Section 1.

SERVICE
INDICATOR/NUT
VACUATOR
245-19 SIGHT VALVE
GAUGE

‘T’ STYLE AIR CLEANER

The safety element should be replaced every

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

2. Remove the split pin and nut that hold the

safety element in place.

3. Remove and discard the safety element.

The safety element should not be cleaned.

4. Clean the inside of the filter housing espe-

cially around the areas of the element sealing
surfaces.

5. Install a new safety element.

6. Install the primary element.

COVER
LATCHES
SAFETY
ELEMENT
SPLIT PIN
PRIMARY
21237s1 ELEMENT

SUPPORT WELDS

SERVICE
INDICATOR/NUT
MOUNTING HARDWARE

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

MAST and PEDESTAL

Inspect the Drill Pipe Safety Hoop

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

Page 2E-6
 EVERY 1000 HOURS OR
DRAIN
6 MONTHS VALVE

245-11
HYDRAULIC SYSTEM

Change Hydraulic Oil

NOTE!
The oil should be warm when changed.

! WARNING 4. Replace the return filter elements as

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

1. Take an oil sample for analysis.

COMPRESSOR
2. Relieve the hydraulic tank pressure by open-
ing the ball valve on the tank as shown.
Re-Torque Compressor Mounts

Using a torque wrench, re-torque the compres-

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

245-49 C25-9

HYDRAULIC TANK BALL VALVE

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

suitable container.

MOUNTING
HARDWARE

1000 Hour Maintenance Checks - Page 2F-1

Change Air/Oil Separator Element
HIGH PRESSURE 1
Refer to the 250 Hour Maintenance Checks for COMPRESSOR
oil sampling procedures. SYSTEM 2

Change the air/oil separator element when the 3

service indicator shows red.
4

245-8
7
ELEMENT
INDICATOR

! WARNING
Be sure that the engine is stopped and pres-
sure relieved before working on the receiver
tank. 5. Install a new element (7) in place.
HIGH PRESSURE COMPRESSOR SYSTEMS
6. Install retaining plate (5) and nuts (4).
1. ENSURE the engine is shut down and the Torque to 6.9 kg/m (50 ft. lb.).
internal pressure relieved.
7. Inspect the condition of cover gasket (3).
2. Remove the bolts (1) from cover (2). Replace if damaged.

3. Lift off the filter cover (2) and gasket (3). 8. Replace cover (2) and torque bolts (1) to 190
Remove the nuts (4) and retaining plate (5). - 210 FT LB (256 - 283 Nm).

4. Lift out the filter element (7) and wipe the LOW PRESSURE COMPRESSORS
element seal and base areas clean.

NOTE!
! WARNING
Inspect the element for damage. Never install Be sure that the engine is stopped and pres-
damaged elements back into the compressor sure relieved before working on the receiver
system. tank.

1. Ensure the engine is shut down and the

Page 2F-2
internal pressure relieved. 6. Replace cover (3) and torque hardware (2)
to 270-292 ft-lbs (364-394 Nm). Install scav-
2. For ease of removal, remove scavenge tube enge tube (1) in the cover.
(1) from cover (3).

3. Remove hardware (2) and lift off receiver

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

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

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

25- 51

RECEIVER TANK
DRAIN
! WARNING
Installing a filter element without staples in
BATTERY
the upper gasket can cause a static charge BOX
and result in fire. Do not remove the staples
from the upper sealing gasket.

5. Install a new element (4) in place making

sure that gaskets (5) are in place on both sides
of the element flange and that the upper gasket Changing the Oil
has staples (6) 180° apart to disipate static
charge. 1. Locate the drain valve and drain the oil into a
suitable container.

1000 Hour Maintenance Checks - Page 2F-3

2. If required, change the separator element.
Refer to the 1000 hours Maintenance Check.

3. Close the drain valve and install the plug.

SIGHT
4. Refill the tank with oil of the type specified in 245-19 GAUGE
the “Recommended Lubricant Viscosities” table
in Section 1.

5. Start the engine and check for leaks.

6. Refill the winch with the type of oil specified

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

7. Remove the vent and clean it in a solvent.

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

1. Unspool all but the final wrap of wire rope

from the drum. ROTARY HEAD
2. Lower the mast to the horizontal position.
Replace Gearbox Breather
3. Disconnect and plug the hoses to the winch
motor and the motor ports. 1. With the mast raised, lower the rotary head
to access the breather.
VENT

245-53

245-51
BREATHER

WINCH
MOTOR

4. Using a suitable lifting device, support the

winch. Remove the mounting hardware and
lower the winch.
2. Remove the breather and replace with a
5. Remove the sight glass and pour the oil into
new breather.
a suitable container.

