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Down-The-Hole Drill

OPERATION MANUAL

IMPORTANT Before operating or servicing the machine, read and understand the contents of this manual thoroughly.


Operation


2. Specifications 2.1 Machine Nomenclature

3

2

1

4

6 8

8

9 11

5

7

15 10

12 14 13

6. Operator Cab

1. Magazine

11. Rotary Head

7. Pre-Cleaner

2. Guide Shell

12. Fuel Tank

8. Foot Pad

3. Arm

13. Track Frame

9. Hydraulic Tank

4. Gearbox

14. Drive Motor

10. Loosening

5. Boom

15. Hose Reel

2-1-1


Specifications

2.2 Specifications

NOTICE For values other than described in this specifications, contact your nearest distributor.

Performance Mass of machine Travel speed Max. traction force Gradeability Oscillating angle Ground pressure

20100 kg 0 - 3.6 km/h 105.0 kN 25° ±7.5° 104.2 kPa

Engine Make & Model Type

Caterpillar C13 Water-cooled direct fuel injection turbo charged diesel engine 328 / 2100 kW/min-1 700 L

Rated output Fuel tank capacity

Compressor Hokuetsu (Air Man) PDSK900 Screw two-stage 24.3 m3/min 2.5 MPa

Model Type Discharge airflow Discharge pressure

Hydraulic system Main pump

Variable displacement two-throw axial piston pump Gear pump Two-throw gear pump Gear pump 280 L

Dust collector pump Boom/pilot/cooling fan pump Hydraulic tank capacity

Boom Fixed type 49° / 14° 30° / 13°

Construction Boom lift angle: up/down Boom swing angle: right/left

Guide shell 9964 mm 5678 mm 1200 mm 300 mm 77° / 16° 130° 30 kN Hydraulic motor drive

Overall length Feed length Guide slide length Foot slide length Guide swing angle: right/left Guide tilt angle Max. extraction force Feed method

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Specifications

Dust collector 70 m3/min 20 Auto pulse air jet Slide

Air flow No. of filter elements Dust removal method Suction cap

Rod changer φ76, φ89, φ102: 8 5000 (4000) mm 76, 89, 102 mm

No. of storing rods Rod length Rod diameter

Drill motor Model Reduction gear ratio Max. torque Max. revolutions Drill diameter (bit diameter used)

DOWMAX ME350 1:3.071 3.25 kN-m 120 min-1 89 - 165 mm

Electrical Battery Lighting (halogen lamp) Power voltage

12 V, 108 Ah/5Hr × 2 24V, 70W × 4 DC24V

Use conditions Ambient temperature Altitude

-15° − +45° 2500 m

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Specifications

Dimensional Drawing

514

Units: mm

330 2400 2986 4330

2865 4720

3570 10645

2-2-3

2210

4460

3800

9964


3. Instruments, Controls and Operator Cab 3

8 1

9

7

6 4 5 2

1. 2. 3. 4. 5. 6. 7. 8. 9.

Meter Panel Messenger Display Travel Levers (or Foot Pedals) Safety Lock Lever Right Console Left Console Hydraulic Cylinder Control Levers Pressure Gauge Panel Operator Seat

3-1


Meter Panel

3.1 Meter Panel

WARNING If fault is shown on IMS display, stop operation immediately and move machine to a safe area and take corrective actions. If emergency relay operates and engine stops, do not restart engine until inspection maintenance is completed.

1 2

8

3 4 5

7

6

1. 2. 3. 4. 5. 6. 7. 8.

Engine Coolant Temperature Gauge Compressor Air Temperature Gauge Hydraulic Oil Temperature Gauge Hour Meter Fuel Gauge Buzzer Rock Drill Oil Lamp IMS* Display *IMS (Intelligent Monitor System)

1. Coolant Temperature Gauge The gauge indicates engine coolant temperature after the engine starts. Run engine at idle speed for 3-5 minutes before starting operation. If engine coolant temperature rises abnormally, stop operation and run engine at idle speed until the gauge needle points to approx 60째C and stop the engine.

NOTICE When engine coolant temperature rises to111째C, warning message is shown on IMS display and engine speed goes down and in 10 seconds engine stops automatically.

3-1-1

17414058


Meter Panel

2. Compressor Air Temperature Gauge The gauge indicates compressor discharge air temperature. If gauge needle points to the red zone during operation, stop

130℃

operation immediately and wait until the needle points to the 120℃ 100℃ 90℃

green zone and then stop the compressor.

NOTICE When compressor discharge air temperature rises over 130°C, engine stops automatically.

60℃

H

C

17314130

3. Hydraulic Oil Temperature Gauge The gauge indicates hydraulic oil temperature. Run engine at idle speed until hydraulic oil temperature rises to about 30°C before starting operation. If gauge needle points to the red zone during operation, stop operation immediately

80℃

H

and run engine at idle speed until the gauge needle points to 50℃

the white zone and stop the engine.

30℃

C

4. Hour Meter The hour meter indicates the total hours of engine operation. Number increases by 1 per elapsed hour of engine operation. Indicator (A) must be turning when hour meter is running. If not turning, inspect the meter or electrical circuits. (A) HOUR METER

NOTICE

0000

Determine when to perform scheduled maintenance, referring to the elapsed time of hour meter.

0

1/10H

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Meter Panel

5. Fuel Gauge The fuel tank is located on the left side of the machine. The gauge indicates the fuel level in the tank. Check the remaining amount of fuel with the starter switch key turned to

About 110L

the ON position. Fuel tank capacity: 700L

6. Buzzer The buzzer sounds repeatedly when the following are detected: Warning message is shown on IMS display. One cycle of rod changer movement is completed.

7. Rock Drill Oil Lamp

NOTICE Drilling without discharging oil can cause hammer to break down. If the lamp is not blinking, stop drilling operation immediately. For adjusting supplying amount of rock drill oil, contact your nearest distributor.

Confirm the normal discharge of rock drill oil with this lamp. The lamp must be blinking before or during drilling operation. ★ Supplying amount of rock drill oil is accomplished with a timer on the control panel. Lamp blinking timing varies depending on the setting time of the timer.

8. IMS (Intelligent Monitoring System) Display This display shows the condition of the machine and the failure during operation, indicating warning information and engine flash codes. If fault is shown on the display, buzzer sounds to warn operator.

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Meter Panel

3.1.1 Messenger Display The Messenger display provides information on operating condition of engine and problem with any of the engine systems. It's a multi-indication device of engine diagnostic readout.

1. Display After turning on the power, self-test is performed and if no fault is detected, Engine Speed or Main Menu will be shown on the display. After turning on the power, if fault is detected, Diagnostics will be shown on the display. ★ On either display if another fault is detected anew, Diag/Event will be shown automatically.

2. Key buttons The Messenger display has four key buttons. Each key button function is described below. Engine settings etc are not changed even if key button is operated erroneously.

Return to the previous display. Scrolls up or to the left. Scrolls down or to the right. Confirms selections made with scroll key buttons.

★ The above display may not be shown if fault is detected during self-test. ★ The Main Menu will not be shown until all detections are completed if multi faults are found.

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Meter Panel

3. Display flowchart

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Meter Panel

★ Shows the indication of list when multi items are detected. ★ Selects with scroll key buttons. SRC

Meter readout at occurrence

CODE

Fault/event and code number

OCC

Number of occurrences

ACT

Occurrence condition, present/past

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Meter Panel

4. The Performance displays

Engine RPM

Engine RPM/Target RPM

Engine Oil Pressure

Turbocharger Inlet Pressure/Load

Display Voltage/Voltage

Intake Temperature

Coolant Temperature

Throttle Position

Fuel Pressure

Coolant level

Fuel Consumption

Service Meter

★ Indication content may vary depending on the mounting engine model and engine settings.

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Travel Levers (or Foot Pedals)

3.2 Travel Levers (or Foot Pedals) 3.2.1 Travel Levers (or Foot Pedals)

WARNING Mis-operation or malfunction by travel levers (or foot pedals) can cause death or serious injury. Keep your foot clear of foot pedals unless needed.

The left and right travel levers (or foot pedals) are used to control the machine travel forward and reverse, travel speed and machine direction.

Travel forward ( ) Move travel levers to the frontward position. (Depress the front side of the foot pedals.) Travel reverse ( ) Move travel levers to the rearward position. (Depress the rear side of the foot pedals.) When travel levers (or foot pedals) are moved the rearward position, a back buzzer at the rear of the machine sounds to warn bystanders that the machine travels reverse. Neutral Move travel levers to the neutral position and the machine will stop. When travel levers (or foot pedals) are released, they return to their neutral position.

3-2-1

17314053


Travel Levers (or Foot Pedals)

3.2.2 Oscillation Auto Lock

DANGER Machine can tip over. When operating work equipment such as boom and guide shell, make sure the both tracks are put on the surface completely.

WARNING Oscillating cylinders can damage and machine travel stability can be affected. If both track frames do not oscillate during travel, stop travel immediately, and contact your nearest distributor for inspection maintenance.

Both oscillating cylinders work together through the hydraulic connecting circuit so when driving on uneven terrain, track on one side oscillates in forward direction and track on the other side oscillates in reverse direction and vice versa to keep machine moving balance. The oscillation auto lock changes the hydraulic connecting circuit automatically from Lock to Open and vice versa.

Lock Both track frames cannot oscillate if travel levers (or foot pedals) or oscillating lever is not operated.

17305002

Open Both track frames can oscillate during travel or operation of oscillating lever.

17305003

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Safety Lock Lever

3.3 Safety Lock Lever

CAUTION Mis-operation or malfunction by safety lock lever can cause death or serious injury. When starting the engine, make sure the safety lock lever is raised up to the Lock position. When leaving the operator seat or performing inspection maintenance, make sure the engine is stopped and the safety lock lever is raised up to the Lock position. The safety lock lever is not operative when it is in a halfway position. Be sure to move the safety lock lever all the way to the Lock position.

The safety lock lever (1) is used to stop machine travel and rod changer functions.

Lock Machine cannot travel when the safety lock lever is raised up to the Lock position. ★ When starting the engine, make sure the safety lock lever is raised up to the Lock position.

Lock

1

Unlock Move the safety lock lever all the way to the Unlock position and the machine travel will be enabled.

Unlock

1

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Right Console

3.4 Right Console

WARNING When starting the engine, make sure all control levers and switches are in their neutral or stop position. If not, malfunction may result.

4

1

5 6

3 2

7 8

1. 2. 3. 4. 5. 6. 7. 8.

Drill Control Lever Engine Throttle Switch Starter Switch Feed Speed Adjust-Dial Feed Force Adjust-Handle Engine Monitor Lamps Rotation Speed Adjust-Handle Air Conditioner Control Panel

1. Drill Control Lever Drill control lever controls feed forward or reverse. Rotation switch on top of the drill control lever controls rotation direction. ★ For operation of drill control lever, see "3.4.1 Drill Control Lever."

2. Engine Throttle Switch Engine throttle switch adjusts engine speed. Select desired position for required engine rpm as described below. Once the switch is set, engine rpm increases automatically from medium to maximum, thanks to the energy saving economy function. ★ For detail of engine throttle switch, see "3.4.2 Engine Throttle Control." I position: engine rpm is maintained at 1250 min-1. II position: engine rpm is maintained at 1600 min-1. III position: engine rpm is maintained at 1800 min-1. IV position: engine rpm is maintained at 2000 min-1. V position: engine rpm is maintained at 2100 min-1.

3-4-1


Right Console

3. Starter Switch Starter switch is used to start or stop the engine. OFF position: Insert and turn starter switch key to OFF position and the engine electrical circuit will be disconnected and the engine be

OFF

stopped. If engine does not stop even when the starter switch

ON START

key is turned to OFF position, engine stopper or electrical circuit failure may occur. Inspect or repair if necessary. ON position: Turn starter switch key to ON position and the machine electrical circuit will be connected and the electrical equipment

17414007

such as a radio and lighting can be used. Select ON position when checking light bulbs of engine monitor lamps. START position: Select START position to start the engine. After starting the engine, release starter switch key and the switch key will automatically return to ON position.

4. Feed Speed Adjust-Dial Adjust rotary head feed speed with this adjust-dial so that hammer idle blow, drill deviation, sticking etc can be prevented. This adjust-dial, however, does not control feed speed during rod changer operation. This adjust-dial is operated only when the machine is in normal forward feed condition, i.e. drill control lever is moved forward (or backward: Lever Pull drilling spec) to the 1st or 2nd position. If feed speed is not fast to follow drilling speed, hammer idle blow may occur. In that case, increase feed speed. If feed speed is too fast to follow drilling speed, drill deviation, sticking etc may occur when drilling into soft rock, fracture zone, cavity etc. Adjust feed speed, while checking the change of drilling sound or rotation speed. To adjust feed speed, loosen the lock-screw and turn adjust-dial clockwise to increase feed speed or turn it counterclockwise to decrease feed speed. After adjusting, tighten the lock-screw.

Lock-Screw

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Right Console

5. Feed Force Adjust-Handle This adjust-handle adjusts feed force during drilling. Adjust it to proper feed force to prevent problems such as drill deviation and rod damage. Generally, feed force must be increased for hard rock mass or large diameter holes, and be decreased for soft rock mass or small diameter holes. First raise up the adjust-handle to unlock, then adjust feed force as follows:

Unlock

Turn the adjust-handle clockwise to increase feed force or turn it counterclockwise to decrease feed force.

Lock

6. Engine Monitor Lamps Engine monitor lamps consist of engine warning lamp (red) (A)and engine diagnostic lamp (orange) (B). (A) Engine warning lamp The lamp goes on when engine failure occurs. When this lamp on, stop operation and move machine to a safe area and take corrective actions. A

(B) Engine diagnostic lamp The diagnostic lamp shows the contents of engine failure by giving number of blinks. This lamp blinks when engine starts running or engine warning lamp goes on due to engine failure. Flash code is also shown on the IMS display. ★ For detail about flash codes of engine diagnostic lamp, refer to the engine operation manual.

7. Rotation Speed Adjust-Handle Unlock adjust-handle and adjust rotation speed. ★ For adjustment, see "3.4.3 Rotation Speed Adjust-Handle."

8. Air Conditioner Control Panel Operate air conditioner from this panel. ★ For air conditioner, see “3.9 How to Operate Air Conditioner.”

3-4-3

B


Right Console

3.4.1 Drill Control Lever

WARNING Mis-operation or malfunction by drill control lever can cause death or serious injury. Before operation, make sure which type of drill control lever - Lever Push or Lever Pull drilling specification - is employed in your machine. Before starting the engine, make sure the drill control lever is in neutral position. If not, malfunction may result.

Drill control lever controls forward or reverse feed. And rotation switch on top of the control lever controls rod rotation direction. Two types of drill control lever are available, Lever Push and Lever Pull drilling specifications.

Lever Push drilling specification This is a standard drill control lever operation for the machine. With this specification, drill control lever is moved forward to the three positions and moved backward to the two positions.

N

③ ② ①

⑤ ④

1. Normal Forward Feed / Anti-jamming OFF position

2. Normal Forward Feed / Anti-jamming ON position

3. Fast Forward Feed position 4. Normal Reverse Feed position 5. Fast Reverse Feed position

Feed Control Rotary head forward or reverse feed is controlled with the drill control lever. The control operation stops when the control lever is moved to the neutral position. Drill control lever can be stopped at any normal feed position. When drill control lever is released from fast feed position, it automatically returns to normal feed position.

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Right Console

Forward Feed Normal forward feed: move drill control lever forward from

Forward Feed

neutral to the 1st position. Fast forward feed: move drill control lever forward all the way to the end position. Reverse Feed Normal reverse feed: move drill control lever backward from

Reverse Feed

neutral to the 1st position. Fast reverse feed: move drill control lever backward all the way to the end position.

Rotation Control Shank rod of rotary head rotates forward (counterclockwise direction) or rotates reverse (clockwise direction) by operating the rotation switch on top of the drill control lever. Forward Rotation Once left side of rotation switch is pressed, shank rod of rotary

Forward Rotation

Reverse Rotation

head rotates forward. Rotation stops when the same side of switch is pressed again. Reverse Rotation Shank rod of rotary head rotates reverse during the time right side of rotation switch is pressed. Rotation stops when the same side of switch is released.

Rotary Head Positioning Control Positioning switch controls the loosening to separate the rod or controls the rotary head to stop at separation position or rod storage position when operating the rod changer.

Positioning Switch

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Right Console

Lever Pull Drilling Specification With this specification, drill control lever is moved backward to the three positions and moved forward to the two positions.

N

⑤ ④

③ ② ①

1. Normal Forward Feed / Anti-jamming OFF position

2. Normal Forward Feed / Anti-jamming ON position

3. Fast Forward Feed position 4. Normal Reverse Feed position 5. Fast Reverse Feed position

Feed Control Rotary head forward or reverse feed is controlled with the drill control lever. The control operation stops when the control lever is moved to the neutral position. Drill control lever can be stopped at any normal feed position. When drill control lever is released from fast feed position, it automatically returns to normal feed position. Forward Feed Normal forward feed: move drill control lever backward from

Reverse Feed

neutral to the 1st position. Fast forward feed: move drill control lever backward all the way to the end position. Reverse Feed Normal reverse feed: move drill control lever forward from

Forward Feed

neutral to the 1st position. Fast reverse feed: move drill control lever forward all the way to the end position.

