Sandvik Drill Rig D75KS Commissioning Manual

023501-058

D75KS COMMISSIONING MANUAL

November 2006

Sandvik Mining and Construction 13500 NW Country Road 235 Alachua, Florida 32615 - USA Tel. (386) 462-4100 Fax. (386) 462-3247

The following three hazard signal words are used throughout this manual to emphasize important instructions. For the purpose of this manual, these signal words are defined as follows:

! DANGER

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

! WARNING

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

! CAUTION

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

California Proposition 65

WARNING: This Product Contains And, When Used, Produces Chemicals Known To The State Of California To Cause Cancer, And Birth Defects Or Other Reproductive Harm.

Table of Contents

SAFE OPERATING PRACTICES FOR DRILLERS iii

DECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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

MAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Prepare Mast For Assembly To Machine . . . . . . . . . . . . . 20 Prepare The Machine Base Mast Pedestal . . . . . . . . . . . . 21 Mast Installation 21 Hydraulic Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Mast Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . 27

INCLEMENT WEATHER and SAFE DRILLING PRACTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi MANAGEMENT’S RESPOSIBILITIES . . . . . . . . . . . . . . . xi RAINFALL AND FLOODING . . . . . . . . . . . . . . . . . . . . . . xi THUNDERSTORMS AND LIGHTNING . . . . . . . . . . . . . . xii Exceptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii

INSTALLING FRONT LEVELING JACK PAD . . . . . . . . . 28 MAST WORKDECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Mounting The Work Deck To Mast Table . . . . . . . . . . . . . 31 PREPARING THE DUST COLLECTOR . . . . . . . . . . . . . . 33 Preparing The Stationary Deck Mount Dust Collector . . . . 34 Preparing The Stationary Side Mount Dust Collector . . . . 35 Connect Dust Collector Hose . . . . . . . . . . . . . . . . . . . . . . 36 Mount Optional Strobe Lights . . . . . . . . . . . . . . . . . . . . . . 37 MACHINE ASSEMBLY IS COMPLETE . . . . . . . . . . . . . . 38

DRILL PIPE INSTALLATION . . . . . . . . . . . . . . . . . 38

MACHINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . xiii GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 NEW MACHINE COMMISSION MANUAL . . . . . . . . . . . 1 D75KS Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Work Site Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Suggested Safe Operating Principals . . . . . . . . . . . . . . . 4 D75KS Mast Lifting Points . . . . . . . . . . . . . . . . . . . . . . . . 5 Assembly Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

MACHINE COMMISSIONING . . . . . . . . . . . . . . . . . 7 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 NEW MACHINE ARRIVAL . . . . . . . . . . . . . . . . . . . . . . . 7 COMPONENT WEIGHTS and LIFTING . . . . . . . . . . . . . 8 DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 PERFORM MACHINE PRESTART CHECKS . . . . . . . . . 10 STARTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . 11 TRAMMING THE MACHINE FROM THE TRANSPORT 12 Accessory Component Inventory . . . . . . . . . . . . . . . . . . . 14 MOUNTING THE RIGHT SIDE LADDER TO THE MACHINE BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 CAB EXTENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Drill Pipe Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 LOADING DRILL PIPE INTO THE MACHINE . . . . . . . . . 40 Load Drill Pipe Method 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Load Drill Pipe Method 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 43 PREDELIVERY CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . 46 Lubricate the Central Grease Points . . . . . . . . . . . . . . . . . 46 Service Lubricator Reservoir (DTH Applications) . . . . . . . 48 Inspect Engine fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Inspect Compressor Oil Level . . . . . . . . . . . . . . . . . . . . . . 49 Inspect the hydraulic oil level . . . . . . . . . . . . . . . . . . . . . . . 50 Inspect Pump Drive Gearbox Fluid Levels . . . . . . . . . . . . 50 Inspect Rotary Head Fluid Level . . . . . . . . . . . . . . . . . . . . 50 Inspect Final Drive Fluid Levels . . . . . . . . . . . . . . . . . . . . . 51 Inspect Winch Drum Fluid Level . . . . . . . . . . . . . . . . . . . . 51 Inspect Water Injection Pump Fluid Level . . . . . . . . . . . . . 51 FACTORY FILL FLUIDS . . . . . . . . . . . . . . . . . . . . . . . . . . 51 COOLANT SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . 56 FILL WATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Coolant Conditioner Elements . . . . . . . . . . . . . . . . . . . . . . 57 FUEL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 57 Cetane Requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Fuel Cloud Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Fuel Sulphur Content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Table of Contents 1

CRANKCASE OIL VISCOSITIES . . . . . . . . . . . . . . . . . . .58 LUBRICANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . .58 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 Engine Oils (CH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 Compressor Oils (COMP) . . . . . . . . . . . . . . . . . . . . . . . . .59 AIR COMPRESSOR LUBRICANT RECOMMENDATIONS 59 Hydraulic Oils (HYDO) . . . . . . . . . . . . . . . . . . . . . . . . . . . .61 Equivalent Hydraulic Oils . . . . . . . . . . . . . . . . . . . . . . . . . .61 MINIMUM PERFORMANCE STANDARDS FOR HYDRAULIC OILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 Multipurpose - Type Gear Lubricant (MPL) . . . . . . . . . . . .65 Lubricating Grease (MPGM) . . . . . . . . . . . . . . . . . . . . . . .65 Refrigeration Oil (REF) . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 DRILL STRING AND DRILL TOOLS . . . . . . . . . . . . . . . .66 Install Top Sub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67 Install Table Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67 Purge New Drill Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 Install Bit Sub and Bit . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 Breakout Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72 SANDVIK MINING AND CONSTRUCTION BLASTHOLE WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74 Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74 Sandvik Mining and Construction Equipment Start Up Inspection Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74 Quality Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74 Fire Suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76 Recommended Torque Values For Std Hardware - UNC 77 Recommended Torque Values For Std Hardware - UNF .78 CONVERSION FACTORS . . . . . . . . . . . . . . . . . . . . . . . . .79

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SAFE OPERATING PRACTICES FOR DRILLERS

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

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

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

Management's Responsibilities It is the responsibility of management to: • See that all operators of this equipment are thoroughly trained (with special emphasis on safety), competent, physically fit and if required, licensed.