Page 2F-4
MAST

Check the Torque of the Pivot Block Bolts

Bend the bolt locking tabs back and check that

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

PIVOT BLOCK
BOLTS (SHOWN
WITH LOCKING
TABS BENT UP)

1000 Hour Maintenance Checks - Page 2F-5

Page 2F-6
 EVERY 2000 HOURS OR
1 YEAR

COOLING SYSTEM

245-52
Change Coolant

! WARNING
Steam can burn. Allow coolant to cool
before draining. Remove the radiator filler RADIATOR DRAIN
cap slowly to relieve pressure. VALVE

1. Loosen the radiator filler cap slowly to

release pressure before removing the cap.
NOTICE
Cooling System Conditioner contains alkali.
Avoid contact with skin and eyes to prevent
personal injury.
FILLER
CAP
4. Replace the coolant conditioner cartridge
with a precharge cartridges (refer to “250 Main-
tenance Checks” for more information on
replacing these cartridges).

SHUTOFF
VALVES

c25-6

2. Open the drain valve underneath the radia-

COOLANT
tor. Allow the coolant to drain into a suitable CONDITIONER
container. CARTRIDGE

3. Close the radiator drain valve.

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

5. Fill the system with a solution of approved

2000 Hour Maintenance Checks - Page 2G-1
water and antifreeze. See “Refill Capacities” for
amount of solution needed.
FILL/LEVEL
NOTE! PLUG
Add solution slowly at 20 litres (5 U.S. gallons)
or less per minute to avoid air locks.
DRAIN
PLUG
6. Start the engine with the radiator filler cap
off. Operate the engine until the thermostat
opens and coolant level stabilizes. Fill the cool-
ing system to the bottom of fill tube. Install the
1. Position the final drive so that oil drain plug
radiator filler cap.
is positioned at the bottom.

2. Remove fill/level plug and take an oil sample

for analysis.
Re-Torque Cooler Mounts
3. Remove the drain plug. Allow the oil to drain
Check the torque of the cooler mounting hard-
into a suitable container.
ware. See “Recommended Torque Values”.
4. Clean the plugs and inspect the O-rings.
Replace the drain plug.

5. Refill the final drive with oil of the type speci-

fied in the “Recommended Lubricant Viscosi-
ties” chart.

245-52
NOTICE
Allow time for the oil to flow through the
gears and ensure that the entire quantity of
oil specified for each compartment is added.
Do not operate the machine with low final
drive oil - final drive failure will result.
RADIATOR MOUNTS

6. Replace the fill/level plug.

UNDERCARRIAGE 7. Completely remove oil spilled onto surfaces.

8. Start the machine and allow the machine to

Change Crawler Final Drive Oil propel in both directions. Position the drives to
recheck the oil levels. Check for leaks after one
NOTE ! hour of operation.
The oil should be warm when changed.

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

Page 2G-2
MAST and PEDESTAL
PIVOT BLOCK
BOLTS (SHOWN
Change the Pivot Block Bolts and Hardware WITH LOCKING
(Every 4000 Hours) TABS BENT UP)

1. Lower the mast into the mast support.

2. Lockout and tagout the machine.

3. Bend the bolt locking tabs back.

4. Support the block cap, it weighs approxi-

mately 17 kg (40 lbs).

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

7. Remove the existing dowel pins and replace

them.

8. Install the block cap over the dowels.

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

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

10. Diagonally tighten the bolts until a torque of

881 Nm (650 ft-lbs) is achived.

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

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

2000 Hour Maintenance Checks - Page 2G-3

Page 2G-4
 SECTION 3 MACHINE STORAGE

GENERAL

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

SHORT TERM STORAGE

General

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

Preparation for Short Term Storage

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

1. Clean the entire machine.

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

3. Lubricate all grease points on the machine.

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

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

5. Contact the engine manufacturer for engine storage procedures.

6. Clean and lubricate the feed chain or cables.

Removal from Short Term Storage

1. Lubricate all points equipped with grease fittings.

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

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

3-1
4. Check the oil level in the hydraulic reservoir. Add oil of the proper type, as specified in Section 1.

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

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

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

LONG TERM STORAGE

General

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

Preparation for Long Term Storage

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

1. Clean the entire machine thoroughly.

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

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

4. Liberally lubricate all points equipped with grease fittings.

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

6. Contact the engine manufacturer for engine storage procedures.

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

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

9. Replace the hydraulic filter elements.

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

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

12. Apply a suitable preservative grease to exposed portions of hydraulic cylinder piston rods, con-
trol valve spools, and other exposed unpainted surfaces.

3-2
13. When the machine is parked in the spot it is to be stored in, fill the hydraulic reservoir to the top
with hydraulic oil.

Removal From Long Term Storage

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

2. Lubricate all points equipped with grease fittings.

3. Check the oil levels in the gear housings including the winch and crawler final drive. Add oil as
required of the types specified in Section 3.

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

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

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3-4