Rotation Control Shank rod of rotary head rotates forward (counterclockwise direction) or rotates reverse (clockwise direction) by operating the rotation switch on top of the drill control lever.

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Right Console

Forward Rotation Once left side of rotation switch is pressed, shank rod of rotary

Forward Rotation

Reverse Rotation

head rotates forward. Rotation stops when the same side of switch is pressed again. Reverse Rotation Shank rod of rotary head rotates reverse during the time right side of rotation switch is pressed. Rotation stops when the same side of switch is released.

Rotary Head Positioning Control Positioning switch controls the loosening to separate the rod or controls the rotary head to stop at separation position or rod storage position when operating the rod changer.

Positioning Switch

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Right Console

3.4.2 Engine Throttle Control Engine speed is controlled with the engine throttle switch. Once the switch is set to desired position and when the blow lever on the left console is operated during drilling, engine rpm increases automatically from medium to maximum by means of energy saving economy function.

NOTICE Do not drive the machine with engine throttle switch set to IV or V position. Failure to do so will increase load excessively to undercarriage, causing damage to drive equipment.

Switch select positions are as follows: I position: engine rpm is maintained at 1250 min-1 after starting engine. This is used when starting or stopping the engine. II position: engine rpm is maintained at 1600 min-1. This is used when driving the machine or operating the boom or rod changer. III position: engine rpm is maintained at 1800 min-1. IV position: engine rpm is maintained at 2000 min-1. V position: engine rpm is maintained at 2100 min-1. This is used when performing normal drilling operation.

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Right Console

Auto Control Energy saving economy function controls engine rpm automatically. When performing drilling, engine throttle switch is set to V position. If blow lever on left console is operated, engine rpm increases automatically from medium to maximum.

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Right Console

3.4.3 Rotation Speed Adjust-Handle

NOTICE Use a special rotation meter to measure rotation speed. For adjusting rotation speed to the geologic conditions on the work site, contact your nearest distributor.

3

1. Rotation Speed Adjust-Handle for rod changer 2. Rotation Speed Adjust-Handle for drill rod 3. Reserve

2 1

1. Rotation Speed Adjust-Handle for Rod Changer When replacing a rod, use this adjust-handle for the rod changer. Unlock and turn adjust-handle to make adjustment of rotation speed.

2. Rotation Speed Adjust-Handle for Drill Rod With this adjust-handle, rotation speed is adjusted to the geologic conditions on the work site and the bit gauge and the down-the-hole hammer so the optimum drilling operation can be performed. Unlock adjust-handle and turn it to make adjustment of rotation speed.

3. Reserve This handle is not used.

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Left Console

3.5 Left Console

WARNING When starting the engine, make sure all control levers and switches are in their neutral or stop position. If not, malfunction may result.

1 4 5 2 3

6

7 8

1. 2. 3. 4. 5. 6. 7. 8.

Rod Changer Control Lever Blow Lever Hood/Loosening Lever Upper Clamp Switch Lower Clamp Switch Greasing Switch Mode Select Switch Switch Panel

1. Rod Changer Control Lever The sequence of rod changer operations is controlled with this control lever. ★ For operation of rod changer control lever, see "3.5.1 Rod Changer Control Lever."

2. Blow Lever Four operations, combining amount of blow air with dust collector operation, are selected with this lever moved to given position. (A) Weak Blow/Dust Collector Weak blow air jets out and dust collector operates. This is used to perform collaring operation. (B) Strong Blow/Dust Collector

A

Full amount of blow air jets out and dust collector operates. This is used to perform normal drilling operation. (C) Strong Blow Only full amount of blow air jets out.

C D

This is used to perform drilling operation without dust collector in such a place as water. (D) Very Weak Blow Very weak blow air, less than weak blow, jets out. ★ In this mode, engine rpm does not increase to maximum.

3-5-1

B


Left Console

3. Hood/Loosening Lever With this lever, the slide hood moves vertically or the loosening (upper clamp) swings in given direction. The lever returns to the neutral position when released. (A) Hood Up Slide hood goes up when the lever is moved forward. (B) Hood Down Slide hood goes down when the lever is moved backward.

A

(C) Loosening Loose Loosening (upper clamp) swings in looseness direction

C

(counterclockwise direction) when the lever is moved leftward. (D) Loosening Tight

D

B

Loosening (upper clamp) swings in tightness direction (clockwise direction) when the lever is moved rightward.

4. Upper Clamp Switch Upper camp opens and closes with this switch. Upper Clamp Close Upper clamp closes when the switch is moved leftward. The switch remains in the same position when it is released. Upper Clamp Open Upper clamp opens when the switch is moved rightward. The switch returns to neutral position when it is released. Upper Clamp Stop Upper clamp stops in operating position when the switch is

Upper Clamp

returned to neutral position.

5. Lower Clamp Switch Lower camp opens and closes with this switch. Lower Clamp Close Lower clamp closes when the switch is moved leftward. The switch remains in the same position when it is released. Lower Clamp Open Lower clamp opens when the switch is moved rightward. The switch returns to neutral position when it is released. Lower Clamp Stop Lower clamp stops in operating position when the switch is returned to the neutral position.

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Lower Clamp


Left Console

6. Greasing Switch Grease is forced out from grease nozzle when the switch is moved upward. Use this when grease is applied to threads of rod or shank rod. Grease nozzle operates during the time the switch is moved to ON position, and greasing stops when the switch is released. ★ For operation of greasing switch, see "4.8 Handling the Auto Greaser."

7. Mode Select Switch Change drilling mode according to the rock or geologic conditions on the work site.

NOTICE Continuously using high-speed drilling H mode can cause premature wear or damage to rotating parts of rotary head, rod, bit etc. Do not use H mode continuously for more than five minutes. Use N mode for normal drilling operation.

H mode High-speed drilling H mode is set with the switch moved upward. Use this mode for drilling into fracture or clay zone. N mode Normal drilling N mode is set with the switch moved downward. Use N mode for normal drilling operation.

8. Switch Panel Switch panel has rod guide switch, anti-jamming switch etc. ★ For operation of each switch on the panel, see "3.5.2 Switch Panel."

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Left Console

3.5.1 Rod Changer Control Lever

WARNING When operating the rod changer control lever, sound horn to warn bystanders.

The sequence of operations from rod addition to rod collection is controlled with the rod changer control lever. ★ For operation of rod changer, see "4.7 Operating the Rod Changer."

Rod Changer Extended Operation (A) Swing In Rod stored in the magazine is grasped with front and rear clamps and is moved to drilling center position when the lever is moved leftward. (B) Swing Out After adding rod, when the lever is moved rightward, front and rear clamps at drilling center position are moved to their retraction position.

Rod Changer Retract Operation (A) Swing In Front and rear clamps are moved to drilling center position and grasp the rod when the lever is moved leftward. The rod at drilling center position is ready to be collected. (B) Swing Out After separating rod, when the lever is moved rightward, front and rear clamps are moved to their retraction position and the rod is stored in the magazine. (C) Magazine Rotation to Addition Clamps open and magazine set plate rotates to the addition side (counterclockwise direction) when the lever is moved backward. (D) Magazine Rotation to Collection Clamps open and magazine set plate rotates to the collection side (clockwise direction) when the lever is moved forward.

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A B

D A B

C


Left Console

Rod Changer Control Switches Each rod changer operation, instead of the sequence of operations by rod changer control lever, is controlled independently with the appropriate rod changer control switch. When centering rod changer or checking rod changer operation, select Manual mode with MANUAL/AUTO select switch.

1. 2. 3. 4. 5.

1 2

3

4

5

MANUAL/AUTO Select Switch Swing Switch Clamp Switch Shutter Switch Magazine Rotation Switch

1. MANUAL/AUTO Select Switch Rod changer auto or manual operation mode is selected with this switch. Press upper side of switch to place rod changer into manual operation mode and each rod changer control switch can operate. ★ Generally, press lower side of switch to place into auto operation mode.

2. Swing Switch Front and rear clamps swing with this switch. Clamps stop when the switch is released.

NOTICE When swinging clamp, make sure the clamp is opened. Otherwise, clamp damage will result.

Clamp Swing In Front and rear clamps swing to drilling center position when upper side of switch is pressed. Clamp Swing Out Front and rear clamps swing to magazine position when lower side of switch is pressed.

3. Clamp Switch Front and rear clamps simultaneously open and close with this switch. Clamps stop when the switch is released.

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Left Console

Clamp Open Front and rear clamps open when upper side of switch is pressed. Clamp Close Front and rear clamps close when lower side of switch is pressed.

4. Shutter Switch Magazine and gearbox shutters open and close with this switch. Front and rear shutters simultaneously open and close. Shutters stop when the switch is released. Shutter Open Shutters open when upper side of switch is pressed. Shutter Close Shutters close when lower side of switch is pressed.

5. Magazine Rotation Switch Magazine set plate rotates with this switch. When the switch is pressed, magazine set plate rotates one-section turn in clockwise direction and stops. After stopping the magazine rotation, release the switch and the set plate rotation stops. If this switch is pressed and held with no rod loaded, operations of 'rotation' to 'stop' to 'rotation' to 'stop' will repeat.

NOTICE When rotating magazine set plate, make sure the clamp is opened. Otherwise, clamp damage will result.

Set Plate Rotation to Addition Set plate rotates to the collection side (clockwise direction) when upper side of switch is pressed. Set Plate Rotation to Collection Set plate rotates to the addition side (counterclockwise direction) when lower side of switch is pressed.

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Left Console

3.5.2 Switch Panel

1 2

1. Rod Guide Switch 2. Anti-Jamming Switch

1. Rod Guide Switch Rod guide on the loosening side opens and closes with this switch. Rod guide closes when upper side of switch is pressed. Rod guide opens when lower side of switch is pressed. Do not release the switch until the rod stops moving completely.

2. Anti-Jamming Switch Anti-jamming switch is used to prevent “jamming” (bit or rod gets stuck during drilling operation). Once anti-jamming function is set, rotary head automatically performs reverse feed if rotary head revolving pressure goes abnormally high when drilling into fracture or clay zone. Press and hold upper side of switch during drilling operation to set anti-jamming function. Anti-jamming function stops when the switch is moved to the neutral position. The switch must be put in neutral position when no drilling operation is performed. ★ Anti-jamming function is operative when the drill control lever is moved forward (or backward: Lever Pull drilling spec) to the 2nd position.

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Hydraulic Cylinder Control Levers

3.6 Hydraulic Cylinder Control Levers

WARNING Machine may tip over. When operating work equipment such as boom and guide shell, make sure the machine body is in horizontal position to the track frame and the tracks on both sides are placed properly on the surface. When operating hydraulic cylinder control levers, make sure the area around the machine is clear of all persons.

3

1 2

1. Boom Lift/Boom Swing Lever 2. Guide Tilt/Guide Swing Lever 3. Oscillating/Guide Slide Lever

Hydraulic cylinder control levers are used to operate work equipment such as boom and guide shell or oscillation of machine body.

1. Boom Lift/Boom Swing Lever A: Boom 'Raise'

Boom is raised when the lever is moved to the rear. B: Boom 'Lower' Boom is lowered when the lever is moved to the front. C: Boom 'Swing Right' Boom swings to the right with the lever is moved to the right.

D: Boom 'Swing Left' Boom swings to the left with the lever is moved to the left.

D 17506005

3-6-1


Hydraulic Cylinder Control Levers

2. Guide Tilt/Guide Swing Lever A: Guide Tilt 'Up'

Top of guide shell is raised when the lever is moved to the rear. B: Guide Tilt 'Down' Top of guide shell is lowered when the lever is moved to the front.

C: Guide Swing 'Right'

Top of guide shell swings to the right when the lever is moved to the right. D: Guide Swing 'Left' Top of guide shell swings to the left when the lever is moved

to the left.

17506003

3. Oscillating/Guide Slide Lever A: Oscillating 'Raise'

Front of machine body is raised and rear of machine body is lowered when the lever is moved to the rear. B: Oscillating 'Lower' Front of machine body is lowered and rear of machine body is B

raised when the lever is moved to the front.

C: Guide Slide 'Backward' Guide shell moves backward when the lever is moved to the right. D: Guide Slide ' Forward' Guide shell moves forward when the lever is moved to the left.

D 17506004

3-6-2


Pressure Gauge Panel

3.7 Pressure Gauge Panel

1 2 3 4

1. 2. 3. 4.

Pressure gauge panel is located in front right of operator seat.

1. Receiver Tank Air Pressure Gauge Indicates receiver tank air pressure.

2. Feed Pressure Gauge Indicates feed pressure when drilling. Feed pressure is a pressure of bit onto rock.

3. Rotation Pressure Gauge Indicates rotary head normal rotation pressure.

4. Blow Air Pressure Gauge Indicates blow air pressure.

3-7-1

Receiver Tank Air Pressure Gauge Feed Pressure Gauge Rotation Pressure Gauge Blow Air Pressure Gauge


Operator Cab

3.8 Operator Cab 3.8.1 Operator Seat

CAUTION Your fingers can get caught in the seat stand. Use the palm of your hand to push down the tilt lever (4). The backrest can fall forward suddenly when the reclining lever (3) is raised up to the maximum. When making reclining adjustment, make sure your back is positioned close to the backrest.

1. Seat forward/backward adjustment Raise up the sliding lever (1) at front lower side of the seat and slide seat forward or backward to the desired position, then release the lever.

2

Forward/backward adjustments: 160mm (10 steps)

2. Suspension adjustment According to the weight of your body, adjust the dial (2) weight

1

indication (kg) needle to the proper value. Adjustments: 50-120kg

3. Reclining adjustment Raise up the reclining lever (3) at left lower side of the seat and adjust backrest to the desired position, then release the lever. In back of the backrest, storage spaces for operation manual,

4

parts list etc are provided.

4. Seat tilt adjustment

3

Push down the tilt lever (4) at right lower side of the seat and adjust height of seat on front or rear side. When front side of seat is raised, put the weight of your body on rear side of seat, while pushing down the tilt lever. When rear side of seat is raised, put the weight of your body on front side of seat, while pushing down the tilt lever. Tilt adjustments: front and rear 13째 (4 steps)

3-8-1


Operator Cab

5. Armrest angle adjustment Armrest can be raised up to an angle of about 90째. Armrest angle can be adjusted with the adjust-dial (5) on lower side of armrest. Adjustment angle: up 5째, down 25째 5

6. Headrest adjustment Headrest (6) can be raised up to the desired position. Also, armrest can be inclined forward to angle of 60째. Adjustments: 0-50mm 6

3-8-2


Operator Cab

Wear Seat Belt Properly (if equipped)

WARNING Always wear seat belt properly when operating the machine. Do not wear seat belt around abdomen, which may cause application of excessive pressure to the abdomen. Always wear seat belt across the hips. Before wearing seat belt, inspect it. Replace if the following symptoms are found: belt fabric is torn or frayed, and latch plate (1) and buckle (2) are damaged or deformed.

Wear seat belt properly, otherwise the effect will be reduced and seat belt may rather be dangerous, depending on the use conditions.

1. When wearing seat belt, adjust seat position and sit straight with your back positioned close to the backrest. 2. Draw seat belt with latch plate (1) and insert latch plate into buckle (2) completely until a clicking sound is heard. ★ If seat belt cannot be drawn because latch plate is locked, return belt to the original position and draw it slowly again with latch plate.

1

3. Adjust seat belt position so that it is put across the hips. 4. To release seat belt, press button (3) of buckle (2) and remove latch plate. Seat belt automatically returns to the original position when latch plate is removed. ★ If seat belt cannot return automatically, draw belt fully once and then make it wind slowly.

3

2

3-8-3


Operator Cab

3.8.2 Cab Door, Room Light and Ashtray

CAUTION Before driving machine or performing drilling operation, make sure the cab door is locked.

Door Lock Door can be locked in either open or close condition. To lock door in open condition, press door to catcher (1). To release door from catcher, move lever (2) forward or press down lever (3), which are in rear and on side of left console.

1

2 3

Door Unlatching Door unlatches and opens when the door latch lever is moved backward.

3-8-4


Operator Cab

Room Light Switch Move sliding switch (1) to the ON position and the room light (2) will go on. ★ Room light goes on when the starter switch key is turned to the ON position.

1

2

Ashtray Ashtray (1) is used with cover opened. Keep ashtray closed when it is not used.

1

3-8-5


Operator Cab

3.8.3 Accessories Around Operator Cab Horn Switch Press horn switch (1) in lower side of cab and the horn (2) will sound. Use this switch to warn bystanders when starting the engine or driving the machine.

1

2

Front Light Switch Front lights (2) on front top of the cab turn on when the front light switch (1) is moved to the front.

2 1

Rear Light Switch Rear lights (2) on rear top of the cab turn on when the rear light switch (1) is moved to the front.

1

3-8-6

2


Operator Cab

Front Windshield Wiper Switch Front windshield wiper (2) operates when the front windshield wiper switch (1) is moved to the up. And washer solution jets out when the switch is turned clockwise during wiper operation.

2

1

Roof Windshield Wiper Switch Roof windshield wiper (2) operates when the roof windshield wiper switch (1) is moved to the up. And washer solution jets out when the switch is turned clockwise during wiper operation.