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

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

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

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

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

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

The Operator’s Responsibilities Safety must always be the operator's most important concern. The operator must refuse to operate the drill if an unsafe Safe Operating Practices for Drillers

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

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

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

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

• The operator should not operate this equipment if any of it's controls display a "lockout" tag.

• If an unsafe condition exists, the operator must place a tag, identifying this condition, on the starting controls and alert other potential users of the drill.

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• The operator should not operate the drill without first checking that all personnel protection devices and machinery guards are in place.

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

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

• Check the machine log book to see that periodic maintenance and inspections have been performed, and that all necessary repairs have been made.

• After starting the engine, check all indicators, emergency stop, trip devices and gauges for serviceability.

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

• Clean the cab interior windows if necessary.

• Test all controls for proper operation.

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

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

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

• The operator should treat all power lines as live.

Safe Operating Practices for Drillers

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Planning the Job The person in charge must have a clear understanding of the work to be done and consider all the hazards at the site.

He must develop a plan to do the job safely and explain the plan to the crew members involved. Factors such as these should be considered: • Will the drilling take place in wet formations?

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

• Are there unusual or extreme weather conditions expected?

• Will drilling be done in night hours?

• Will the machine be propelled on inclines?

• Will drilling be done into difficult formations?

• Has a drilling pattern been developed?

• What is the required depth of the drilling pattern?

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

• Will vertical or angle drilling be required? vi

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Operating Precautions

• Operating near or contacting a power line with any part of the machine can result in electrocution.

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

• Raising or lowering the mast, and drilling with an unsupported or unleveled machine can result in excessive structural stress to the machine frames or can cause the machine to overturn.

Do not raise or lower the mast or attempt to drill until the machine is fully supported and leveled by the leveling jacks.

• Drilling with an unlocked mast can result in excessive pressure at the mast raising cylinders causing the mast to fall.

Do not attempt to drill until the mast locking pins are fully engaged. .

• Before leaving the operator's station, all controls must be in the neutral position with all locking and safety devices engaged.

Do not allow the drill to operate unattended.

• Do not park or position the machine on grades that exceed the tilt ratings.

Park or position the machine on level ground or across (horizontal) grade

• Park or position the machine to allow the wind to carry engine exhaust fumes away from the operator.

Exhaust fumes from diesel engines are lethal.

Safe Operating Practices for Drillers

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.

• Drill pipe that is free to slide through the opening in the top plate could be released from the loader while traveling.

Before lowering the mast, index the loader to a position such that the top plate of the loader prevents all drill pipe from moving past the top plate

General Maintenance Safety Practices While operating and servicing this machine be aware of the following:

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

Do not open hydraulic tanks, air reservoirs or hydraulic connections while the machine is running or the systems are under pressure.

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

Enclosures can cause suffocation.

• Climbing the mast is a crushing and falling hazard.

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

• Hydraulic oil under extreme pressure from a small opening can penetrate the skin and inject oil into the body.

Do not attempt to locate a hydraulic leak by using your hand.

• Pressure in hydraulic systems can be retained for long periods of time. If not properly released before maintenance people attempt to work on the hydraulic system, this pressure can let components move or cause hot oil to spray and hose ends to shoot out at high speed.

Release system pressure before attempting to make adjustments or repairs.

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• Carelessness in getting on and off equipment can result in serious injuries.

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

• Riding the rotary head up and down the mast is a crushing hazard.

Never ride the rotary head for any reason!!! It was not designed to be an elevator.

When there is a need for an operator or helper to work on the rig in the working area or danger zone and this work involves activation of one or several machine functions, this work shall only be done under the following conditions: a. There must be two safety trained people present, one should supervise the safety of the other doing the servicing.

Supervision should be done from the operator’s station to ensure immediate access to an emergency stop at all times. b. The area where the service work is to be done should be properly illuminated. c.

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

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

Fire Prevention

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

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

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

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

• Do not use the drilling machine in oil, gas or waterwell operations unless the well head is properly equipped with blowout preventers and safety equipment required by law or as recommended in the American Petroleum Institute's docSafe Operating Practices for Drillers

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ument API 54.

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

• Keep the batteries secured in their compartment and covered.

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

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

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

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

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

• Disconnect the battery cables before welding on the machine.

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

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

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

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

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INCLEMENT WEATHER and SAFE DRILLING PRACTICES GENERAL The following safety precautions were developed to minimize the risk of injury during inclement weather when using Driltech drilling equipment.

All persons involved in the planning, operation and serving of Driltech equipment MUST read and understand the following safety precautions, the manuals developed for this machine and the Safe Operating Practices outlined in the front of this manual.

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

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

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

It is the responsibility of management to: •

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

•

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

•

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

•

Consider that drill operators need ample time: a. to retrieve drill pipe from blastholes and well bottom. b. lower masts to a horizontal position or position feed rails into feed supports. c. give the drill engine an adequate cool down period prior to shutting machine down. d. leave machine cabin or operator platform and transport to central meeting location.

•

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

Note To Supervisors!

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

RAINFALL AND FLOODING When notified of an impending storm, machine operators should: Safe Operating Practices for Drillers

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•Move the drill machine to higher ground conditions.

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

•Move the drill machine to stable ground and away from unstable crests or the face.

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

•When operating machines in a construction application, equipment operators shall move the drill machine to higher stable ground.

Never leave a drill machine in any construction zone roadway, river bed or drainage ditch.

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

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

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

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

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

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

•

Equipment operators shall retrieve drill pipe from blastholes, secure drilling tools and lower mast to a horizontal position into the mast rest supports.

Understand that the mast in a vertical position with drill pipe in the ground is capable of attracting high voltage lightning.

NOTE !

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

•

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

•

Equipment operators shall give adequate engine cool down period prior to shutting machine down. Adequate engine cool down periods range between 3 to 5 minutes.