1 2

3-8-7


Operator Cab

3.8.4 Additional Interior Equipment Fire Extinguisher For fire extinguisher (1), read and understand the provided operation manual and confirm the type of fire extinguishing liquid and the operating procedure. After machine is delivered, install fire extinguisher on its bracket and secure it with the band (2). ★ For operation of fire extinguisher, see "3.10 How to Use Fire Extinguisher."

2

1

Radio When turning on the radio, extend antenna fully, which is on the rear of the cab, and make sure the sound volume is proper not to disturb safe operation of machine. For use of the radio, see the provided operation manual.

3-8-8


Operator Cab

Clinometer (if equipped) Clinometer indicates incline angle of machine in front and rear and left and right direction. When checking incline angle of machine, put machine with oscillating angle of ±0° (horizontal). ★ Two clinometers are installed in front upper and right upper of operator seat.

Safety Hammer (if equipped)

WARNING Flying of pieces of broken window glass may result. Wear protective goggles when breaking glass with this hammer (1).

If cab door does not open in an emergency, use this hammer (1) to break the front or rear window glass and escape from the machine. ★ Safety hammer is installed in left front of operator seat.

1

3-8-9


How to Operate Air Conditioner

3.9 How to Operate Air Conditioner

CAUTION The blower breaks down when the air conditioner is used in the state of internal air circulation with the door opened. Change the switch to the external air introduction when opening the door with the air conditioner operated.

With air conditioner operated, the outside air is taken into the cab through the filters and the air pressure in the cab is increased. This prevents dust from entering the cab and provides operator comfort at all times.

Air Conditioner Control Panel 4

1

3

A/C

OFF

2

6

LO

HI

5

1. 2. 3. 4. 5. 6.

Air Conditioner Switch Temperature Control Switch Air Duct Select Switch Inside/Outside Air Select Switch Fan Switch OFF Switch

17414049

1. Air Conditioner Switch Press air conditioner switch during operation of the fan and the air conditioner will start running and the indicator light comes on. When the switch is pressed again, the air conditioner will stop and the indicator light come off.

A/C

17314007

3-9-1


How to Operate Air Conditioner

2. Temperature Control Switch This switch controls air temperature. All indicator lights (eight) turn on as the engine starts. If the lowest temperature is set with the switch pressed, all indicator lights will turn on in green. If the highest temperature is set with the switch pressed, all indicator lights will turn on in red. Indicator lights change in red in sequence from the left end of

Low Temp.

indicator light as the air temperature changes from the lowest

High Temp.

17314002

to the highest by pressing the appropriate switch.

3. Air Duct Select Switch Select the desired air duct with this switch. ★ For front and rear air ducts, direction of air can be changed with adjusting louvers.

17314003

Front Air Duct Air blows from the front air duct (A) in front of operator seat when this switch is pressed and indicator light comes on. A

Front and Rear Air Ducts Air blows from both the front air duct (A) and the rear air duct (B) in rear of operator seat when this switch is pressed and indicator light comes on. B

3-9-2


How to Operate Air Conditioner

Bottom Air Duct Air blows from the bottom air duct (C) in bottom of operator seat when this switch is pressed and indicator light comes on. C

4. Inside and Outside Air Select Switch With the appropriate switch pressed, the inside air circulates or the outside air flows into the cab. Inside Air Circulation: With the switch pressed, the inside air is quickly cooled or warmed and the indicator light comes on and the outside air is shut out.

Inside Air Circulation

Outside Air Taking In

Outside Air Taking In:

17314004

With the switch pressed, the outside air is taken into the cab through the filters, where the air pressure is increased so dust entering can be prevented.

5. Fan Switch During cooling or heating, press the appropriate switch to get the desired amount of air. LO

HI

Light Wind

with the air conditioner switch indicator light OFF.

Weak Wind

★ Fan operates independently when the switch is pressed

Strong Wind

OFF

Medium Wind

When the switch is pressed, the indicator light comes on.

17314005

6. OFF Switch With the switch pressed, the air conditioner (or fan) stops and the fan switch indicator lights turn off. LO

HI

Stop

OFF

17314006

3-9-3


How to Operate Air Conditioner

Cooling Operation

CAUTION The healthful comfortable temperature may be 5-6°C in difference between the inside air and the outside air. Avoid excessively low inside air temperature or exposing your body to the cold air for hours. Pay attention to the temperature adjustment. Air in the cab is dry due to dehumidification by air conditioner. When air conditioner is used, open the window or door at least once an hour for ventilation. Dry air with cigarette smoke etc in the cab can cause pains in the eyes. When smoking, open the window frequently for ventilation.

Perform cooling, while circulating the outside air into the cab and removing humidity.

1. Press outside air select switch and the indicator light will come on. ★ For quickly cooling, press inside air select switch temporarily.

1

4

2. Select the desired air duct with the air duct select switch (1).

A/C

OFF

3. Press temperature control switch (2) to set the air temperature to the lowest. Check that all eight indicator lights come on in green. 4. Press fan switch (3) to adjust the amount of air. Press air conditioner switch (4) to start the air conditioner. Check the indicator light comes on. ★ To stop the air conditioner, press OFF switch (5). 5. Adjust air temperature in the cab with the temperature control switch (2) and the fan switch (3).

3-9-4

2

5

LO

HI

3

17314099


How to Operate Air Conditioner

Heating Operation Heating Perform heating, while taking the outside air into the cab. Warm air comes from the bottom air duct so the optimum heating of "head cool and feet warm" can be maintained. 1. Press outside air select switch and the indicator light will come on. ★ For quickly cooling, press inside air select switch temporarily. 2. Press bottom air duct switch

3

A/C

.

OFF

3. Press temperature control switch (1) to set the air temperature to the highest. Check that all eight indicator lights come on in red. 4. Press fan switch (2) to adjust the amount of air. 5. Adjust air temperature in the cab with the temperature control switch (1) and the fan switch (2).

NOTICE To perform dehumidification and heating, press air conditioner switch (3) and the indicator light will come on and the air conditioner will be operating.

3-9-5

1

LO

HI

2 17414055


How to Operate Air Conditioner

Defrosting When humidity in the cab is high due to rain etc, window glass may be white with frost. In that case, start air conditioner to defrost it. 1. Press outside air select switch will come on. 2. Press front air duct switch come on.

and the indicator light 3 and the indicator light will A/C

OFF

3. Press temperature control switch (1) to set the air temperature to the highest. Check that all eight indicator lights come on in red. 4. Press fan switch (2) to adjust the amount of air. 5. Press air conditioner switch (3) to start the air conditioner. Check the indicator light comes on. To stop the air conditioner, press OFF switch (4). 6. Adjust air temperature in the cab with the temperature control switch (1) and the fan switch (2).

3-9-6

1

4

LO

HI

2 17414054


How to Operate Air Conditioner

Care of Air Conditioner

NOTICE For recharging cooling refrigerant (gas) or servicing air conditioner, contact your nearest distributor.

In-Season Recharge cooling refrigerant (gas) or perform inspection maintenance to maintain good air conditioner performance during the season. ★ For inspection of cooling refrigerant (gas), see "14.1.2 General Maintenance. Off-Season If cooling refrigerant (gas) leaks during the off-season, corrosion or rust may occur in the parts of the air conditioner. During the off-season, operate the air conditioner for 5-6 minutes two or three times per month, which is useful for preventing refrigerant (gas) leaking from the seals of the compressor.

3-9-7


How to Use Fire Extinguisher

3.10 How to Use Fire Extinguisher

WARNING Never attempt to disassemble fire extinguisher - cylinder explosion will result. If the eyes or skin comes into contact with fire extinguishing liquid, inflammation may result. In that case, wash out with clean water immediately and consult a doctor.

CAUTION Life of fire extinguisher is about eight years. Replace if the following are found: Pressure gauge (1) needle is not pointing to green zone. Cylinder rusts or damages. Hose deteriorates.

1

CX15004

When machine is delivered, install fire extinguisher on its bracket and secure it with the band (2). Fire extinguisher must be fastened properly and ready to be used.

2

3-10-1


How to Use Fire Extinguisher

3.10.1 Fire Extinguishing Precautions Fire extinguisher provided with the machine is effective for the following fires: Ordinary fire: fiber, paper or wood etc fire Fuel or oil fire: diesel fuel or other oil fire Electrical fire: fire in electrical equipment that may suffer electrocution

Avoid Fighting Beyond Your Control Fighting a fire beyond your control can spread the fire. Avoid breathing harmful smoke from fire. Always stand on windward side when fighting a fire. Fighting a fire may be impossible, which depends on the size of a fire or the timing of start of fire extinguishing. When fighting a fire, access the fire after flames become weaker, while maintaining a safe distance of at least about 3 m from the fire. Before fighting a fire, arrange the escape route.

Handle Fire Extinguisher Correctly Do not tilt fire extinguisher, which can cause poor injection of fire extinguishing liquid. Keep fire extinguisher as vertical as possible. Holding the hose, point the nozzle at the flames and jet out fire extinguishing liquid. Fire extinguishing substances conduct electricity. When fighting a fire on electrical equipment, be sure to turn off the power to prevent short circuits or electrocution.

3-10-2


How to Use Fire Extinguisher

3.10.2 How to Use Fire Extinguisher 1. Pull out the yellow safety stopper on top of the lever.

CX15001

2. Remove the nozzle from its holder and position it at flames.

CX15002

3. Grasp and squeeze the upper and lower levers strongly to inject the fire extinguishing liquid. Injection stops as levers are released.

CX15003

3-10-3


4. Operation 4.1 Pre-Start Inspection Perform pre-start inspection before starting the day's operation. Pre-start inspection on every work day is essential for safe machine operation and maintaining good machine performance. This also prevents machine failures.

Opening/Closing Cover for Maintenance

CAUTION Cover can spring open due to gas spring force. Open or close cover carefully, while holding it. Your finger can get caught in the stopper. Operate stopper carefully.

Open or close covers on both sides of the machine as follows:

Open Cover 1. Insert a key in the lock handle and turn it clockwise to unlock (1). ★ Use an exclusive key for the cover. 2. Raise the handle (2). Two lock handles are installed on a piece of cover.

2

1

3. Turn the handle (2), while holding the cover, and open the cover slowly.

2

4-1-1


Pre-Start Inspection

4. Raise up the cover until the gas spring (3) is stopped with the stopper (4). 4

3

Close Cover 1. Press the stopper (1) of the gas spring to unlock and lower the cover slowly by hand. 1

2. After cover is lowered to a position that it can be grasped with both hands, press and close the cover by both hands.

3. Turn the handle (2) and return it to the right place in the holder. Insert the key in the lock handle (3) and turn it counterclockwise to lock the cover.

2

4-1-2

3


Pre-Start Inspection

4.1.1 Inspection Before Starting the Engine Walk-Around Inspection Walk around the machine and check for fuel or oil leaks or missing bolts or nuts and any abnormality in the work equipment, hydraulic system etc. Check hydraulic cylinders for scuffing or damage and hydraulic hose fittings for oil leaks.

Inspect Around Rotary Head and Work Equipment

7

1 3

2 5

2

3 4 6

1. 2. 3. 4. 5. 6. 7.

Check rotary head for excessive wear, damage or deformation. Check front and rear clamps on rod changer for excessive wear, damage or deformation. Check magazine and gearbox for excessive deformation or damage. Check boom and boom pedestal for excessive deformation or damage. Check guide shell and guide mounting for excessive wear, crack or deformation. Check foot pad and loosening for excessive wear, crack or deformation. Check hose reel for excessive deformation, damage or crack.

4-1-3


Pre-Start Inspection

Inspect Around Machine Body and Undercarriage

3

2 1

6

7

4

5

1. Open left and right covers and check for oil or fuel leaks. 2. Check radiator and oil cooler for clogging, coolant or oil leaks. Also check air conditioner condenser for clogging. 3. Check fuel tank for deformation or damage. 4. Check front idlers and track rollers for excessive wear, damage or crack. 5. Check track frames for excessive wear, damage or crack. 6. Check carrier rollers for excessive wear or damage. 7. Check drive motors for oil leaks. Also check sprockets for excessive wear or damage.

4-1-4


Pre-Start Inspection

Inspect Around Operator Cab

3 1

3

2 4

1. Clean front and side window glasses. Also clean interior of cab. 2. Check step and handrail for dirt or oil. Clean if necessary. 3. Clean lights and mirrors. Fix damage if necessary. 4. Check oscillating cylinders for scuffing or damage. Also check hydraulic hose fittings for oil leaks.

4-1-5


Pre-Start Inspection

Check Engine Oil Level

WARNING Spilled engine oil can cause a fire. Wipe up spilled oil. When checking engine oil level, put machine in horizontal position and stop the engine. Do not check it while the engine is hot. After stopping the engine, wait about 10-20 minutes until it is cooled down or serious burns may result.

1. Open cover on left side of machine. 2. Remove dipstick (1) and wipe it clean with a cloth. 3. Insert dipstick (1) all the way. 1

4. Remove dipstick (1) again and check oil level. It should be between FULL and ADD marks. ★ Also check oil contamination and viscosity.

Upper Limit

Lower Limit

AD

LL FU

D

17303053

5. If oil level is not sufficient, remove oil filler cap (2) and pour recommended oil to specified level. Do not overfill. ★ For adding oil, see "11. How to Select Fuel, Water and Lubricating Oil." 6. After refilling, wait about fifteen minutes, then check engine oil level again.

4-1-6

2


Pre-Start Inspection

Check Coolant Level

WARNING Do not remove radiator cap (2) when engine is hot. If not observed, steam or hot water can gush out from the radiator, resulting in serious burns. When checking coolant level, stop the engine and cool it down completely, then check coolant level in reservoir tank (1).

NOTICE For coolant, use soft water with less-impurities such as city water. Do not use well water, river water etc.

1. Open cover on left side of machine. Check coolant level with reservoir tank (1). It should be between FULL and LOW marks. If coolant level is below LOW mark, remove reservoir tank cap and pour coolant to level of FULL mark. 1 If amount of coolant in reservoir tank (1) is insufficient, refill tank in following procedure.

2. Remove radiator cap (2) and pour coolant to radiator filler cap. Do not overfill. ★ Also check radiator cap (2) for packing or spring failures. Replace if necessary. 3. After checking, reinstall and tighten radiator cap (2).

2

4. Check coolant level in reservoir tank (1) again. Add coolant if necessary. FULL

NOTICE If coolant level becomes low suddenly, coolant may leak from radiator or hose line so check it.

LOW 17203001

4-1-7


Pre-Start Inspection

Drain Oily Water And Sediments From Fuel Water Separator

WARNING Spilled fuel can cause a fire. Place a suitable drain pan when draining oily water and sediments. Wipe up if necessary.

Fuel water separator (1) separates water mixed with fuel and prevents trouble by water. ★ To access fuel water separator, open cover on left side of machine. Check that water is not collected in bowl (2). If collected, open drain valve (3) and drain it. After draining, retighten drain valve (3) by turning it clockwise. 1

2

2

3

4-1-8


Pre-Start Inspection

Drain Mixed Water And Sediments From Fuel Tank

WARNING Spilled fuel can cause a fire. Place a suitable drain pan when draining mixed water and sediments. Wipe up if necessary.

Open drain cock (1) on lower side of fuel tank and drain mixed water and sediments accumulated on bottom of tank in a suitable drain pan. Close drain cock as soon as pure fuel flows.

1

4-1-9


Pre-Start Inspection

Check Fuel Level

WARNING Fuel (diesel fuel) is highly flammable. When refilling, stop engine and wait until it is cooled down. Keep smoking materials, flame and sparks away from fuel. Spilled fuel can cause a fire. Wipe up if necessary.

Check fuel level with level gauge (1). Refill tank after day's work. Remove filler cap (2) and pour fuel to maximum level, which must be matched to ambient temperature. Do not overfill. Fuel tank capacity: 700L ★ For fuel used, see "11. How to Select Fuel, Water and Lubricating Oil."

1

When refilling, use a strainer to fuel tank and take care no water and contaminants enter the tank. After refilling, retighten filler cap (2) firmly.

2

4-1-10


Pre-Start Inspection

Drain Mixed Water And Sediments From Rock Drill Oil Tank

WARNING Oil is highly flammable. Place a suitable drain pan when draining mixed water and sediments. Wipe up if necessary.

Open drain cock (1) on lower side of rock drill oil tank and drain mixed water and sediments accumulated on bottom of tank in a suitable drain pan. Close drain cock (1) as soon as pure oil flows.

1

4-1-11


Pre-Start Inspection

Check Rock Drill Oil Level

WARNING Spilled oil can cause a fire. Wipe out if necessary.

NOTICE When checking oil level, put machine in horizontal position and perform inspection before starting the engine.

★ To access rock drill oil tank, open cover on right side of machine. Check oil level with oil level gauge (1) located on side of oil tank. If it is insufficient, remove filler cap (2) and pour rock drill oil to

2

maximum level, which must be matched to ambient temperature. Do not overfill. Oil tank capacity: 45L ★ For rock drill oil, see "11. How to Select Fuel, Water and Lubricating Oil."

1

When refilling, use a strainer to oil tank and take care no water and contaminants enter the tank. After refilling, retighten filler cap (2) firmly.