Follow engine manufacture specifications as a standard.

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•

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

•

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

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

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

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

all windows are closed

•

all doors closed

•

do not touch metal parts

•

do not use two way radio communication

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

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

Seek adequate shelter immediately.

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

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

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

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

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

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

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

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

Safe Operating Practices for Drillers

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Electrical charge should dissipate immediately after impact.

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

Reference material MSHA Holmes Safety Association Bulletin April 2001 Federal Metal and Nonmetallic Mine Safety and Health Standards 30CRF 56/57/58 Ninth Edition (1999).

National weather service (www.noaa.gov)

xiv

D75KS NEW MACHINE COMMISSION MANUAL The purpose of this manual is to provide assembly details, required tools and lifting apparatus as needed to field assemble a new D75KS machine on a customer location.

D75KS Dimensions

6’ 9”

52’ 9” D75KS TWO PIECE SHIPMENT MAST 52’ 9” LONG X 7’ 10” WIDE X 6’ 9” HIGH 38,000 LBS BASE 35’ 6” LONG X 14’ WIDE X 13’ 6” HIGH 103,000 LBS

13’ 6”

35’ 6”

14’

The D75KS uses a standard length mast designed for multi pass drilling applications. The mast for this machine is shipped as one piece on a standard flat bed trailer.

Sandvik Mining and Construction Page 1

The D75KS mast assembly may support work decks, dust collector hose and drill pipe.

The D75KS machine base is shipped on a I-Beam type trailer with a detachable goosekneck, maximum height of 18” and length of 24” to meet the local US transportation requirements.

Accessories for the D75KS machine assembly will be placed in box containers strapped to the machine deck unless specified within the sales order entry. A cab extension is removed for transit. Wood panels are bolted over both cab pieces to seal the cab from the elements.

Due to wood panels bolted to the cab sections the cab entry is limited to the left side door for transit purpose only.

The cab extension will be secured to the right side deck for transit.

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Remove machine accessories and box containers from machine deck and mast structures.

Organize machine accessories near the intended mounting position to minimize lifting.

Work Site Preparation Establish a proper work area to assemble a new drill machine.

•

Inside a enclosed workshop (with access to 50 ton overhead crane)

•

Outside on flat solid ground without overhead power transmission lines, (with access to one 50 ton crane)

•

Inside or outside on flat solid ground without overhead power transmission lines, (with 2 each 20 ton cranes)

•

Minimum of 3 assembly technicians

•

Estimated 50 hours assembly time

•

Appropriate 5 ton crane and lifting slings for positioning cab extension, decks and mast work deck

•

Air compressor and hand tools

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MINIMUM DISTANCE 60 FOOT (18 METERS)

MINIMUM DISTANCE 80 FOOT (24 METERS) ASSEMBLY LOT SIZE D75KS MACHINE BASE

Suggested Safe Operating Principals Follow local and Governmental Safety regulations.

Designate a lead assembly person for the assembly process.

Perform a site specific risk analysis prior to commencing machine assembly.

Follow the guidelines prescribed in this manual for assembly and commissioning the new drill machine.

File the required commissioning paperwork as needed to the proper authorities.

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D75KS Mast Lifting Points The D75KS mast will require appropriate lifting slings placed thru the mast chords. Mast lifting points vary due to mast component distribution and shipping weight.

Mast lift points vary when using one crane lift vs two crane lift.

EXAMPLE LIFT POINTS FOR BARE MAST NO DRILL PIPE AND ACCESSORIES SINGLE LIFT POINT DUAL LIFT POINT

With adequate lifting slings in place lift mast with crane less than 3 feet (1 meter) checking that the mast is stable and balanced both front/rear and left/right. Lower mast and adjust straps accordingly to get the mast balance correct.

When lifting the mast to set it on the machine the crown of the mast may be slightly higher than the mast table during the lift to enable mast raise cylinder rod installation.

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Assembly Tools Sandvik offers a mechanic tool kit •

006190-002

The tool kit is a tool chest and an assortment of up to 944 handtools that may be used by field technicians to assemble and provide service work on heavy equipment.

Specialty tools such as torque multiplier, air compressor an air tools are not part of this kit.

This service truck (maintenance truck) is well equipped with a portable welder, oxygen and acetylene cutting torches, portable compressor and a auto crane. The Ford truck shown in this picture as an example of a typical field service truck used in the heavy equipment service business.

The mechanic or technician in charge of this truck has service tools to perform mechanical labor on heavy equipment.

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MACHINE COMMISSIONING GENERAL Due to the size of Sandvik Mining and Construction blasthole equipment several components have been removed to enable the rig to be safely and legally transported. The purpose of this manual is to provide suggested tools, equipment and procedures for safely commissioning a new machine. This manual was written to cover a series of models so assembly times may differ slightly.

SAFETY Use a proper assembly site. Maintain safe and level ground conditions, clear of debris.

Use adequate lifting tools, allocate one assembler and crane operator to communicate the load handling during lifting and setting procedures.

Do not assemble machine near overhead power lines.

Use caution when ambient conditions are extreme. Use appropriate personnel protective equipment as required by mine specific regulations and safety programs.

NEW MACHINE ARRIVAL Machines arrive on a I beam type transport trailer appropriate for the base machine.

Perform a walk around inspection of the base machine visually checking for damage and loose accessories.

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Note any damage to the truck company.

The picture represents portable ramps used to load machines onto transport trailers at the factory. The portable ramps are not shipped with a machine. When the machine arrives at the mine site place suitable timbers under each track assembly to stabilize the machine as it is driven off the transport trailer.

Remove any timber from trailer utilized for support during transportation.

Once the truck is disassembled and tie down chains removed the machine may be started.

COMPONENT WEIGHTS and LIFTING •

Avoid manual lifting by using correct lifting equipment

•

Never stand under a suspended load

•

Ensure loads are correctly supported

•

Lifting apparatus must be serviceable and have sufficient capacity for the load

•

Follow recommended guidelines and crane load charts. Do not exceed manufacture rated capacity.

The chart below is approximate component weights for the purpose of selecting the proper lifting slings. Component weights vary according to part number. Drill tool weights vary according to dimensions and length specific to the part number.

As a general rule select a heavier rated lifting sling than the intended load weight.

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D75KS MAST 38,000 LB (17236 KG)

MAST BEARING CAP 80 LB (36 KG)

FRONT JACK PAD 600 LB (272 KG)

ACCESSORY CRATE 800 LB (363 KG)

ACCESSORY CRATE 2200 LB (998 KG)

RIGHT BOARDING LADDER 010296-001 145 LB (66 KG)

CAB EXTENSION 009834-001 2200 LB (998 KG)

A/C FOPS COVER 017576-001 119 LB (54 KG)

REAR CAB DECK OPTION 014877-002 225 LB (102 KG)

LEFT BOARDING LADDER 006955-001 30 LB (14 KG)

LEFT REAR DECK OPTION 022031-001 295 LB (134 KG)

RIGHT CAB DECK OPTION 014875-002 652 LB (296 KG)

DUST COLLECTOR DUCT 014966-002 73 LB (33 KG)

TIPTON DUST COLLECTOR 3070 LB (1393 KG)

12” X 17’ DUST COLLECTOR HOSE 230 LB (105 KG)

ANGLE DRILL WORK DECK 692 LB (314 KG)

7” TABLE BUSHING 212 LB (96 KG)

8 5/8” TABLE BUSHING 150 LB (68 KG)

7 “X 24 “BIT SUB 210 LB (95 KG)

8 5/8” X 30 “BIT SUB 440 LB (200 KG)

7” X 25’ X 1” WALL DRILL PIPE 2400 LB (1090 KG)

8 5/8 X 35’ X 0.906 WALL DRILL PIPE 2973 LB (1350 KG)

DIMENSIONS D75KS machines are shipped as two loads for domestic and export deliveries. The mast, cab extension and work decks are disassembled from the machine base. The mast supports some of the items for transit. Mounting hardware and drill accessories will be inside a crated container positioned on the right side deck as shown here.

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A service truck with air compressor and standard hand tools will be required to assemble work decks, ladders, dust control accessories and drill tools to the new machine.

A hand held grease gun and grease cartridges should be available to service the lube points prior to new machine start up.

For DTH applications the customer must have a minimum of 5 gal (20 liters) of a selected rock drill oil to fill the lubricator reservoir. This oil is required to lubricate the down the hole hammer and drill bit shank.

PERFORM MACHINE PRESTART CHECKS •

Check the batteries

•

When applicable engage battery disconnect switch

•

Check engine oil level

•

Check engine water level

•

Check gearbox oil level

•

Check compressor oil level

•

Drain condensation/water from air receiver tank

•

Check hydraulic oil level

•

Drain condensation/water from hydraulic receiver tank

•

Check cab controls and accessories

Add fluid as needed to the respective compartment prior to starting the machine.

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STARTING THE MACHINE The controls on the operator station must be in neutral modes prior to starting the machine.

1. Check that the engine idle switch is in the ‘LOW’ idle mode for start up.

2. Check that the emergency stop buttons are released.

3. Turn the key switch to the start position.

4. Apply the bypass switch.

5. Engage the start push button to start the engine.

ENGINE IDLE SWITCH

START PUSH BUTTON BYPASS SWITCH

KEY SWITCH

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The engine idle speed switch enable selection of the engine rpm. Toggle switch down is low idle speed set for 1200 rpm. Toggle switch up is high idle speed set for 1800 rpm.

Engine idle speeds affect hydraulic pump flow. For the purpose of tramming the machine from a transport or in a confined space such as a work shop the engine idle speed may be at low idle mode for short distance. The engine idle speed must be at high idle mode for the purpose of tramming the machine long distances.

TRAMMING THE MACHINE FROM THE TRANSPORT Perform a risk assessment of the off loading procedure with the transport driver and available ground support personnel.

A tram interlock system option may hinder tram conditions unless the operator applies the foot switch first. Machines equipped with tram interlock use a foot pedal on the floor inside the cab.

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1. The machine will be off loaded to the rear. This position enables best overall view through cab windows. Ground level personnel may assist in guiding the operator.

2. Equipment with a foot switch apply the foot switch first, disregard this step if the machine does not have a foot switch.

3. Apply push lock buttons on tram levers to move the controls.

NOTE! The machine may be operated at low engine idle speed (1200 RPM) during unloading conditions.

NOTE! Operator control configuration: left control operates left track, right control operates right track. The controls shall be pulled slowly toward the operator to initiate reverse track motion.

As the controls are moved to full position tram speed will increase.

4. Use caution as machine comes off timbers onto level ground as not to drag front jack on the transport trailer.

5. Set the machine to high idle speed (1800 rpm) to tram the machine to the designated assembly area.

6. Assembly area must be smooth surface, free of debris and hazardous working conditions.

Stay away from electric power lines or power transmission facilities.

7. Center tram controls to stop machine travel.

8. Equipment with a foot switch release the foot switch when tram is complete, disregard this step if the machine does not have a foot switch.

9. Lower engine idle to (1200 rpm) for proper engine cool down period.

10. Turn key switch to the off position to activate machine shutdown. If immediate shutdown is required engage any of three emergency stop switches.

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NOTE! It is recommended by the engine manufacturer to allow an adequate cool down period of 3 to 5 minutes for engine turbo speed and engine oil pressure to stabilize.

Accessory Component Inventory Remove decks, ladders, front jack pad, chain supports, optional dust collector hose and accessory crate from machine deck, mast rest and or mast.

Place the component near the intended assembly position.

MOUNTING THE RIGHT SIDE LADDER TO THE MACHINE BASE The right side boarding ladder is shipped separately.

Mounting hardware consists of 12 ea 3/8 inch bolts for the boarding ladder.