4-1-12


Pre-Start Inspection

Check Hydraulic Oil Level

WARNING Spilled oil can cause a fire. Wipe out if necessary.

NOTICE When checking oil level, put machine in horizontal position and perform inspection before starting the engine.

Check oil level with oil level gauge (1) located on side of hydraulic tank. It should be between Upper and Lower limits. If amount of oil is insufficient, pour oil to specified level with oil feed pump. Oil

1

must be matched to ambient temperature. ★ For supplying hydraulic oil, see "11.5 How to Operate Oil Supply Pump." ★ For hydraulic oil, see "11. How to Select Fuel, Water and Lubricating Oil."

Upper Limit

Lower Limit 17305001

4-1-13


Pre-Start Inspection

Drain Mixed Water And Sediments From Receiver Tank

WARNING Oil is highly flammable. Place a suitable drain pan when draining mixed water and sediments. Wipe up if necessary.

Open drain cock (1) on lower side of receiver tank and drain mixed water and sediments accumulated on bottom of tank in a suitable drain pan. Close drain cock (1) as soon as pure oil flows.

1

4-1-14


Pre-Start Inspection

Check Oil Level In Receiver Tank (For JIS Specification)

WARNING Spilled oil can cause a fire. Wipe up if necessary.

NOTICE When checking compressor oil level, put machine in horizontal position and perform inspections before starting the engine and during the operation of compressor.

★ For inspection of oil during the operation of compressor, see "4.2.3 Inspection After Starting the Engine." ★ To access receiver tank, open cover on left side of machine. Before starting the engine, check compressor oil level with oil level gauge (1) located on side of receiver tank. It should be within the range marked with STOP arrow. If amount of oil is insufficient, remove filler cap (2) and pour oil to specified level. ★ For compressor oil, see "11. How to Select Fuel, Water and Lubricating Oil."

2 1

運 転

RUN

RUN

STOPSTOP

停 止

17304001

4-1-15


Pre-Start Inspection

Check Oil Level In Receiver Tank (For ASME and EU Specification)

WARNING Spilled oil can cause a fire. Wipe up if necessary.

NOTICE When checking compressor oil level, put machine in horizontal position and perform inspections before starting the engine and during the operation of compressor.

★ For inspection of oil during the operation of compressor, see "4.2.3 Inspection After Starting the Engine." ★ To access receiver tank, open cover on left side of machine. Before starting the engine, check compressor oil level with oil level gauge (1) located on side of receiver tank.

Stop

It should be in the level gauge (1) that shows STOP. Run

If amount of oil is insufficient, remove filler cap (2) and pour oil 2

to specified level.

1

★ For compressor oil, see "11. How to Select Fuel, Water and Lubricating Oil." Insufficient

4-1-16


Pre-Start Inspection

Inspect Batteries

DANGER Batteries emit inflammable explosive gas. Keep sparks, flames and lighted tobacco away from batteries. Battery electrolyte is hazardous. Be careful not to spill or contact with battery electrolyte. But if the eyes or skin comes into contact with, wash out suffered part of your body with large amount of water and get medical attention immediately.

★ For detail, see "6.3 How to Handle Batteries." ★ To access batteries, open cover on left side of machine and remove cover (1). Battery electrolyte level should be between UPPER and LOWER levels. If it is below LOWER level, remove battery vent cap and pour 1

same electrolyte or distilled water to UPPER level. If no LEVEL marks are available on batteries, proper battery electrolyte level must be 10-15mm above polarity plates. After checking battery electrolyte level, inspect battery terminals. Check terminals for looseness and wipe off dirt or corrosions with a suitable brush if necessary. After cleaning, apply grease thinly onto terminals.

UPPER LEVEL

UPPER LEVEL LOWER LEVEL

LOWER LEVEL 26110071

4-1-17


Pre-Start Inspection

Drain Mixed Water And Sediments From Air Filter

WARNING Do not attempt to remove bowl (1) when residual pressure is in air filter - bodily injury may result. When removing bowl (1), check that pressure gauge (2) needle is pointing to "zero (0)," which means that no residual pressure is in air filter.

Air filter separates and removes water and debris from air circuit. Water and debris are collected in bowl (1) of air filter and drained by auto drain when collected to certain level. Auto drain, however, cannot operate properly if large amount of water and debris is in bowl (1) so be sure to discard those waste before they are collected to certain level. If large amount of water and debris accumulates in bowl (1), remove bowl (1) and discard those waste. Then clean inside of bowl (1) with a cloth. After cleaning, reinstall bowl (1) to air filter and put latch in lock position. 1

4-1-18

2


Pre-Start Inspection

Clean Dust From Loosening

WARNING When using compressed air, wear protections such as dust mask and safety goggles and adjust air pressure to under 0.2 MPa in advance.

Continuing operation with loosening covered with accumulated dust can cause rod to slip, leading to obstruction to safe rod collection and separation operation, and seal to damage, resulting in cylinder oil leak. Remove accumulated dust from loosening by using compressed air.

4-1-19


Pre-Start Inspection

Check Oil Level In Drill Motor Reduction Gear

WARNING Spilled oil can cause a fire. Wipe up if necessary.

NOTICE When checking oil level, put guide shell in horizontal position and perform inspection before starting the engine.

Check oil level with oil level gauge (1) located on side of reduction gear of drill motor. It should be to upper limit of red 2

mark. If amount of oil is insufficient, remove plug (2) and pour oil to upper limit level. ★ For oil, see "11. How to Select Fuel, Water and Lubricating Oil."

1

4-1-20


Operating the Engine

4.2 Operating the Engine This section describes engine operation from starting to stopping.

4.2.1 Before Starting the Engine 1. Perform pre-start inspection before getting on the machine and starting the engine. ★ For check items, see "4.1 Pre-Start Inspection." 2. Move safety lock lever (1) rearward to Lock position. 1

3. Turn engine throttle switch (2) to the "I" position. 4. Move all control levers and switches to their neutral or stop position. ★ Reset emergency stop system (if equipped). 2

5. Adjust operator seat so the operator can access the travel levers or foot pedals easily with his back positioned close to backrest. ★ For detail, see "3.8.1 Operator Seat." 6. Fasten the seat belt properly (if equipped).

4-2-1


Operating the Engine

Check Engine Monitor Lamp

CAUTION If engine monitor lamp does not go on at all, contact your nearest distributor.

Engine monitor lamp comes on when starter switch key is turned to the ON position. And about five minutes later, engine monitor lamp turns off. After starting the engine, all lamps must go on.

4-2-2


Operating the Engine

4.2.2 Starting the Engine

WARNING When starting the engine, sound horn to warn bystanders.

NOTICE Do not operate engine starter continuously for more than 30 seconds at a time. If engine fails to start, wait about two minutes and restart it.

1. Turn starter switch key to the ON position for about 20 seconds. Mini-compressor (1) starts running and unload valve closes and compressor stops temporarily. Engine monitor lamp on meter panel comes on for about 5 seconds and then turns off.

OFF

ON STAR

17314078 17214021

1

2. After mini-compressor (1) running sound stops, turn starter switch key to the START position to start the engine. ★ Compressor automatically starts running as engine starts.

OFF

ON STAR

17214020

4-2-3


Operating the Engine

3. After starting engine, release starter switch key. Starter switch key automatically returns to the ON position.

OFF

ON STAR

17314078 17214021

4. About 15 seconds later, receiver tank air pressure gauge (2) needle points to 0.39-0.49MPa. 2

5. After warming up compressor, receiver tank air pressure gauge (2) needle points to 1.3-1.5MPa. ★ Compressor warming-up time varies depending on timer set time (about one minute 30 seconds to three minutes). 6. Indications on IMS display darken if there's no problem in the machine.

4-2-4


Operating the Engine

Precautions When Restarting the Engine

CAUTION Wait five minutes or more until air in the receiver tank is removed completely, then restart the engine. Otherwise, not only engine but also pump, coupling and compressor may be damaged.

When restarting the engine, check that pressure gauge (1) needle is pointing to "0 (zero)" which means that internal pressure has been released completely.

1

4-2-5


Operating the Engine

4.2.3 Stopping the Engine Engine is hot after running in full load so cool it down slowly and stop it.

1. Park machine on a firm, level surface and put in travel posture or put guide shell in vertical position and make foot pad press on the surface. 2. Move safety lock lever (1) rearward to the Lock position. 1

3. Move all control levers and switches to their neutral or stop position.

4. Turn engine throttle switch (2) to the "I" position. Run engine at idle speed for 2-3 minutes.

2

5. Turn starter switch key to the "O" (stop) position to stop the engine.

OFF

ON STAR

17214014

4-2-6


Inspection After Starting the Engine

4.3 Inspection After Starting the Engine Do not operate the machine immediately after starting the engine. Instead, the following should be performed. And engine must be stopped with emergency stop system operated (if equipped). After stopping the engine, return starter switch key to the OFF position to reset the stop condition.

1. After checking with the pressure gauge that internal pressure in the receiver tank has been released completely, restart the engine. 2. Check that no warning indications are shown on the IMS display (1). 3. Warm up the engine at idle speed for about five minutes. 4. Check that there is no abnormal engine vibration, sound, or fume. Check for oil leak from engine and hydraulic equipment.

NOTICE Do not run engine at high speed or operate levers quickly until the warming-up operation is completed.

4-3-1

1


Inspection After Starting the Engine

Check Receiver Tank Safety Valve Operation

WARNING Compressed air can jet out. When operating safety valve lever (2), wear safety glasses and keep your face and hand away from the jet-out port (3).

With the safety valve, air in the receiver tank jets out to maintain constant air pressure in the tank. Jetting-out pressure of safety valve: 2.94MPa.

1. Warm up the engine. 2. Using receiver tank air pressure gauge (1), check that internal pressure in the receiver tank is set to 1.3-1.5MPa.

1

3. Operating safety valve lever (2) on upper side of receiver tank, check that air jets out properly from the port. 3

2

4-3-2


Inspection After Starting the Engine

Check Oil Level In Receiver Tank (For JIS Specification)

WARNING Spilled oil can cause a fire. Wipe up if necessary.

NOTICE When checking compressor oil level, put machine in horizontal position.

On completion of the inspection of receiver tank safety vale, check oil level in receiver tank as follows:

1. Check with the pressure gauge that receiver tank air pressure is set to 1.3-1.5MPa. 2. Check with the oil level gauge (1). It should be within the range marked with STOP arrow. 2 1

停 止

運 転

RUN

RUN

STOPSTOP

3. If amount of oil is insufficient, first stop the engine, then about 10-20 minutes later, remove oil filler cap (2) and pour oil to specified level. ★ For compressor oil, see "11. How to Select Fuel, Water and Lubricating Oil."

17304001

4-3-3


Inspection After Starting the Engine

Check Oil Level In Receiver Tank (For ASME and EU Specification)

WARNING Spilled oil can cause a fire. Wipe up if necessary.

NOTICE When checking compressor oil level, put machine in horizontal position.

On completion of the inspection of receiver tank safety vale, check oil level in receiver tank as follows:

1. Check with the pressure gauge that receiver tank air pressure is set to 1.3-1.5MPa. 2. Check with the oil level gauge (1). It should be in the level gauge (1) that shows RUN. 3. If amount of oil is insufficient, first stop the engine, then about 10-20 minutes later, remove oil filler cap (2) and pour oil to specified level. ★ For compressor oil, see "11. How to Select Fuel, Water and Lubricating Oil."

4-3-4

Stop

Run

2 1 Insufficient


Inspection After Starting the Engine

Check Difference Pressure Indicator of Oil Separator Use difference pressure indicator (1) of oil separator on right side of receiver tank to check when to replace oil separator. The indicator needle must be within the green zone. Before the needle points to the red zone, replace the oil separator. Clogging oil separator can cause delivery air with oil, resulting in failure in the system.

1

Difference Pressure Indicator

FILTER CONDITION

147kPa

Needle

4-3-5


Inspection After Starting the Engine

Inspect/Adjust Feed Chain Tension Feed chain to move rotary head and hose reel forward and backward must have proper tension at all times. Feed chain elongates gradually during a certain period so the tension must be checked and adjusted prior to the operation.

Inspection Put the guide shell in horizontal position and lower it. Rotary head is at the rear end of the guide shell. Insert a steel bar under the middle of the feed chain and raise it. Proper tension in feed chain is 60-80 mm. Adjust if necessary. Adjustment Adjust tension in feed chain with chain adjusters on both left and right sides of guide shell. 1. Loosen chain adjuster securing nuts (1) on both sides. 2. Tighten left and right adjusting nuts (3) one after the other so that front shaft (2) is at right angle to guide shell. 1

3. Check that feed chain is properly tight. 3

4. After obtaining proper tension, tighten left and right securing nuts (1) firmly.

2

2 1

4-3-6

3


Inspection After Starting the Engine

Lubricate Each Part of Machine Before lubrication, lower guide shell to the surface by operating hydraulic cylinder control levers and stop the engine. Use a grease pump for lubrication. Using grease polluted with dust, sand etc can cause rotating parts to wear early. After lubrication, wipe off old grease forced out. Lubrication points are as follows:

Guide Shell 1. Sprocket shaft: one

1

1. 2. 3. 4. 5.

Loosening Loosening swing cylinders: two on both sides Clamp arm bushes: two on both sides Loosening cylinders: two on both sides Loosening: one Clamp arm pin: two on both sides

4

2

1

5

Magazine 1. Magazine: one

1

4-3-7

3


Inspection After Starting the Engine

2. Gearbox

2

Clamps Clamps are located on front and rear sides of machine. 1. 2. 3. 4. 5.

1

Arm pin: one Swing cylinder: two 2

Clamp cylinder: one Swing pin: two on both sides Swing cylinder plate pins: two

3

4

5

Auto Grease 1. Bracket arm pin: one

1

4-3-8


Inspection After Starting the Engine

2. Swing cylinder plate pins: two

2

4-3-9


Driving the Machine

4.4 Driving the Machine

WARNING If any problem is found, do not drive or operate the machine until it is cleared up. Perform inspection maintenance if necessary.

Select a firm, level surface with ample spaces when driving the machine. After starting the engine, perform warm-up operation. Move work equipment slowly, while warming hydraulic oil. Check that indications of each hydraulic control lever are matched to the moving directions of work equipment. Drive the machine at slow speed and check that machine has no problem in the straight drive or travel lever operation.

4-4-1


Driving the Machine

4.4.1 Travel Posture

WARNING Before driving the machine, be sure to put the machine in travel posture.

2

1

1. Put the machine in horizontal position to the surface by operating hydraulic cylinder control levers. 2. Put the rotary head to the rear end of the guide shell. 3. Put the bracket (1) of the guide shell on the pedestal (2) of the machine by operating hydraulic cylinder control levers.

4-4-2


Driving the Machine

4.4.2 Starting the Machine

WARNING When starting the machine, sound horn to warn bystanders. The rear of the machine is a blind spot for the operator. When moving the machine backward, be sure all persons and obstacles are clear of the back area. Use the under-mirror on the rear of the machine for ensures vision.

CAUTION When changing from travel forward into backward and vice versa, be sure to stop the machine at a time to reduce stress on the drive system.

1. Turn engine throttle switch (1) to the "II" position. 2. Put the machine in travel posture. ★ For travel posture, see "4.4.1 Travel Posture."

1

3. Move safety lock lever (2) forward to the unlock position. 4. To drive the machine forward or backward, move left and right travel levers (3) (or foot pedals) forward or backward slowly. Adjust travel speed by operating travel levers (3) (or foot pedals) and engine throttle switch (1).

4-4-3

3 2


Driving the Machine

4.4.3 Changing the Machine Direction

WARNING Avoid changing machine direction on a slope. If ignored, machine tipping over or skidding may result.

NOTICE Do not attempt to perform spin-turn at high speed or rapid turn on rocky, clayey or rough surface. If ignored, track slipping or premature wear to undercarriage may result.

Use travel levers (1) (or foot pedals) to change the machine direction.

1

Changing Machine Direction From a Stop Change machine direction from a stop as follows: To travel forward and turn left, move right travel foot pedal) forward. To travel reverse and turn left, move right travel foot pedal) backward. To travel forward and turn right, move left travel foot pedal) forward. To travel reverse and turn right, move left travel foot pedal) rearward.

4-4-4

lever (or lever (or lever (or lever (or

Travel Forward and Turn Left Travel Reverse and Turn Left


Driving the Machine

Changing Machine Direction During Travel Change machine direction during travel as follows: To turn left during travel forward, move left travel lever (or foot pedal) slowly to the neutral position. To turn left during travel reverse, move left travel lever (or foot pedal) slowly to the neutral position. To turn right during travel reverse, move right travel lever (or foot pedal) slowly to the neutral position. Travel Forward and Turn Left Travel Reverse and Turn Left

Spin Turn To spin turn left, move left travel lever (or foot pedal) backward and at the same time move right travel (or foot pedal) lever forward. To spin turn right, move right travel lever (or foot pedal) backward and at the same time move left travel lever (or foot pedal) forward.

NOTICE When performing spin turn, select a firm, level surface and stop the machine at a time.

4-4-5


Driving the Machine

4.4.4 Stopping the Machine

WARNING When stopping the machine on a slope, put the guide shell in vertical position and make the foot pad press on the surface and block up the tracks.

NOTICE When stopping the machine, decrease engine speed and move left and right travel levers (or foot pedals) slowly to their neutral position.

1. Select a firm, level surface and stop the machine by moving left and right travel levers (or foot pedals) slowly to their neutral position. ★ Travel levers (or foot pedals) return to their neutral position when they are released. 2. Put the machine in travel posture or put the guide shell in vertical position and make the foot pad press on the surface. ★ For travel posture, see "4.4.1 Travel Posture." 3. Turn engine throttle switch (1) to the "I" position.

1

4. Move safety lock lever (2) backward to the Lock position.

2

4-4-6


Parking the Machine

4.5 Parking the Machine

WARNING Avoid unstable surface such as possibly landslides. Always park the machine in a level, firm surface.

If parking on a slope is unavoidable, put the guide shell in vertical position and make the foot pad press on the surface and block up the tracks.

1. After selecting a level, firm surface, park and stop the machine by moving left and right travel levers (or foot pedals) to their neutral position. Travel levers (or foot pedals) return to their neutral position when they are released. 2. Put the machine in travel posture or put the guide shell in vertical position and make the foot pad press on the surface. 3. Move all control levers and switches to their neutral or stop position. 4. Turn engine throttle switch (1) to the "I" position.

1

5. Move safety lock lever (2) backward to the Lock position. 6. Remove starter switch key. Store starter switch key in the right place. 2

4-5-1


Parking the Machine

4.5.1 Locking Door and Covers

CAUTION When you leave the machine, be sure to lock the door and covers to prevent machine theft or unexpected trouble.

1

2 3

(1) Cab door ★ Cab windows must be closed (2) Outside air filter cover (3) Side covers (on both sides)

4-5-2


Drilling Operation

4.6 Drilling Operation

WARNING Before drilling operation, clear all persons of the dangerous work area; otherwise death or serious injury may result. Drilling operation without wearing hearing protections can cause impairment or loss of hearing. Wear earplugs, earmuffs etc to protect against objectionable loud noises. Avoid breathing dust for hours. Failure to do so may cause lung disease such as pneumoconiosis. Wear a dust mask when performing drilling operation.

CAUTION Engine exhaust gas is toxic. Beware of the direction of a wind and the position or direction of the machine to avoid engine exhaust gas.

This section describes the sequence of drilling operations from preparation for drilling operation to inspection after drilling operation. Adjusting feed force, feed speed and rotation speed to the rock or geologic conditions on the work site is essential for proper drilling operation. ★ For operation of rod changer, see "4.7 Operating the Rod Changer."

4-6-1


Drilling Operation

4.6.1 Preparation for Drilling Operation First move the machine to the work area, then check the following functions:

1. Move safety lock lever (1) rearward to the Lock position.

1

2. Turn engine throttle switch (2) to the "II" position. 3. Move blow lever (3) rightward. Air jets out from the tip of the hammer.

3 2

4. Check that rock drill oil lamp (4) on meter panel is blinking. ★ Amount of rock drill oil varies, depending on the type of a hammer. For detail, see operation manual of down-the-hole hammer. ★ For rock drill oil lamp, see "3.1 Meter Panel."

4

4-6-2


Drilling Operation

4.6.2 Collaring Operation

WARNING Before cleaning drillhole or filling up with clay, be sure to stop the drilling operation.

NOTICE If upper layer is not stable, hole wall may collapse, resulting in drilling operation or rotary head reverse feed inoperative. If drillhole is not firm and stable, reinforce hole wall with clay etc.

Before drilling, perform collaring operation to make later drilling more smooth and efficient and to minimize wear or damage to drilling tools. Perform collaring in a depth of 20-30 cm so that proper collaring point or direction is fixed. ★ In a limestone mine, for example, collaring in a depth of 1-2 m may be performed to reach stable upper layer.

1. Adjust guide shell tilt angle to the bench set angle by operating hydraulic cylinder control levers. Position guide shell to the collaring point, and make foot pad press on the surface.

2. Move guide shell forward until the front of the tracks is lifted off the surface by 5-10 cm, and stop it.

5 – 10cm

4-6-3


Drilling Operation

3. Rotate shank rod in normal rotation (counterclockwise direction) by pressing left side of rotation switch on top of the drill control lever (1).

1

4. Move blow lever (2) to the right. 5. Make anti-jamming operative by pressing front side of anti-jamming switch (3). 2

3

6. Move drill control lever (1) forward to the 1st position. Rotary head performs forward feed to start collaring. ★ In lever pull drilling specification, move drill control lever (1) backward to the 1st position.

Lever Push Drilling Spec.

4

7. After starting collaring, turn feed pressure adjust-handle (4) to perform drilling at low feed force. ★ For feed pressure adjust-handle, see "3.4 Right Console."

1

Lever Pull Drilling Spec.

1 4

4-6-4


Drilling Operation

4.6.3

Drilling Operation

After collaring is performed, while collaring point or direction is fixed, drilling upper layer, start drilling operation as follows:

1. Close rod guide on loosening side by pressing front side of rod guide switch (1). ★ Hold the switch until rod guide movement stops completely.

1

2. Make hood (3) press on the drillhole (drillhole should be covered) by moving hood/loosening lever (2) to the rear. Return the lever (2) to the neutral position. 2

3

3. Turn engine throttle switch (4) to the "V" position.

4

4-6-5


Drilling Operation

4. Move blow lever (5) to the rear. Full blow air jets out and dust collector starts operating.

5. Move drill control lever (6) forward to the 1st position and then the 2nd position and stop there. Drilling starts. ★ In lever pull drilling specification, move drill control lever (6) backward to the 1st position and then the 2nd position and stop there.

5

Lever Push Drilling Spec.

7

6

Lever Pull Drilling Spec.

6 7

6. Adjust feed force by turning feed force adjust-handle (7) to the proper position.

4-6-6


Drilling Operation

Check/Adjust Discharge and Consumption of Rock Drill Oil

NOTICE Discharge of rock drill oil varies depending on the kind of oil or ambient temperature. For discharge of rock drill oil, refer to the manual of the down-the-hole hammer.

Lower discharge of rock drill oil can cause the hammer to seize up. Check that the discharge of rock drill oil is the specified level during the drilling operation. ★ Discharge of rock drill oil when shipping is 1.8 L/H. Check the consumption of rock drill oil with the level gauge on the rock drill oil tank. If the residual oil level is less than 6 L, the oil may not be discharged, which is often affected by the leaning of the machine. Refill the tank so that the oil level is at least 10 L.

If the discharge of rock drill oil is not the specified level, perform adjustment using the lubrication timer ON dial (1) and OFF dial (2). ★ Those lubrication timers are located at the control panel. Adjustment of discharge of rock drill oil for reference: Discharge

ON dial (orange pointer)

OFF dial (green pointer)

2.4 L/H

15 sec

15 sec

1.8 L/H

20 sec

20 sec

1.2 L/H

30 sec

30 sec

4-6-7

1 2


Drilling Operation

Drilling Precautions Cleaning Drillhole If cuttings are not blown properly or flushing air pressure is increased excessively, stop drilling once and make down-the-hole hammer move vertically two or three times. After cleaning drillhole, resume drilling operation. In anti-jamming function ON, rotary head feed stops automatically if rotation speed is increased abnormally. ★ For anti-jamming switch, see "3.5.2 Switch Panel." Watching for Water Taking dust with water into dust collector causes filter element clogging, resulting in the decrease of the effect of dust collecting. If water is found during drilling operation, move blow lever (1) to the left. Result: Dust collector stops operating and full blow air jets out.

1

4-6-8


Drilling Operation

4.6.4 Inspection After Drilling Operation

CAUTION If any failure is found, fix or repair it or replace if necessary.

After drilling operation, collect rods. Then perform walk-around inspection for any failure in each part of the machine. This inspection is very important for safe machine operation and prevents failure from occurring. ★ For collecting rods, see "4.7 Operating the Rod Changer."

1. Walk around machine to check for fuel, oil or water leaks. 2. Check boom and boom mounting bracket for deformation or damage. 3. Check down-the-hole hammer for excessive wear or damage. 4. Check guide shell for deformation or damage. 5. Check rotary head for oil leaks. 6. Check hose and hose fittings for oil leaks. 7. Check front and rear clamps for excessive wear or damage. 8. Check magazine and set plate for deformation or excessive wear. 9. Check collected rods for excessive wear in threads, bend, damage or crack. 10. Check engine room for oil or fuel leaks. 11. Check undercarriage and remove dirt.

4-6-9


Operating the Rod Changer

4.7 Operating the Rod Changer

WARNING Keep your hand clear of rotating parts such as rod (1), hammer and cushion sub during operation of rod changer or rotary head (2). If not, your finger getting caught in those parts may result. Cutting or crushing hazard. Keep your hand clear of loosening (3) when opening/closing upper and lower clamps. Operator and service person should arrange signs in advance and do the work carefully, giving signs each other. Miss-operation by drill control lever can cause death or serious injury. Before operating rod changer (rod storing, adding and collecting), be sure to check which type of drill control lever (Lever Push or Lever Pull drilling specification) is employed in your machine and operate it correctly.

2

1

3

To clearly understand the operating procedure of the rod changer by the type of drill control lever, the text described later is divided into lever push and lever pull drilling specifications.

4-7-1


Operating the Rod Changer

Storing Rods

WARNING Rod is a heavy object. When storing rod in rod changer, use a suitable lifting device such as a crane. When storing rod in rod changer, operator and service person should arrange signs in advance and do the work carefully, giving signs each other.

1. Turn engine throttle switch (1) to the "II" position. 2

2. Lower guide shell in horizontal position to the surface so that rod can be screwed in easily. 4

1

3. Move rotary head (3) backward to the rear end of guide shell at fast speed by moving drill control lever (2) backward all the way to the end position. ★ In lever pull drilling specification, move lever forward all the way to the 2nd position. 5

4. Turn set plate (5) and determine rod insertion position by moving rod changer control lever (4) forward or backward. Return lever to the neutral position.

6

3

5. Move front and rear clamps (6) back to the retraction position on the magazine side by moving rod changer control lever (4) rightward. After clamp movement stops, return lever to the neutral position. 6. Attach a nylon sling to the rod and lift rod with a crane and place it in the set plate (5). ★ The maximum eight rods can be stored.

4-7-2

6 5


Rod Changer Operation: Lever Push Drilling Specification

4.7.1

Rod Changer Operation: Lever Push Drilling Specification

This section describes the operating procedure of rod changer operation - rod adding and collecting under Lever Push drilling specification. In this section, shank rod of rotary head is equipped with cushion sub and joint piece. For recommended cushion sub and joint piece installation dimensions, refer to the following:

705mm

Stroke: 60mm

300mm

Joint Piece

Cushion Sub

Adding Rod 1. Stop jetting out air by returning blow lever to neutral position.

2. Move drill control lever backward all the way to the end position and the rotary head will move backward so stop it at a position where the connection of rod and joint piece is between upper clamp and lower clamp. ★ Distance between carriage and stopper varies, depending on the length of cushion sub and joint piece.

Approx 30−100mm

Rod Separation Position

4-7-3


Rod Changer Operation: Lever Push Drilling Specification

3. Secure rod on connection lower side by moving lower clamp switch to the left. After lower clamp stops, return switch to neutral position.

Lower Clamp

4. Move rotary head backward slowly until there is some stroke between shank rod and cushion sub by moving drill control lever backward to the 1st position.

5. Press right side of rotation switch and shank rod will rotate reverse and connection of rod and joint piece be loosened. 6. When connection rod and joint piece is fully loosened, there is no stroke between shank rod and cushion sub. Release rotation switch. 7. If connection rod and joint piece is not loosened, perform the following procedures to loosen it.

4-7-4


Rod Changer Operation: Lever Push Drilling Specification

8. Secure joint piece with upper clamp by moving upper clamp switch to the left. ★ Switch is held in the same position.

9. Swing upper clamp in clockwise direction by moving hood/loosening lever to the right. ★ When upper clamp swings in clockwise direction, clamp slightly opens and releases joint piece.

Upper Clamp

10. Move hood/loosening lever to the left and upper clamp will secure joint piece and swing in counterclockwise direction. Loosen connection of rod and joint piece.

11. Move upper clamp switch to the right. After upper clamp fully opens, return switch to neutral position.

4-7-5


Rod Changer Operation: Lever Push Drilling Specification

12. After connection of rod and joint piece is loosened, move drill control lever backward to the 1st position and rotary head will move backward to a position where top of joint piece comes in middle of stopper. Then return lever to neutral position.

13. Put grease onto threads of joint piece by moving greasing switch to the up. After greasing, release switch.

14. Move rotary head backward at fast feed by moving drill control lever backward all the way to the end position. When rotary head reverse feed changes from fast to normal feed, return lever to neutral position.

15. Move rod changer control lever to the left and magazine shutter will open and front and rear arms grasping rod will move to drilling center. After front and rear arms stop moving and buzzer sounds, return lever to neutral position.

4-7-6


Rod Changer Operation: Lever Push Drilling Specification

16. Press left side of rotation switch and move drill control lever forward to the 1st position. Rotary head will move forward, while shank rod is rotating in normal rotation, to make joint piece to screw onto top of rod. 17. After joint piece is completely screwed onto top of rod, clamp grasping rod slightly opens and releases rod.

18. After rotary head moves forward to a position where bottom of rod comes in middle of stopper, return drill control lever to neutral position.

19. Put grease onto threads of rod by moving greasing switch to the up. After greasing, release switch.

20. Move drill control lever forward to the 1st position. Rod will move forward, while it's rotating, to screw onto lower rod secured with lower clamp.

4-7-7


Rod Changer Operation: Lever Push Drilling Specification

21. After rotating rod stops, press left side of rotation switch to stop rotating shank rod and return drill control lever to neutral position.

22. Move rod changer control lever to the right. Clamps will open and front and rear arms retract. After magazine shutter closes and buzzer sounds, return lever to neutral position. ★ When retracting arms, check that no rod is stored on set plate.

23. Move lower clamp switch to the right and lower clamp will open. Resume drilling operation.

4-7-8


Rod Changer Operation: Lever Push Drilling Specification

Collecting Rods 1. Move drill control lever backward all the way to the end position and press the positioning switch. 2. Rotary head reverse feed changes from fast to normal feed as rod comes up to storage position (loosening position). If reverse feed continues, rotary head stops automatically and buzzer sounds.

Positioning Switch

3. Return drill control lever to neutral position and release positioning switch.

4. Secure rod by moving lower clamp switch to the left. After lower clamp stops moving, release switch. ★ Rod is held in center position by closing lower clamp.

Lower Clamp

5. Secure rod by moving upper clamp switch to the left. ★ Switch is held in the same position.

Upper Clamp

4-7-9


Rod Changer Operation: Lever Push Drilling Specification

6. Move hood/loosening lever to the left. Upper clamp holding upper rod will swing in counterclockwise direction to loosen connection to lower rod.

NOTICE Do not loosen thread excessively - thread damage may result. Note that only upper rod rotates but lower rod does not rotate.

7. If rod is not loosened, move hood/loosening lever to the right and upper clamp will swing in clockwise direction. ★ When swinging upper clamp, clamp slightly opens and releases rod. 8. Move hood/loosening lever to the left again and upper rod will be loose.

9. Move upper clamp switch to the right to open upper clamp. After upper clamp opens completely, release switch. Switch returns to neutral position.

10. Press right side of rotation switch to completely separate upper rod from lower rod.

4-7-10


Rod Changer Operation: Lever Push Drilling Specification

11. Secure separated rod by moving upper clamp switch to the left. ★ Switch is held in the same position.

12. Loosen connection of rod and joint piece by pressing right side of rotation switch. Release switch.

NOTICE Do not loosen thread excessively - rod slipping off may result.

13. Move upper clamp switch to the right. After upper clamp opens completely, release switch. Switch returns to neutral position.

14. Move rod changer control lever to the left. Clamps will open and front and rear arms move from retraction position to drilling center and grasp rod. After buzzer sounds, return lever to neutral position. Arm is in half-clamp* position.

4-7-11


Rod Changer Operation: Lever Push Drilling Specification * half-clamp: Rod is grasped with front and rear clamps and maintained in drilling center. In short, rod is maintained and supported. This is different from a condition that rod is grasped with clamps and secured not to move.

NOTICE

Rod

Arm can be damaged - check that no rod in magazine is held with clamps when moving arms to drilling center.

Clamp

15. Move drill control lever backward all the way to the end position and press positioning switch. Sequences of operations up to grasping of rod are performed automatically. 16. Move drill control lever backward all the way to the end position and press positioning switch. Sequences of operations up to grasping of rod are performed automatically. ★ Lower end of separated rod must be over magazine guide.

17. After buzzer sounds, front and rear clamps close and grasp rod. Return drill control lever to neutral position and release positioning switch.

4-7-12

Magazine Guide

Positioning Switch

Arm


Rod Changer Operation: Lever Push Drilling Specification

18. Press right side of rotation switch and move drill control lever backward to the 1st position. Shank rod will rotate reverse and connection of rod and joint piece be loosened. 19. When connection rod and joint piece is fully loosened, there is no stroke between shank rod and cushion sub.