Suggested tools •

3/8 or 1/2 inch air ratchet

•

9/16 inch (14 mm socket)

•

9/16 inch (14 mm) open end wrench

•

flat blade screwdriver

•

four point phillips head screwdriver

•

small alignment bar

•

Auto crane and lifting sling

1. Secure the emergency stop panel to the side frame with two mounting screws.

2. Position the auto crane and appropriate lifting sling for lifting the right side ladder in place.

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EMERGENCY STOP PANEL

RIGHT SIDE BOARDING LADDER

3. Secure the boarding ladder onto the entry deck with 12 bolts.

4. Clean the hand and foot rails to remove road dirt and oils that may have accumulated during transit.

After the boarding ladder has been installed be sure to utilize a three point stance (two hands on the rails and one foot on the step at all times) when mounting the machine.

CAB EXTENSIONS The cab extension allows for larger cab interior and easy access to the cab from right side deck.

Suggested tools •

3/8 or 1/2 inch air ratchet

•

9/16 inch (14 mm) socket

•

9/16inch (14 mm) open end wrench

•

Silicon sealant

•

3/4 inch (19 mm) socket

•

3/4 inch (19 mm) open end wrench

•

Auto crane and lifting sling Sandvik Mining and Construction Page 15

1. Position the crane and appropriate lifting sling for lifting the cab extension in place.

2. Remove sound abatement panels from cab sections to access the cab mounting bolts and nuts.

3. Remove the bolts that secured the plywood panels to the cab extension and machine cab.Use caution when removing plywood, do not damage roof seals for air conditioner unit.

REMOVE BOLTS AND PLYWOOD PANELS

4. Clean cab mating surfaces and apply bead of silicone to both surfaces.

5. Attach appropriate lifting strap to cab roof panel and lift cab extension into place.

6. Roll cab floormat away at the two outside corners to access shock mount bolts.

7. Set cab extension on 2 each shock mounts and secure the cab with the 1 X 5.5 inch UNC bolts, washers and self locking nuts. Final bolt torque shall be 1000 ft lb (827 Nm).

8. Secure cab extension panel to the cab with 24 each 3/8 bolts, washers and self locking nuts.

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9. Replace sound abatement into cab wall and ceiling panels.

10. Replace the floormat.

NOTE! Steps 11 through 16 will require a site specific safety harness and lanyard PPE. 11. Apply silicone to top surface seam of cab extension.

12. Check that air conditioner seal fits smooth onto mounting surface and secure air conditioner flange to cab roof top.

13. Check air conditioner electric supply plug is tight.

14. Place FOPS cover over air conditioner, mount with 4 each 1/2 inch bolts.

FOPS COVER

15. Install the cab pressurization precleaner and filter assembly to the air conditioner unit.

16. Secure the pressurization filter electric connectors and test cab fan switch positions.

17. Clean the cab roof window.

18. Apply the main light switch in the cab to check the night light operation, inspect the electrical plugs. Rotate the night lights to suit the operating condition.

The cab is ready for occupancy.

DECKS Deck features available for the D75KS machines may vary from those depicted in this manual.

Suggested tools •

3/8 or 1/2 inch air ratchet Sandvik Mining and Construction Page 17

•

3/4 inch (19 mm socket)

•

3/4 inch (19 mm) open end wrench

•

small alignment bar

•

auto crane and lifting sling

1. Position the auto crane and appropriate lifting sling for lifting the right side cab deck with handrail.

RIGHT DECK

2. Secure right side cab deck and handrail with 12 each 1/2 bolts.

3. Position the auto crane and appropriate lifting sling for lifting the rear cab deck with handrail.

REAR DECK

4. Attach the right side hand rail to the cab panel with 9 each 1/2 bolts. Connect both rear handrails with 2 each 3/8 inch bolts and self locking nuts.

5. Remove decals and clean windows to remove transit road dirt.

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6. Secure boarding ladder to left front deck with 4 each 1/2 inch bolts. This ladder allows maintenance access to the air receiver tank and air filter assemblies.

LEFT LADDER

Avoid slip and fall hazards by keeping deck surfaces clear of debris as service work is being performed.

After the boarding ladder has been install be sure to utilize a three point stance (Two hands on the rails and one foot on the step at all times) when mounting the machine.

When service tools are required on the machine decks, place the tools on deck prior to climbing the ladder or ask for assistance with handing tools up to the deck level.

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MAST The D75KS mast assembly consists of the structure with pulldown and hoist chains, rotary head, drill pipe loader, power breakout tool, holding wrench, dust hood, winch with wire rope, all hydraulic and air hose connections, angle drill pipe guide, electrical switches and junction box.

The mast may be loaded with work decks and drill accessories for transit purpose.

Prepare Mast For Assembly To Machine 1. Perform a walk around inspection of the mast assembly and related components visually checking for damage and loose accessories.

2. Note any damage to the truck company.

3. Remove decks and accessories from mast, set decks aside in a logical order according to frame mounting for final assembly.

4. The mast must be lifted from the transport and placed on solid ground.

5. Remove straps supporting wood cribbing.

6. Remove mast support bearing caps and mast cylinder pins, clean and prepare for installation. Note that the bearing caps are stamped and must be replaced as left and right with the matching mast bearing block.

7. Remove tape and tie straps from hoses and electrical components.

8. Inspect and prepare electrical limit switches and proximity switches wire connectors as they apply for mast options.

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Prepare The Machine Base Mast Pedestal The mast pedestal pivot shaft bearing surfaces and both mast raise cylinders are protected for transit purpose.

Remove tape from mast pivot shaft bearing surfaces and clean. Apply a small film of grease to the pivot shaft bearing surfaces.

Loosen the transit rope from the mast raise cylinders and lay the cylinders towards the engine prior to placing the mast onto the machine base.

Mast Installation It is the region and/or local dealer responsibility to locate and make available proper tools to assemble the machine mast to the machine frame.