20. Move drill control lever backward all the way to the end position. Shank rod will rotate reverse and upper rod be separated from joint piece. Move rotary head backward at fast feed until it stops at rear end of guide shell.

21. After rod is separated, move rod changer control lever to the right and rod in drilling center will be stored in carriers. ★ Do not return lever to neutral position until rod changer stops moving.

4-7-13


Rod Changer Operation: Lever Push Drilling Specification

22. Move drill control lever forward all the way to the end position and rotary head will move forward at fast feed. Joint piece will move forward near upper clamp and stop.

23. Press left side of rotation switch and move drill control lever forward to the 1st position. Rotary head will move forward, while shank rod is rotating in normal rotation, to make joint piece to screw onto rod secured with lower clamp.

24. After joint piece is completely screwed onto and rotation of shank rod stops, return drill control lever to neutral position and press left side of rotation switch once again. Shank rod will stop rotating. ★ If joint piece is screwed completely, rotation pressure gauge needle points to 10-14MPa.

25. Repeat steps 1 to 24 to collect other remaining rods.

4-7-14


Rod Changer Operation: Lever Pull Drilling Specification

4.7.2 Rod Changer Operation: Lever Pull Drilling Specification This section describes the operating procedure of rod changer operation - rod adding and collecting under Lever Push drilling specification. In this section, shank rod of rotary head is equipped with cushion sub and joint piece. For recommended cushion sub and joint piece installation dimensions, refer to the following:

705mm

Stroke: 60mm

300mm

Joint Piece

Cushion Sub

Adding Rod 1. Stop jetting out air by returning blow lever to neutral position.

2. Move drill control lever forward all the way to the end position and the rotary head will move backward so stop it at a position where the connection of rod and joint piece is between upper clamp and lower clamp. ★ Distance between carriage and stopper varies, depending on the length of cushion sub and joint piece.

Approx 30−100mm Rod Separation Position

4-7-15


Rod Changer Operation: Lever Pull Drilling Specification

3. Secure rod on connection lower side by moving lower clamp switch to the left. After lower clamp stops, return switch to neutral position.

Lower Clamp

4. Move rotary head forward slowly until there is some stroke between shank rod and cushion sub by moving drill control lever forward to the 1st position.

5. Press right side of rotation switch and shank rod will rotate reverse and connection of rod and joint piece be loosened. 6. When connection rod and joint piece is fully loosened, there is no stroke between shank rod and cushion sub. Release rotation switch. 7. If connection rod and joint piece is not loosened, perform the following procedures to loosen it.

4-7-16


Rod Changer Operation: Lever Pull Drilling Specification

8. Secure joint piece with upper clamp by moving upper clamp switch to the left. ★ Switch is held in the same position.

9. Swing upper clamp in clockwise direction by moving hood/loosening lever to the right. ★ When upper clamp swings in clockwise direction, clamp slightly opens and releases joint piece.

Upper Clamp

10. Move hood/loosening lever to the left and upper clamp will secure joint piece and swing in counterclockwise direction. Loosen connection of rod and joint piece.

11. Move upper clamp switch to the right. After upper clamp fully opens, return switch to neutral position.

4-7-17


Rod Changer Operation: Lever Pull Drilling Specification

12. After connection of rod and joint piece is loosened, move drill control lever forward to the 1st position and rotary head will move backward to a position where top of joint piece comes in middle of stopper. Then return lever to neutral position.

13. Put grease onto threads of joint piece by moving greasing switch to the up. After greasing, release switch.

14. Move rotary head backward at fast feed by moving drill control lever forward all the way to the end position. When rotary head reverse feed changes from fast to normal feed, return lever to neutral position.

15. Move rod changer control lever to the left and magazine shutter will open and front and rear arms grasping rod will move to drilling center. After front and rear arms stop moving and buzzer sounds, return lever to neutral position.

4-7-18


Rod Changer Operation: Lever Pull Drilling Specification

16. Press left side of rotation switch and move drill control lever backward to the 1st position. Rotary head will move forward, while shank rod is rotating in normal rotation, to make joint piece to screw onto top of rod. 17. After joint piece is completely screwed onto top of rod, clamp grasping rod slightly opens and releases rod.

18. After rotary head moves forward to a position where bottom of rod comes in middle of stopper, return drill control lever to neutral position.

19. Put grease onto threads of rod by moving greasing switch to the up. After greasing, release switch.

20. Move drill control lever backward to the 1st position. Rod will move forward, while it's rotating, to screw onto lower rod secured with lower clamp.

4-7-19


Rod Changer Operation: Lever Pull Drilling Specification

21. After rotating rod stops, press left side of rotation switch to stop rotating shank rod and return drill control lever to neutral position.

22. Move rod changer control lever to the right. Clamps will open and front and rear arms retract. After magazine shutter closes and buzzer sounds, return lever to neutral position. ★ When retracting arms, check that no rod is stored on set plate.

23. Move lower clamp switch to the right and lower clamp will open. Resume drilling operation.

4-7-20


Rod Changer Operation: Lever Pull Drilling Specification

Collecting Rods 1. Move drill control lever forward all the way to the end position and press the positioning switch. 2. Rotary head reverse feed changes from fast to normal feed as rod comes up to storage position (loosening position). If reverse feed continues, rotary head stops automatically and buzzer sounds. 3. Return drill control lever to neutral position and release positioning switch.

Positioning Switch

4. Secure rod by moving lower clamp switch to the left. After lower clamp stops moving, release switch. ★ Rod is held in center position by closing lower clamp.

Lower Clamp

5. Secure rod by moving upper clamp switch to the left. ★ Switch is held in the same position.

Upper Clamp

4-7-21


Rod Changer Operation: Lever Pull Drilling Specification

6. Move hood/loosening lever to the left. Upper clamp holding upper rod will swing in counterclockwise direction to loosen connection to lower rod.

NOTICE Do not loosen thread excessively - thread damage may result. Note that only upper rod rotates but lower rod does not rotate.

7. If rod is not loosened, move hood/loosening lever to the right and upper clamp will swing in clockwise direction. ★ When swinging upper clamp, clamp slightly opens and releases rod. 8. Move hood/loosening lever to the left again and upper rod will be loose.

9. Move upper clamp switch to the right to open upper clamp. After upper clamp opens completely, release switch. Switch returns to neutral position.

10. Press right side of rotation switch to completely separate upper rod from lower rod.

4-7-22


Rod Changer Operation: Lever Pull Drilling Specification

11. Secure separated rod by moving upper clamp switch to the left. ★ Switch is held in the same position.

12. Loosen connection of rod and joint piece by pressing right side of rotation switch. Release switch.

NOTICE Do not loosen thread excessively - rod slipping off may result.

13. Move upper clamp switch to the right. After upper clamp opens completely, release switch. Switch returns to neutral position.

14. Move rod changer control lever to the left. Clamps will open and front and rear arms move from retraction position to drilling center and grasp rod. After buzzer sounds, return lever to neutral position. Arm is in half-clamp* position.

4-7-23


Rod Changer Operation: Lever Pull Drilling Specification * half-clamp: Rod is grasped with front and rear clamps and maintained in drilling center. In short, rod is maintained and supported. This is different from a condition that rod is grasped with clamps and secured not to move.

NOTICE

Rod

Arm can be damaged - check that no rod in magazine is held with clamps when moving arms to drilling center.

Clamp

15. Move drill control lever forward all the way to the end position and press-positioning switch. Sequences of operations up to grasping of rod are performed automatically. 16. Move drill control lever forward all the way to the end position and press positioning switch. Sequences of operations up to grasping of rod are performed automatically. ★ Lower end of separated rod must be over magazine guide.

17. After buzzer sounds, front and rear clamps close and grasp rod. Return drill control lever to neutral position and release positioning switch.

4-7-24

Magazine Guide

Arm


Rod Changer Operation: Lever Pull Drilling Specification

18. Press right side of rotation switch and move drill control lever forward to the 1st position. Shank rod will rotate reverse and connection of rod and joint piece be loosened. 19. When connection rod and joint piece is fully loosened, there is no stroke between shank rod and cushion sub.

20. Move drill control lever forward all the way to the end position. Shank rod will rotate reverse and upper rod be separated from joint piece. Move rotary head backward at fast feed until it stops at rear end of guide shell.

21. After rod is separated, move rod changer control lever to the right and rod in drilling center will be stored in carriers. ★ Do not return lever to neutral position until rod changer stops moving.

4-7-25


Rod Changer Operation: Lever Pull Drilling Specification

22. Move drill control lever backward all the way to the end position and rotary head will move forward at fast feed. Joint piece will move forward near upper clamp and stop.

23. Press left side of rotation switch and move drill control lever backward to the 1st position. Rotary head will move forward, while shank rod is rotating in normal rotation, to make joint piece to screw onto rod secured with lower clamp.

24. After joint piece is completely screwed onto and rotation of shank rod stops, return drill control lever to neutral position and press left side of rotation switch once again. Shank rod will stop rotating. ★ If joint piece is screwed completely, rotation pressure gauge needle points to 10-14MPa.

25. Repeat steps 1 to 24 to collect other remaining rods.

4-7-26


Handling the Grease Nozzle

4.8 Handling the Grease Nozzle Grease nozzle ejects grease to the threads of the shank rod or rod. When adding or collecting rod, operate the grease nozzle (1) to apply grease to the threads of the rod, joint piece etc. ★ For operation of rod changer, see "4.7 Operating the Rod Changer”. Grease is forced out through the grease nozzle (1) by moving greasing switch (2) to the up, located on left console, and greasing stops when greasing switch (2) is released.

1

2

Adjust Amount of Grease Amount of grease from the nozzle can be adjusted with the needle valve handle (1). ★ Before drilling operation, adjust it to the proper amount of grease.

1

4-8-1


Handling the Grease Nozzle

Replace Grease

WARNING Putting grease into the eyes or skin can cause bodily injury or inflammation. When replacing grease can (pail), wear protections such as safety glasses and gloves. If it occurs, wash eyes or skin with clean water for at least 15 minutes, and get medical attention immediately.

NOTICE If dirt, dust etc accumulates in the grease pump or follower disc, grease pump failure will result. When replacing grease can (pail), clear of dirt, dust etc.

If grease needs to be replaced because of shortage in amount or changed ambient temperature, remove grease pump and replace grease can (pail).

Replacement Procedure Grease pump (1) can be used with grease can (pail) available on the market. 1. Remove air hose (2) and grease hose (3) from the grease pump (1). Loosen three set screws (4) and remove grease pump (1).

1

2

3

2. Remove follower disc (6) from grease can (5) and replace grease can (5) with the new one. Use heat/pressure-resistance grease matched to ambient temperature. ★ For grease, see "12. List of Fuel, Water and Lubricating Oil." 3. Place follower disc (6) and slightly presses it by hand not to allow air enters between follower plate and oil surface.

6

4 5

17312034

4. Install grease pump (1) and tighten set screws (4). Install air hose (2) and grease hose (3).

4-8-2


Handling the Grease Nozzle

Test Grease Pump After replacing grease can (pail), test the grease pump. Press greasing switch. Auto grease nozzle should operate and grease be forced out. If air motor of grease pump does not operate, press reset button (1) on lower side of air motor.

1 17312035

Clean Grease Pump Wash out grease inlet (2) if grease is not forced out smoothly through the grease nozzle even when air motor of grease pump (1) is running. When washing grease inlet (2), remove grease pump (1). See "Replacement Procedure� on previous page. Wash out grease inlet (2), using diesel fuel or kerosene. After washing, check grease inlet (2) for damage or

1

deformation. Replace grease pump (1) if necessary.

2 17312036

4-8-3


5. Transport 5.1 Loading/Unloading the Machine

DANGER Do not attempt to change the machine direction on a ramp - machine can tip over from the ramp and death or serious injury may result. If changing machine direction on a ramp is unavoidable, first drive the machine back to the level surface, then change it.

WARNING When loading/unloading the machine, follow the supervisor's instruction. Operator and supervisor should arrange signs in advance and do the work carefully according to the supervisor's signs or instructions. The ramp tool board must be strong enough to withstand machine's weight and be sufficiently wide and long. The claw-type board should be used not to slip off the vehicle's bed. Keep the vehicle's bed and the ramp tool board clear of slippery materials such as dirt, oil or grease and snow. Remove those materials if necessary.

Load/unload the machine as follows:

1. Park the transport vehicle on a firm, level surface, and engage the parking brake. Chock the wheels to prevent from rolling.

Ramp Tool Board

2. Fasten the ramp tool board securely to the vehicle's bed, and set the tool board slope of less than 15째. Less than 15째

3. Adjust the ramp tool board so the correct alignment of vehicle's bed, machine and tool board is obtained. 4. Drive the machine carefully at low speed according to the supervisor's signs or instructions. Stop the machine in front of the slope at a time and recheck the target loading/unloading point. 5. Climb up/down the ramp carefully at low speed and reach the target loading/unloading point correctly.

5-1-1

Wheel Chocks


Transport

Operations After Loading the Machine 1. Stop the machine at given position on vehicle's bed. Put the machine in transport posture. 2. Turn engine throttle switch to the "I" position. Move safety lock lever to the Lock position. 3. Stop the engine and remove the starter switch key. 4. Close windows and lock the cab door and engine covers. 5. Secure the work equipment with a suitable support device not to move. 6. Attach the rigging to the designated track and drawbar hitching points on the machine to prevent from moving.

5-1-2


Towing the Machine

5.2 Towing the Machine

DANGER Incorrectly towing the machine or making drive function inoperative can cause death or serious injury. For towing the machine, consult your nearest distributor.

Do not tow the machine if the machine cannot be self-propelled because of drive function or hydraulic system failure. In that case, first disengage the parking brake, then perform the procedure of towing the machine, observing the following: Before towing, put the machine in travel posture. Tow the machine to the inspection maintenance place. Do not tow over long distance of 100m or more. If towing over longer distance is unavoidable, use a special transport vehicle. Drive motor can seize up. Keep a slow speed of 2km/h or less when towing the machine. Use a wire rope strong enough to withstand 1.5 times or more the towed machine's weight. Do not use twisted, kinked wire ropes. Do not use a chain for towing - chain rings can cut off. The size of a towing vehicle must be equal or larger than the towed machine. Move the towing vehicle to a proper position so that the coupling device of the vehicle is aligned with the hitching point of the machine. Then attach the wire rope. Before towing, check that no person is in spaces between towing vehicle and machine. Do not start the towing vehicle abruptly - wire rope can cut off. Move the vehicle at slow speed according to the supervisor's signs or instructions. The machine can move by itself. Do not tow the machine on a slope.

5-2-1


6. Handling Electrical Parts 6.1 Control Panel

WARNING Do not attempt to modify electrical parts in the control panel or change the wiring machine failure can occur, causing death or serious injury.

CAUTION Precision electrical parts are included in the control panel so avoid inflammable gas, dust, saline substances, water or oil grease when opening/closing the control panel.

Electrical parts to control the machine are included in the control panel. To access the control panel (1), open the engine cover on the left side of the machine. 1

6-1-1


Control Panel

6.1.1 Economy Switch Economy switch controls engine maximum speed during drilling operation. With this select switch, engine maximum speed is limited to proper rpm. ★ To access economy switch, open the cover of the control panel. In N mode, engine maximum rpm is maintained at 2100min-1. In Economy mode, engine maximum rpm is maintained at 2000min-1.

6-1-2


Fuses

6.2 Fuses

CAUTION Before replacing fuses, be sure to remove the starter switch key. Make sure a substitute fuse is of the same amp rating. Replacing a fuse or wire of incorrect amp rating can cause overheat or burning out.

NOTICE If a fuse continues to blow, do not fit another fuse. Contact your nearest distributor for inspection.

Fuses are used for protection against excessive currents. With fuses, electrical devices and wires are protected from melting or breaking the circuit. If electrical system does not work properly, check the fuses in the fuse box (1). If the fuse has blown, fix a substitute fuse of the correct amp rating.

1

6-2-1


Fuses

Fuse amp ratings and circuit names

P7

F7

P6

F6

P5

F5

P4

F4

P3

F3

P2

F2

PC1

F1

P1

P1 P1 PC

PC

F7 F6 F5 F4 F3 F2 F1

Serial No. -3211014

No.

P7 P6 P5 P4 P3 P2 PC1

Serial No. 3211015-

Fuse Capacities Cable No.

Circuit Name

F1

15A

P1

Main power, starter switch, radio, engine electric control module (ON at all times)

F2

15A

P2

Compressor start timer, engine diagnostic lamp, hydraulic oil temp gauge, air temp gauge, fuel gauge, water temp gauge, emergency stop switch, lubrication lamp, oil tank air pressure switch (signal), hydraulic oil level switch (signal), and discharge air temp signal

F3

30A

P3

Front light, rear light, horn, back horn, crawler forward/reverse detection switch, mini-compressor for unloader, pressure switch for unloader, solenoid for unloader, and work light (option)

F4

15A

P4

Wipers (top and front), window washer, room lamp, and radio

F5

30A

P5

Air conditioner

F6

15A

P6

Electric control module (starter switch ON signal), and stabilizing power device (for programmable controller power)

F7

15A

PC1

Control circuit (for solenoid power), air flushing, and dust collector pulsejet

6-2-2


Handling the Batteries

6.3 Handling the Batteries

DANGER Battery gas can ignite and explode. Keep sparks, flames and lighted tobacco away from batteries. Dilute sulfuric acid in battery electrolyte is corrosive and poisonous. It is strong enough to burn skin, eat holes in clothing and cause blindness. If such liquid is splashed into the eyes, flush eyes with large amount of water and get medical attention immediately. If such liquid is splashed onto the skin, flush skin with water and soap.

WARNING Static electricity can cause gas to ignite and explode. Do not wipe off batteries with a dry cloth. Battery electrolyte can leak, causing burns or bodily injury. Do not fall down or give impact onto batteries.

To access batteries, open the cover on the left side of the machine and remove the battery box cover (1). 1

In Cold Weather Conditions When ambient temperature is low, battery performance is degraded. Also, battery electrolyte may be frozen if batteries are not fully charged. Keep batteries in charging rate of almost 100%. Add distilled water before the operation (or charging) to prevent freezing.

6-3-1

Always-proper charging rate


Handling the Batteries

In Hot Weather Conditions When ambient temperature is high, the water in the battery electrolyte will evaporate. If battery electrolyte level is low, the plates will be damaged and the service life be shortened. Always check battery electrolyte level before starting the engine. ★ For battery electrolyte level, see "4.1.1 Inspection Before Starting the Engine."

UPPER LEVEL

UPPER LEVEL LOWER LEVEL

LOWER LEVEL 26110071

Measuring Specific Gravity of Electrolyte Charging rate is known by measuring specific gravity of electrolyte in each battery cell. Maintain a charging rate of 75% or higher at all times. Convert charging rate according to the values in the table below. Specific Gravity

Battery Condition

Over 1.300

Over 100% (Over charged)

1.290 – 1.270

100%

1.260 – 1.230

75%

Below 1.230

Below 50% (Insufficiently charged)

Charging Batteries Safely

NOTICE Before charging batteries, disconnect the battery cable terminals and remove batteries from the machine.

SS-047

When charging batteries, remove all battery vent caps so the gas comes out. If batteries overheat, stop charging at a time. Stop charging immediately after completing charging. Do not overcharge.

6-3-2


Handling the Batteries

6.3.1 Replace Batteries

WARNING Sparks can damage your eyes or skin. When removing battery terminals, wear safety glasses and rubber gloves to prevent bodily injury. If a tool etc comes into contact with the surface between positive (+) terminals and the machine, it may spark. Keep sparks and flames away from batteries. When removing battery, disconnect negative (-) battery terminals first and then positive (+) terminals second. To install battery, reverse the removal procedure. Connect the terminals firmly. If loosened, failure in contact will occur, causing sparks. When replacing batteries or connecting/disconnecting cables, be sure to stop the engine and remove the starter switch key. Battery is a heavy object. When removing/replacing batteries, use a suitable lifting device such as a crane.

When removing battery, disconnect negative (-) terminals first and then positive (+) terminals second.

When installing battery, disconnect positive (+) terminals first and then negative (-) terminals second.

6-3-3


Handling the Batteries

Precautions When Replacing Batteries Battery is a heavy object. When removing/installing batteries, attach a nylon sling to the hitching points on both sides of the batteries and lift it, using a suitable lifting device such as a crane. Nylon sling must be strong enough to withstand the mass of batteries (approx 35kg). Replace two batteries of the same capacity simultaneously.

Starting the Engine After Replacing Batteries After installing batteries on the machine, start the engine. Starting engine should be accomplished within 10 seconds. If it fails at first attempt, wait two minutes or more and restart the engine. If engine does not start, although attempted five or six times, inspect the battery or engine start circuit.

6-3-4


Handling the Batteries

6.3.2 Starting Engine with Booster Cables

WARNING Sparks cause battery to explode. When attaching booster cable clips, be careful that negative (-) cable clip is connected to negative (-) battery terminal and positive (+) cable clip is connected to positive (+) battery terminal. Do not allow positive (+) cable clip come into contact with negative (-) battery terminal and vice versa. If normal vehicle comes into contact with trouble vehicle, sparks may be produced, causing battery to explode. When taking power from another vehicle, keep normal vehicle in a certain distance from trouble vehicle.

CAUTION Sparks can damage your eyes or skin. When attaching/detaching booster cable clips, wear safety glasses and rubber gloves to prevent bodily injury. When attaching booster cable clip to the machine's body or engine block, attach the clip farthest from the batteries to prevent producing spark at battery surrounding area. Attach the booster cable clips firmly. If loosened, sparks can be produced due to failure in contact. Battery capacity for normal vehicle must be same as for trouble vehicle. Thickness of booster cable and clip must be fit for the size of the battery. Check booster cable and clip for disconnection or corrosion.

BATTER 17310070

6-3-5


Handling the Batteries

Attaching Booster Cables To attach booster cables, proceed as follows:

1. Turn engine starter switch key to STOP position on both normal and trouble vehicles.

4

2. Attach one end of booster cable (A) clip to positive (+) battery terminal (1) on trouble vehicle. 3. Attach the other end of booster cable (A) clip to positive (+) battery terminal (2) on normal vehicle.

to trouble vehicle body

Trouble vehicle battery

1 B

A

4. Attach one end of booster cable (B) clip to negative (-) battery terminal (3) on normal vehicle.

3

5. Attach the other end of booster cable (B) clip to the body (or engine block) (4) of the trouble vehicle.

2

Normal vehicle battery

17310063

6. After attaching, check that the clips are connected to battery terminals properly.

Starting the Engine After Attaching Booster Cables Start the engine on the trouble vehicle by turning starter switch key to ON position. If it fails to start, wait two minutes or more and restart the engine.

Detaching Booster Cables After starting engine on trouble vehicle, detach booster cables as follows:

1. Detach one end of booster cable (B) clip from the body (or engine block) (4) of the trouble vehicle.

4

2. Detach the other end of booster cable (B) clip from negative (-) battery terminal (3) on normal vehicle. 3. Detach one end of booster cable (A) clip from positive (+) battery terminal (2) on normal vehicle. 4. Detach the other end of booster cable (A) clip from positive (+) battery terminal (1) on trouble vehicle.

to trouble vehicle body

Trouble vehicle battery

1 B

A 3

2

Normal vehicle battery

6-3-6

17310063


Handling the Batteries

6.3.3 Battery Cut-Off Switch (if equipped)

WARNING Always turn off the battery cut-off switch when the machine is serviced or not used for three weeks or more.

Battery cut-off switch shuts off energizing circuits from the battery so when it is turned off once, engine cannot start and all electric circuits of the machine shut off. ★ To access battery cut-off switch, open cover on left side of machine and it’s located on right side of battery box. Energize: Move lever switch to the energizing position and all electric

Shut-Off

circuits will be energized. Engine can start and electrical equipment such as radio and lighting can turn on. Shut-off: Move lever switch to the shut-off position and all electric circuits will be shut off. Energizing

6-3-7


Emergency Stop System (if equipped)

6.4 Emergency Stop System (if equipped)

WARNING Do not modify or remove emergency stop system, which is provided to ensure operator safety. If wire (1) of emergency stop system is damaged or stretched, inspect and repair. Contact your nearest distributor..

Emergency stop system functions to emergency-stop the engine, which is used when a failure occurs during operation of machine. To emergency-stop the engine, pull the red wire (1) or press the emergency stop button (blue) (2), which are located on the guide shell or in the engine room. Once this system is operative, engine stops and all functions stop. ★ Emergency stop system can stop the engine even if the wire (1) is cut off.

2

1

2 1

6-4-1


Emergency Stop System (if equipped)

Inspection Before Starting the Engine For the machine equipped with the emergency stop system, inspect the wire before starting the engine. Visually check the wire for twist or damage. Then check the wire tension.

Check When Starting the Engine When starting the engine, check that the wire emergency stop condition is reset. If it’s not reset, engine cannot start. Reset the wire emergency stop condition as follows: When starter switch key is in OFF position, pull the emergency stop button (blue).

Inspection After Starting the Engine After starting the engine, start to operate the emergency stop system and check that the engine emergency-stops properly. To restart the engine, first return the starter switch key to OFF position, then pull the emergency stop button (blue). ★ Engine cannot start, if the wire emergency stop condition is not reset.

6-4-2


7. In Cold Climate Area When ambient temperature is low, symptoms may occur, for example, engine is not easy to start, and fuel or lubricating oil is frozen. Take care of the following in cold climate area.

Fuel/Lubricating Oil Fuel and lubricating oil may not move smoothly as ambient temperature is low. Replace with fuel and oil of proper viscosity matching to low ambient temperature. ★ For fuel and lubricating oil, see "11. How to Select Fuel, Water and Lubricating Oil."

NOTICE In hot weather season, replace with fuel and oil of specified viscosity matching to high ambient temperature.

Care of Fuel After operation, drain water accumulated on the fuel line by opening the fuel drain cock to prevent fuel from freezing. Refill the fuel tank fully so drops of water in the tank are reduced. ★ For drain fuel, see " 4.1.1 Inspection Before Starting the Engine."

Care of Receiver Tank After operation, drain mixed water and sediments accumulated on the bottom of the tank by opening the drain cock. ★ For drain compressor oil, see " 4.1.1 Inspection Before Starting the Engine."

Care of Rock Drill Oil Tank After operation, drain mixed water and sediments accumulated on the bottom of the tank by opening the drain cock. ★ For drain rock drill oil, see " 4.1.1 Inspection Before Starting the Engine."

Care of Batteries When ambient temperature is low, battery performance is degraded. Also, battery electrolyte may be frozen if batteries are in low charging rate. Keep batteries fully charged and warm them until tomorrow operation. ★ For batteries, see "6.3 Handling the Batteries."

7-1-1


In Cold Climate Area

Precautions Before Operation Remove ice or dirt on piston rod of hydraulic cylinder carefully so as not to damage seals. After starting the engine, warm hydraulic oil.

Precautions After Operation Remove sticking materials such as snow, ice and dirt from the undercarriage to prevent from freezing. Remove ice or dirt on piston rod of hydraulic cylinder carefully so as not to damage seals.

7-1-2


8. Storage for Long Periods If machine is not used for more than three weeks, store it in the following manner:

Before Storage Clean outer elements of engine air cleaner and compressor air cleaner. Wash out each part of the machine and dry those parts. Change fuel and oil. Put grease fully until old grease is forced out. Apply grease to exposed piston rods of hydraulic cylinders on the boom, arm etc. Remove batteries from the machine and store in well-ventilated indoor place or disconnect negative (-) battery terminals. Add antifreeze to coolant to prevent from freezing when ambient temperature is below 0째C. Put machine in travel posture and store in well-ventilation indoor place. If storing outdoors is unavoidable, select a well-drainage, firm, level surface and put cover sheet on the machine.

In Machine Out of Service

CAUTION Exhaust gas is poisonous. When engine is started at indoor place, open windows and entrance doors for ventilation.

In machine out of service, move machine once a month to prevent oil film breakdown. Charge batteries before moving the machine. Before moving work equipment such as boom, arm and guide shell, remove grease on exposed piston rods of hydraulic cylinders.

Before Operation When the machine is put back after long periods of storage, perform the following inspection maintenance before operation. Drain mixed water and sediments from fuel tank and receiver tank. Wash out each part of the machine and dry those parts. Apply grease fully until old grease is forced out. Remove grease on exposed piston rods of hydraulic cylinders. Check lubrication in each part of the machine and lubricate if necessary. Check whether replacement time for engine oil, engine oil filter cartridge, fuel filter cartridge and fuel water separator is over. Replace if necessary.

8-1-1


Storage for Long Periods

Add fuel and bleed air from fuel line. ★ For air bleeding, see "14.1 General Maintenance." Measure specific gravity of electrolyte and check charging rate. If charging rate is low, charge battery. Walk around the machine and visually check for fuel or oil leak, bolt or nut slipping off, and abnormality in drifter, work equipment and hydraulic line. Especially check for scuffing or damage to hydraulic cylinders and oil leaking from hose fittings.

8-1-2


9. Troubleshooting Trouble comes from various causes and problems. If you feel abnormal and trouble is not cleared, contact your nearest distributor for inspection maintenance. When requesting inspection maintenance, check the following items in advance.

NOTICE For detailed troubleshooting malfunctions of engine, see the Operation and Maintenance Manual of Caterpillar C13 Engine.

Engine Malfunctions Symptom

Main Cause

Remedy

Starter motor rotates but engine does not start

{ Low fuel level { Water in fuel { Fuel filter cartridge clogged { Air cleaner clogged

{ Refill fuel tank { Drain water and sediment { Replace fuel filter cartridge { Clean or replace air cleaner

Excessive black smoke in exhaust gas

{ Improper fuel { Air cleaner clogged

{ Replace with specified fuel { Clean or replace air cleaner

White or blue exhaust gas

{ Engine oil level too large { Low viscosity engine oil { Improper fuel

{ Adjust to specified level { Replace with proper viscosity oil { Replace with specified fuel

Engine coolant temperature too high

{ Low coolant level { Radiator fin clogged { Dirt or scale accumulated in cooling system { Loose fan belt

{ Add coolant { Clean radiator fin { Clean cooling system

9-1-1

{ Adjust to proper tension


Troubleshooting

Hydraulic System Malfunctions Symptom

Main Cause

Remedy

Hydraulic oil temperature too high

{ Hydraulic oil level too large { Deterioration or poor quality of hydraulic oil { Return filter element clogged { Oil cooler fin clogged

{ Adjust to specified level { Replace with specified hydraulic oil { Replace filter element { Clean

Machine does not travel (or difficult to travel)

{ Safety lock lever put in lock position { Low hydraulic oil level { Track link tension too high { Track link tension too low { Stones etc caught in track link or roller { Pilot filter element clogged

{ Unlock safety lock lever

Work equipment moves too slow Work equipment does not move

{ Low hydraulic oil level { Return filter element clogged

{ Pour oil to specified level { Replace filter element

Carriage moves too slow Carriage does not move

{ Improper adjustment of feed pressure { Loose feed chain

{ Adjust pressure with feed control valve { Adjust chain tension

Rod changer does not move Rod changer moves too slow

{ Low hydraulic oil level

{ Pour oil to specified level

Rod cannot be collected Rod cannot be added

{ Grease stuck to rollers { Rollers worn

{ Clean { Replace

9-1-2

{ Pour oil to specified level { Adjust { Adjust { Remove { Replace filter element


Troubleshooting

Dust Collector & Compressor Malfunctions Symptom

Main Cause

Remedy

Drill cuttings not blown properly

{ Bit tip clogged

{ Clean

Dust collector fan does not rotate Dust collector fan rotates too slow

{ Low hydraulic oil level { Dust collector element clogged

{ Pour oil to specified level { Clean or replace

Dust collector suction poor

{ Suction hose clogged { Dust collector element clogged

{ Clean { Clean or replace

Pressure in receiver tank is not increased to 2.4 MPa

{ Compressor switch off { Insufficient amount of suction air

{ Turn on compressor { Clean or replace air cleaner

Oil in air

{ Oil level in receiver tank is too large { Collecting orifice clogged

{ Adjust to specified level

{ Oil filter cartridge clogged { Oil check valve function no good { Oil cooler fin clogged

{ Replace oil filter cartridge { Replace gasket

Compressor discharge air temperature is too high

9-1-3

{ Clean

{ Clean oil cooler fin


Inspection Maintenance


10. Maintenance Precautions CAUTION If you feel insecure or abnormal during driving or operating the machine, perform inspection maintenance. If cause cannot be found or abnormality recurs, contact your nearest distributor for inspection.

NOTICE Check hour meter every work day to determine when to perform periodic inspection maintenance.

Observe Precautions in the Decals The decals on the machine describe important precautions. Observe those items when performing service work.

Put Machine in Maintenance Posture Park the machine on a firm, level surface in a workshop etc. Put the guide shell in horizontal position and lower it to the lowest position. Then block tracks. Stop the engine and remove the starter switch key. Move the safety lock lever to the Lock position not to move the machine. Attach a CAUTION tag to the operator seat to show that the machine is under service work.

Perform Service Work with More Than Two Persons Before service work, confirm that service persons are well-trained and work procedures are arranged. Always stop engine when performing service work. Do not open engine or top covers until the engine is stopped completely. Place more than two persons at all times. One person as a supervisor gives safety instructions. Service person(s) and supervisor together arrange signs in advance. Perform service work according to the supervisor's signs and instructions. Supervisor should sit in the operator seat and be ready to stop the engine, if the service work must be done with the engine running. For emergency stop system if equipped, confirm the operating method and the location of the system.

10-1-1


Maintenance Precautions

Wear Protective Clothing Wear protective clothing appropriate to the job. Wear close fitting clothing to prevent from getting caught in the control levers, projections etc. Oily work clothes can start a fire so do not wear. Wear a helmet, safety glasses, earplugs, dust mask, safety shoes etc. Wear protective gloves and safety belt as needed.

Clean the Machine Before service work, clean the machine to easily find out abnormality. Clean the oiling/greasing points and the level gauges. Do not allow debris or dirt enter.

NOTICE Be careful that the water does not splash on electrical parts such as control panel and batteries - short circuit or malfunction may result.