Suggested tools •

50 ton overhead crane or 2 each 15 ton cranes

•

Appropriate lifting slings

•

1 1/2 (38 mm) socket

•

Torque multiplier for bearing cap bolts

•

1/2 inch chisel

•

Ball peen hammer

•

1 1/4 (32 mm) open end wrench

•

7/8 (22 mm) open end wrench

•

13/16 (20 mm) open end wrench Sandvik Mining and Construction Page 21

•

3/4 (19 mm) open end wrench

•

9/16 (14 mm) open end wrench

•

1/2 (13 mm) open end wrench

•

Antisieze compound for pins or bushings

NOTE! Perform a risk assessment with assembly crew and crane operator prior to lifting mast structure. Establish who will be communicating during the lift and install process.

1. Secure mast with adequate lift slings through both left and right side mast chords.

2. Secure a guide rope on the mast to assist manuevering the mast as it is raised.

3. Lift mast with crane less than 3 feet (1 meter) from ground checking that the mast is stable and balanced both front/rear and left/right. Lower mast to ground and adjust straps accordingly to get the balance correct.

4. When mast balance is correct: continue to raise mast so machine may be driven under raised mast.

5. One operator shall be in cab driving machine as needed.

One person from ground level is the director to assist the operator as needed to align the mast bearings to the machine pedestal shaft.

Mast bearing caps are identified as left or right side.

If a spacer is on the mast pivot shaft move the spacer towards the right side. The spacer is a shim to gain additional clearance so the mast will not contact the cab.

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Mast bearing cap bolts use lock washers and lock plates that must be bent over to secure the bolt upon final torque.

6. Secure each mast bearing cap with 4 each bolts.

BEND THE LOCK PLATE OVER THE BOLT HEAD

7. Final torque for the bearing cap bolts shall be 650 ft lbs (880 Nm).

8. Bend lock plates over bolt head and bearing cap.

9. Connect grease line for auto grease systems or manually grease lube point as needed.

10. Connect mast raise cylinder rod ends to mast. The crane may have to lift the mast slightly to allow the cylinder rod clevis end to fit into the pin recess.

MAST CYLINDER PIN RETAINER AND BOLT

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The operator may have to cycle the mast raise cylinders to enable proper rod bore and recess alignment.

! DANGER Do not use fingers to check bore alignment of mast cylinder mounts Personnel injury to fingers or hand may result 11. Remove transit tape from air hose and air pipe adapter. Connect air supply hose and safety restraint chain to air pipe adapter.

Hydraulic Connections Machine must be stopped and ‘LOTO’ Lock Out/Tag Out applied. Follow regional and governmental safety policies prior to working with the hydraulic system.

Relieve hydraulic pressure from the reservoir by opening the ball valve on the hydraulic reservoir air pressurization components.

Relieve hydraulic pressure from the valves and hose connections by moving the middle stacker, upper stacker and feed directional control valve handles.

Use caution when opening the flange plugged feed system pipes as oil will be present.

Loosen flange bolts slightly and open flange plug slowly to allow oil to drain from pipe.

Use suitable containers for collecting residual hydraulic oil.

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Hydraulic hoses have to be connected at the mast pivot point. Check the hydraulic plug and caps for numeric or alphabetical stamps. Connect #1 to #1 or A to A accordingly.

! DANGER Cycle the feed direction control handle forward and reverse prior to opening feed system hydraulic pipes Hydraulic oil under pressure can spray out from the flange adapter if not opened correctly Loosen the flange adapter bolts slowly in a cross pattern while deflecting the hose slightly to relieve pressure between the flange adapter and the pipe flange Pay attention to the two large diameter hose connections. One hose is to extend the feed cylinder in a down mode and one is used to retract the feed cylinder for the up mode.

Rotation pump hoses are looped at the mast pipes and at the pump ports. Prepare the pipe and pump ports by cleaning the adapter flanges prior to opening.

Flange adapters require buna N type oring seals. Fit the oring into the flange adapter. Use caution to not damage the oring seal when connecting hose flange adapter to the pipe flange or pump port.

NOTE! Save the flange plugs as they may be used for troubleshooting hydraulic systems.

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Position the hoses without twist prior to final flange clamp tightening.

Hydraulic oil is lost from the rotation pump hoses due to this assembly procedure so it is mandatory to follow new pump startup guidelines when the machine is started. Refer to hydraulic book 5 new pump startup procedures.

Allow a minimum of 15 minutes of neutral pump run time prior to operating the rotation pump and turning the rotary head or drill pipe. This pump run time is critical to purge air from the hoses.

NOTE! Cycle the feed system in both directions (down and up) to remove air from the feed cylinder prior to installing drill pipe to the rotary head.

! DANGER Failure to cycle air out of the feed cylinder could lead to operational problems, loads falling and possible personnel injury or component damage Apply middle and upper stacker valve controls. Cycle the accessory cylinders full stroke numerous times to purge air out of the cylinders for the functions of: •

air control (cylinder)

•

mast lock (cylinders)

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•

holding wrench (cylinder)

•

dust and/or water injection (motors)

•

loader (cylinders)

•

winch (motor)

•

power tong (cylinders)

•

pipe positioner (cylinders)

•

centralizer D55SP (cylinders)

•

dust hood (cylinder)

•

dust door (cylinder)

Clean spilled hydraulic oil from components as needed.

Mast Electrical Connections Mast electrical components power and ground connections are separated at a mast junction box positioned on the left side mast pedestal frame.

1. Inspect proximity switch and/or limit switch positions for damage, obstructions and tightness.

2. Open the mast pedestal junction box with a flat blade screwdriver.

3. Bring the mast wires through the junction box and secure wires to the corresponding terminals accordingly.

EXPLODED VIEW

4. Secure the incoming wires to limit wear.

5. Close and secure the junction box door.

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INSTALLING FRONT LEVELING JACK PAD In some cases due to transport trailers the front jack pad is removed for shipping. Install the front jack pad as follows: Suggested tools •

15/16 (24 mm) open end wrench

•

7/8 (22 mm) open end wrench

•

13/16 (20 mm) open end wrench

•

1/2 (13 mm) open end wrench

•

7/16 (11 mm) open end wrench

•

Medium pliers

1. Place the front jack pad on the ground under the front jack assembly.

2. Start the machine (engine at low idle speed 1200 RPM).

MOVE FAST FEED PUMP CONTROL

20%

ADJUST PRESSURE CONTROL CW

3. Place the fast feed pump control on 20% to enable oil for the lower stacker valves.

4. Pull the front leveling jack control reverse to extend the front leveling jack cylinder down.

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quality/rig photos 2819 pic 182f

5. Adjust pressure control CW accordingly to develop operating pressure for the leveling jack circuit.

6. With a second person as a guide stop the front leveling jack control when the jack and pad alignment enables the pin to be inserted.

7. Operators must center the fast feed pump control and front leveling jack control prior to personnel installing the pin into the leveling jack pad.

8. Secure the jack pad pin in place.

9. Cycle all jacks to assure air is out of the system.

10. After the leveling jack cylinders are cycled and all jacks are raised so the green jack up lights are alluminated, stop the machine engine by standard procedure.

MAST WORKDECK Depending on transport methods the mast work deck is typically strapped to the mast as shown. Remove the mast workdeck from the transport position prior to installing the mast to the machine frame.

There are a variety of mast workdecks available.

•

stationary workdecks for vertical drilling applications

•

adjustable workdecks for angle drill applications

Sandvik Mining and Construction Page 29

The work deck must be positioned onto the mast and pinned into place with mast raised and locked into a vertical position. To install the workdeck proceed as follows: 1. Start machine.

2. Apply the fast feed pump approximately 80% to enable oil for leveling the machine.

3. Operate level jacks to level the machine. Monitor the level indicator for true machine frame level position.

!

DANGER

OPERATING NEAR OR CONTACTING A POWER LINE WITH ANY PART OF THE MACHINE CAN RESULT IN ELECTROCUTION. DO NOT RAISE THE DRILLING MAST OR OPERATE THE MACHINE IN THE VICINTY OF ELECTRICAL POWER LINES WITHOUT CHECKING THE MINIMUM SAFE OPERATING PERIMETER SET BY LOCAL, STATE OR NATIONAL REGULATIONS. 4. Set the engine to high idle speed to operate the mast raise cylinders.

5. Pull the mast raise control reverse to raise the mast. Derate the fast feed pump control from 80% to 10% as the mast nears overcenter to let the mast set slowly into the mast frame.

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quality/rig photos 2819 pic 182f

6. Lock the mast to the machine frame by applying the middle stacker control for mast lock cylinders.

7. Mast lock engage light illuminates indicating frame mounted cylinders have engaged the mast table.

8. Engage light is green - Disengage light is red NOTE! Mast lock pins will not engage if the machine is not level left to right.

9. Stop the machine engine by standard procedure.

Mounting The Work Deck To Mast Table Suggested tools •

Auto crane

•

Hammer

•

9/16 (14 mm) open end wrench

Mount the work deck to the mast table as follows: 1. Auto crane and appropriate lifting apparatus will be needed to balance and set the mast work deck in place.

2. Work decks pin into fixed lugs welded to the bottom end of the mast table.

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WORKDECK PINS UNDER MAST TABLE

3. The deck is adjustable to maintain a horizontal surface. Adjustments and/or fixing the deck in place is made available with pins at the mast table top front.

4. Utilize a small layer of never seize compound inside the bore and on the pin assembly.

5. Position the rubber dust curtain around the work deck matching mounting hole position prior to final mounting. Secure rubber curtain with mounting straps with 3/8 bolts and nuts.

Dust curtains may need to be modified to suit the local drilling environment. Angle drilling at 20° or 30° may require two curtains to enable the bottom of the dust hood skirt to make full circumference contact with the ground condition.

6. Remove dust deflector retainer from dust hood.

7. Remove dust wiper seal retainer from dust hood.

It may be advisable to leave the dust deflector and drill pipe wiper seals out of the dust hood ‘so they will not become damaged’ until after drill pipe is added. Installing drill pipe is explained later in this commission manual.

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1. Install drill pipe wiper seals as needed.

2. Install dust deflector as needed.

PREPARING THE DUST COLLECTOR The dust collector has been prepped for transportation.

There are two variations of dust collectors available for the D75KS blasthole drill machine.

The chosen dust collector is based on the customer requirements.

There may be some minor adjustments required for local operating environments.

Suggested tools •

Auto crane

•

Lifting slings

•

9/16 (14 mm) open end wrench

•

11/16 (17 mm socket)

•

11/16 (17 mm) open end wrench

•

3/4 (19 mm) open end wrench

•

1 1/4 (32 mm) open end wrench Sandvik Mining and Construction Page 33

Preparing The Stationary Deck Mount Dust Collector 1. Remove tape from the fan exhaust port prior to starting the dust collector.

2. Remove tape from the dust vent ports.

3. Inspect rubber seals on the dust vent ports that they are free to open as needed.

When applicable open the air supply ball valve for the dust collector air control regulator. Air regulators may be fitted to the top or bottom of the dust box according to dust collector model. I 4. Check air regulator pressure and/or calibrate the air regulator to 50 psi for the dust filter purge cycle.

LOW PRESSURE APPLICATIONS

HIGH PRESSURE APPLICATIONS

5. The dust collector timer may need to be calibrated to suit the dust control timed cycle.

Typical on time is 1 second and off time is 6 seconds.

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6. Open the dust filter doors and tighten the dust filter hold down nuts prior to drilling.

Preparing The Stationary Side Mount Dust Collector This dust collector is shipped as a assembly on a seperate transport trailer.

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1. Perform a walk around inspection of the dust collector assembly and related components visually checking for damage and loose accessories.

2. Note any damage to the truck company.

3. Remove tape from the fan exhaust port prior to starting the dust collector.

4. Remove tape from the dust vent ports.

5. Position the auto crane and appropriate lifting sling for lifting the dust collector to the machine frame left side mounting position.

6. Secure the dust collector and mounting plate with 18 each 1/2 bolts and self locking nuts.

7. Connect three hydraulic hoses to the motor, matching numeric or alpha stamped cap and plugs to the appropriate motor ports.

8. Connect air supply hose to the air regulator.

9. Connect electrical plug for the electronic timer system.

10. Fit the dust seal to the drop port.

The stationary side mount dust collector may need adjustments once it is started.