Attach a CAUTION Tag Attach a CAUTION tag to the operator seat to show prohibitions such as "Do Not Start Engine" and "Do Not Operate Levers and Switches."

Remove Hydraulic/Pneumatic Equipment Safely Residual pressure in the hydraulic circuit is released into the air from the air breather on the hydraulic tank. Wait about ten minutes after stopping the engine to loosen hydraulic piping or replace hydraulic parts. As compressor stops, air in the receiver tank is released into the air from the auto relief valve. Wait five minutes or more after stopping the compressor to completely remove the air in the receiver tank, then perform inspection maintenance of pneumatic equipment.

Avoid Hot Surface/High Temperature Each part of the machine is hot immediately after completing the drilling operation or stopping the engine. Contact with those hot surface can cause burns or bodily injury. Rotary head is very hot immediately after completing the drilling operation so avoids contact with rotary head, rod hammer. When replacing engine oil, hydraulic oil or filter etc, wait until the appropriate part of the machine is cooled down to normal temperature. To easily drain oil in low ambient temperature, warm oil to 30-40째C. Hot steam or boiling water can gush out. When removing the cap of the reservoir tank, wait until the radiator is cooled down to normal temperature and remove the cap carefully, while slowly relieving the internal pressure with a cloth put on the cap.

10-1-2


Maintenance Precautions

Avoid Fires Handle materials with great care to prevent fires. Fuel, oil or battery electrolyte can ignite. Do not handle those materials while smoking or when near flames or sparks. Use noninflammable flushing oil for washing parts or hydraulic tank. Use anti-explosion light bulbs for the lighting equipment. Keep fire extinguisher in the right place.

Handle Tools or Parts Safely Put only required tools or parts in the pockets of the work clothing and be careful that any tool or part does not drop into when opening the covers or filler caps.

Use Clean Oil and Grease Use clean oil and grease and also use a clean container. Do not allow debris or dirt enter.

Handle Fuel and Lubricating Oil Properly Use fuel and lubricating oil of specified viscosity matched to ambient temperature. When refilling, use a clean container. Do not allow debris or dirt enter. ★ For fuel and lubricating oil, see "12. List of Fuel, Water and Lubricating Oil."

NOTICE Do not use a different brand of oil. When refilling, replace the whole quantity of oil. Otherwise, failure will result.

Pour Oil Properly When pouring oil, use a strainer on filler port if available. Select a clean area for oil inspection and replenishment and do not allow any debris or dirt enter.

Drain Oil Properly When changing oil or filter, place a large clean drain pan. After draining, check drained oil or filter for debris or foreign matter.

NOTICE Do not reuse drained oil or filter. Failure to do so can cause breakdown or failure.

10-1-3


Maintenance Precautions

Use Furukawa Genuine Parts When replacing parts, always use Furukawa genuine parts in the parts list. Problems from the use of imitation parts could not be covered by our warranty.

Replace Seals Properly If parts with seals such as O-rings and packing materials are inspected and repaired, clean the mounting surfaces and put in the new seals.

NOTICE Do not reuse seals such as O-rings and packing materials. Failure to do so can cause breakdown or failure.

Remove Rust Inhibitor When new parts are installed, remove rust inhibitor coated on the machining surface, using a cloth.

Weld Safely Only qualified persons are allowed to perform welding work. Weld in a safe well-equipped work area. If weld indoors, open windows and doors for ventilation. Stop the engine and remove the starter switch key. Place the ground within 1 m from the welds. Make sure there are no seals or bearings between the ground and the welds. Remove batteries from the machine to prevent explosions. Remove electrical parts from the machine to prevent malfunction or damage. Keep first-aid kit and fire extinguisher near the work area against unexpected accident or fires.

Dispose of Waste Properly Do not pour drained engine oil or hydraulic oil onto the ground but into a suitable container. Do not pour waste such as drained oil or hydraulic oil down a drain or into any water source. Do not burn or discard oily clothes in incorrect manner. Do not dispose of harmful waste such as fuel, oil, solvent, filters and batteries. Strictly separate those from general waste. Improperly disposing of waste can threaten the environment. Follow your applicable local regulations.

10-1-4


11. How to Select Fuel, Water and Lubricating Oil 11.1 Preparing for Emergencies

WARNING Incorrectly handling fuel and lubricating oil can cause environmental damage or unexpected accident, resulting in death or serious injury. Handle fuel and lubricating oil with great care.

Take Emergency Measures If fuel or lubricating oil is splashed into eyes, flush eyes with clean water for at least 15 minutes, then get medical attention immediately. If fuel or lubricating oil is splashed onto skin, flush skin with clean water and soap. If the mist of oils is sucked, move to a place with fresh air and keep the body warm with a blanket etc, then get medical attention immediately. If oil is swallowed, do not vomit forcibly but get medical attention immediately. Wash the mouth with water as needed.

Take Measures Against Leaks Do not allow fuel or lubricating oil flow down the drain or into any water source to prevent secondary trouble and environment pollution. Find locations of oil leaking and fix leak points. Keep fire extinguisher in the right place. Keep sparks, flames and lighted tobacco away from the work area. Wear conductive clothing to prevent static electricity. Wear gas mask as needed. If leak is small, absorb oil with sand, wood chips, cloth etc. If leak is large, enclose leaking spot with earth to stop flowing. Cover leaked oil with foam and collect it in a suitable container. If leaking occurs indoors, open windows and doors for ventilation.

Take Measures Against Fires Wear fire fighting protective clothing such as gas mask and gloves and extinguish fires from the windward. Keep all personnel except firefighting persons clear of the fire area. Foam fire extinguishers are most effective against fires. Do not attempt to hose water on the fire, which may blow up. To prevent spreading fire, hose water over the surrounding area of the fire.

11-1-1


How to Select Fuel, Water and Lubricating Oil

11.2 Fuel

CAUTION Use diesel fuel. Do not use a substitute fuel such as gasoline or alcohol mixed fuel and kerosene, which causes degradation of engine performance or engine failure.

Fuel Specifications The following specific natures are required for the diesel fuel. Must be free from minute dust particles. Must have adequate viscosity. Must have high cetane value. Must have high fluidity at low temperature. Muse is less sulfur content. Must have little residual carbon. Caterpillar recommends the use of fuel meeting the Grade No.2-D requirements of the American Society for Testing and Materials (ASTM) D975, Standard Specifications for Diesel Fuel Oils. At operating temperatures below 0°C, use a blend of No.1-D and No.2-D fuels, also know as “winterized” No.2-D. ★ For a more detailed description of fuel properties, see the Operation and Maintenance Manual of Caterpillar C13 Engine.

Handle Fuel Safely The engine fuel injection pump and nozzle are precision-made so do not use fuel with water or debris, which can cause failure in the engine system. Refill the fuel tank on the machine on completion of the day's work. Store fuel in a storage tank for at least 24 hours to make water and debris settle and use upper layers of fuel. When refilling, be careful that sediments at the bottom of the fuel can are not pumped out. Open the drain plug on the bottom of a storage tank periodically, and drain mixed water and sediments properly. Replace fuel filters and elements periodically. Before starting the engine, drain mixed water and sediments at the bottom of the fuel tank properly. ★ For draining mixed water and sediments in the fuel tank, see "4.1 Pre-Start Inspection."

11-2-1


How to Select Fuel, Water and Lubricating Oil

11.3 Lubricating Oil

CAUTION Characteristic of oil varies, depending on makers. Do not mix a different brand of oil, which causes oil deterioration or change in quality. When refilling, be sure to use the same brand of oil.

NOTICE When adding oil, be sure to use the same brand of oil. If oil is replaced at disassembly or repair work, remove old oil completely. Then flush with flushing oil and change with the new oil. After changing oil, bleed air. Oil becomes soft as oil temperature goes high and oil becomes hard as oil temperature goes low. Use oil matched to ambient temperature. When replenishing, wipe off filler port, grease nipple, hand, and lubrication tool and be careful that dirt or foreign matter does not enter.

★ For use of oil by type and ambient temperature, see "12. List of Fuel, Water And Lubricating Oil."

11.3.1 Engine Oil Engine Oil Pan Engine oil is very important to proper engine performance, good storability and service life. Before starting the engine, check oil level with oil level gauge and also check oil contamination and viscosity. Change the engine oil periodically, based on operating hours on engine hour meter. ★ For details of engine oil, see the Operation and Maintenance Manual of Caterpillar C13 Engine or contact your nearest Caterpillar sales company. Recommended Oil: Caterpillar diesel engine oil 10W30. Caterpillar diesel engine oil 15W40. Equivalent to API classification CI-4 or higher

11-3-1


How to Select Fuel, Water and Lubricating Oil

Carrier Roller/Track Roller

NOTICE If engine oil level in the carrier roller and track roller is low, contact your nearest distributor for inspection maintenance.

Check the engine oil level in the carrier roller and track roller periodically, according to operating hours on engine hour meter.

11.3.2 Hydraulic oil Selecting and keeping hydraulic oil in good condition is very important to proper hydraulic equipment and rotary head performance. If wrong grade or deteriorated hydraulic oil is used for long hours, operating efficiency of hydraulic equipment is largely affected and system failure or excessive wear occurs. Use wear-resistance hydraulic oil, ISO viscosity grade VG46.

Pollution Control of Hydraulic Oil

NOTICE A special measuring device is needed to measure allowable debris or particles in hydraulic oil, based on the NAS-1638. For measurement of oil contamination level, contact your nearest distributor.

If contaminations such as metallic particles and debris are in hydraulic oil, hydraulic equipment will be worn earlier and a failure in the system may occur. Use hydraulic oil with NAS-11 or under class, based on the NAS*-1638 standard. * National Aerospace Standard Committee Measure the hydraulic oil contamination level when the return filter elements are replaced according to the operating hours on the engine hour meter. If the hydraulic oil contamination level is beyond the NAS-11 class, change hydraulic oil earlier.

11-3-2


How to Select Fuel, Water and Lubricating Oil

11.3.3 Gear Oil Gear oil is used under severe conditions so selecting the right gear oil is very important. The following may be required when selecting the gear oil: Proper viscosity Good sticking to teeth face and no peeling away by centrifugal force Good fluid flow at low ambient temperature and no solidification and peeling Extreme-pressure properties No foaming Outstanding oxidizing stability Good water separation

Drive Motor Check the gear oil level in the drive motor periodically, according to the operating hours on the engine hour meter. Add oil if necessary.

Feed Motor Change the gear oil in the feed motor periodically, according to the operating hours on the engine hour meter.

Front Idler Check the gear oil level in the front idler periodically, according to the operating hours on the engine hour meter. Add oil if necessary.

11.3.4 Compressor Oil Lubrication and cooling of compressor is made with compressor oil. Mixed water or debris in the receiver tank degrades compressor performance and shortens service life. Change the compressor oil periodically, based on operating hours on engine hour meter. Use a Compressor Oil Long Life HP for the compressor oil. ★ If a Compressor Oil All Season is used, replace it at every 250 hours. ★ For details of compressor oil, contact your nearest Hokuetsu Industry (AIR MAN) sales company. Use our recommended Hokuetsu Industry (AIR MAN) genuine oil for the compressor oil. Available oil: When ambient temperature is +5 to +40°C, use the AIR MAN Compressor Oil Long Life HP. When ambient temperature is -30 to +5°C, use the AIR MAN Compressor Oil All Season.

NOTICE Always use a Compressor Oil All Season for the compressor oil when ambient temperature is less than 5°C.

11-3-3


How to Select Fuel, Water and Lubricating Oil

11.3.5 Rock Drill Oil Lubricating or cooling the down-the-hole hammer is made with rock drill oil. Recommended rock drill oil varies, depending on the down-the-hole hammer being used. ★ For detail about rock drill oil, see the operation manual of the down-the-hole hammer.

11.3.6 Grease Use grease of NLGI consistency No.2 if ambient temperature is over 0°C. Use grease of NLGI consistency No.1 if ambient temperature is under 0°C.

General-purpose Grease Use general-purpose grease for pins and bearings on the machine. Put grease fully until old grease is forced out. Molybdenum Grease Apply molybdenum grease to threads of rod, swivel and shank rod. Use disulfide, mineral or graphite molybdenum grease with heat resistance and extreme-pressure properties.

11-3-4


How to Select Fuel, Water and Lubricating Oil

11.4 Coolant

WARNING Do not allow waste fluid such as waste coolant flow down the drain or into any water source - environment pollution will result. Follow your applicable local regulations.

Use soft water with less-impurities such as city water for coolant. Do not use well or river water. When adding coolant, use water mixed with Long Life Coolant at the same ratio as before.

Long Life Coolant

WARNING Long life coolant can start a fire. Keep it away from sparks and flames. If long life coolant is splashed into eyes, flush eyes with water and get medical attention immediately. If such coolant is splashed onto skin, flush skin with water and soap. If long life coolant is swallowed, vomit it immediately and get medical attention. When you feel sick while working, stop operation immediately and move to a well-ventilated place and keep quiet. If you feel worse, get medical attention.

Long life coolant provides anti-freezing and corrosion resistance for the cooling system. The mixture ratio of long life coolant is 50% when shipping. ★ For more detailed description of coolant, see the Operation and Maintenance Manual of Caterpillar C13 Diesel Engine.

11-4-1


How to Select Fuel, Water and Lubricating Oil

11.5 Operating Oil Feed Pump

WARNING Hydraulic tank is hot immediately after stopping the engine. When replenishing, make sure the engine is stopped and the hydraulic tank is cooled down to normal temperature. After replenishment be sure to turn the stop valve handle (3) to the CLOSE position. If it's in the OPEN position, the oil can flow backward. Hydraulic oil is flammable. Wipe up if spilled.

Use the oil feed pump to perform oil lubrication and to prevent hydraulic oil from contamination. ★ The oil feed pump can operate independently without starting the engine.

1. Open cover on right side of machine. 2. Wipe off suction hose (1) with a cloth. 2

3. Loosen adapter (2) and remove suction hose (1). Put suction hose (1) in oil can filled with hydraulic oil. 1

4. Turn stop valve handle (3) counterclockwise to the OPEN position.

3

11-5-1


How to Select Fuel, Water and Lubricating Oil

5. Start oil feed pump by moving oil feed pump switch (4) to ON position (direction of arrow). Supply oil to specified level.

4

6. Check oil level with level gauge (5) on side of hydraulic tank. The oil level should be between Upper and Lower limits. ★ For hydraulic oil, see "12. List of Fuel, Water and Lubricating Oil."

5

7. After checking oil level, stop oil feed pump by moving switch (4) to the OFF position (original position).

8. Turn stop valve handle (3) clockwise to the CLOSE position.

3

9. Remove sticking oil on suction hose (1), and screw adapter (2) into suction hose (1). 10. Close cover.

2

1

11-5-2


12. List of Fuel, Water and Lubricating Oil Compartment or System

Category and Classification

For Temperature Range (°C)

Quantity -10

0

10

20

30

No.2-D

Fuel tank

Diesel fuel oil *1

700 L No.1-D (Ä)

SAE 10W-30

Engine oil pan

Diesel engine oil

*2

40 L SAE 15W-40

Hydraulic tank

Hydraulic oil

Receiver tank

Screw compressor oil *3

280 L

ISO VG46

ISO VG46

65 L ISO VG32

Feed motor

Gear oil API: GL-4

1.1 L

SAE 90

Rotary head (Reduction gear)

Gear oil API: GL-5

1.8 L

SAE 90

ISO220

Down-the-hole-hammer

Rock drill oil

45 L

ISO150 ISO100

Drive motor

Gear oil API: GL-4

2.5 L (each)

SAE 90

Front idler

Gear oil API: GL-5

0.15 L

SAE 80W90

12-1

40


List of Fuel, Water and Lubricating Oil

Compartment or System

Category and Classification

For Temperature Range (°C)

Quantity -10

0

10

20

Carrier roller

Diesel engine oil API: CD

0.075 L

SAE 30

Track roller

Diesel engine oil API: CD

0.11 L

SAE 30

Fittings

Universal grease

30

NLGI No.2

- NLGI No.1

Rod, Shank rod and Sleeve, etc.

Molybdenum grease

Cooling system

Coolant

*4

60 L

*1 For detail, see "11.2 Fuel." *2 For detail, see "11.3.1 Engine Oil." *3 For detail, see "11.3.4 Compressor Oil." *4 For detail, see "11.4 Coolant."

12-2

Antifreeze (LLC additive)

40


13. Security Parts Periodic Replacement WARNING Replace security parts every two years or 4000 operating hours on engine hour meter, whichever comes first.

CAUTION For security parts replacement, contact your nearest distributor.

Performing periodic inspection maintenance is essential for safe machine operation. Security parts especially anti-fire parts must be replaced periodically.

Security Parts Security parts can damage, wear or deteriorate with the passage of time. It is difficult to determine when to replace those parts so change periodically no matter how long they are used. Replace security parts even before reaching replacement interval, if something wrong is found. If deformation, damage, cracks etc is found in hose clips and clamps or piping clamps, replace those parts, together with related abnormal parts. When replacing hoses, seals such as O-rings and gaskets must be replaced together if equipped

Fuel tank

Engine

1

No.

Security Part

Location of Use

1

Fuel hose

Fuel tank�Injection pump

2

Fuel hose

Engine�Fuel tank

2

13-1


Manual operacional DCR-20