1. It may be necessary to calibrate the air regulator to 50 psi for the dust filter purge cycle.

2. The dust collector timer may need to be calibrated to suit the dust control timed cycle.

Typical on time is 1 second and off time is 6 seconds.

Connect Dust Collector Hose Suggested tools •

3/4 (19 mm) open end wrench

•

Flat blade screw driver

Secure dust hose to dust collector and workdeck. Use hand cleaner on the pipe connectors to aid installing the dust hose. Secure dust hose with supplied clamps.

1. Position the dust collector hose onto the dust collector port.

2. Position the dust collector hose onto the dust hood port.

3. Install and tighten the hose clamps accordingly.

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TIPTON#6 OR #6H

TIPTON#7 REGULATOR

TIMER

MOTOR CONNECTIONS B PORT IN A PORT OUT C PORT DRAIN

Mount Optional Strobe Lights Suggested tools •

9/16 (14 mm) open end wrench

Mount the strobe light to the top of the cab as follows: 1. Place strobe light stand on cab roof.

2. Secure with supplied bolts.

3. Plug electrical connectors together.

Mount the strobe light to the crown of the mast when the mast is horizontal as follows: 1. Place strobe light stand on mast crown mounting pad.

2. Secure with supplied bolts.

3. Plug electrical connectors together.

Sandvik Mining and Construction Page 37

MACHINE ASSEMBLY IS COMPLETE Add number 1 or number 2 diesel fuel to the fuel tank relative to local operating ambient temperature.

Add water and water additives to water tank for dust control as needed.

Add drill tools per site specific requirements. Refer to operator manual when adding or removing drill tools from a drill machine.

DRILL PIPE INSTALLATION GENERAL The drill pipe loading process requires competent personnel and a unregulated time frame to perform the task safely.

DESCRIPTION Drill pipe supplied from the factory and shipped with the machine may be positioned •

inside the mast loader

•

on wood cribbing as part of the mast shipment

•

on the transport trailer

When drill pipe is shipped inside the drill pipe loader no action is required for loading drill pipe into the machine.

Remove any shipping restraints prior to using the drill pipe loader system.

When drill pipe is shipped separated use caution when loosening the restraints if the drill pipe is transported on wood cribbing or on the transport trailer.

Sandvik Mining and Construction

Page 38

Drill Pipe Weights

DIMENSION

WEIGHT

7 x 35 X 0.50

2300 LB (1043 KG)

7 5/8 X 35 X 1.0

2718 LB (1233 KG)

8 5/8 X 35 X 0.906

2973 LB (1349 KG)

Drill pipe weights may vary from this chart according to a specific part number, dimension and wall thickness.

DRILL PIPE ON WOOD CRIBBING

Drill pipe must be lifted with overhead crane and appropriate weight rated lifting slings.

Use a balanced two point contact for lifting drill pipe from the wood cribbing or ground position.

LIFT DRILL PIPE WITH TWO LIFTING SLINGS

BOX END

PIN END

Lift and balance drill pipe in a horizontal position. Set the drill pipe on smooth ground beside the machine frame.

Sandvik Mining and Construction Page 39

LOADING DRILL PIPE INTO THE MACHINE There are two methods typically used to safely load drill pipe into a machine.

It is strongly recommended to check with the mine safety department and follow local regulations for site specific safety standards according to lifting objects.

Perform a risk analysis of the task with all participants involved with loading and operating equipment.

! WARNING Remove all unnecessary personnel from the work area during drill pipe loading procedures.

Load Drill Pipe Method 1 The drill supervisor and/or mine management have to approve of this method because it does require personnel to be in the mast for a limited part of the drill pipe loading process.

Loading drill pipe from ground level into the horizontal mast with a overhead crane is a safe means of installing drill pipe.

A top sub must be in the rotary head to perform this task.

Tools Required •

safety approved nylon lifting sling at least 2 inch (52 mm) wide or 1/2 inch wire rope in good service condition

•

five ton overhead crane

•

crane operator

•

mechanic and/or helper

•

drill machine operator

Three persons should be communicating during the drill pipe installation procedure.

Crane operator must communicate with the mechanic working in the mast to lift and position the drill pipe.

Mechanic must communicate with the crane operator for positioning the drill pipe and the drill operator for threading drill pipe onto the rotary head.

Drill machine operator must communicate with the mechanic for threading drill pipe to rotary head and maintaining rotary head hose position.

Sandvik Mining and Construction

Page 40

! WARNING All personnel must clear the mast and be in clear view of the drill operator prior to the operator raising the mast into position for loading drill pipe into pipe loader.

All personnel must wear appropriate PPE for the assigned task. The personnel assigned to work in the horizontal mast must use a safety harness and a site specified length lanyard.

1. Start the machine 2. Operate at low idle speed 3. Level the drill machine frame 4. Rotary head at top of mast clear of the loader top plate 5. Two lifting slings attached to drill pipe 6. Crane operator lifts the drill pipe so the pipe is balanced horizontally 7. Mechanic and crane operator position drill pipe in the mast 8. Mechanic removes both pin and box thread protectors from the drill pipe 9. Drill operator set rotation torque control to minimum setting so not to over torque drill pipe threads during the threading process APPLY FEED DOWN TORQUE CONTROL MINIMUM

FEED PUMP ON 10%

ROTATION ON SLOW

PRESSURE CONTROL MINIMUM

10. Drill operator set pressure control to minimum setting during the drill pipe threading process

Sandvik Mining and Construction Page 41

11. Drill operator place the feed pump on 10% 12. Drill operator move feed control to the down position 13. Drill operator thread rotary head top sub onto pin end of drill pipe according to mechanic guidance 14. Drill operator stop the rotation upon mechanics guidance so not to wrap the lifting straps around the drill pipe with excess torque or rotation 15. Drill operator move feed down to place box end of drill pipe in mast table 16. Mechanic observe hydraulic hoses so they do not get caught or crimped during rotary head travel 17. Mechanic remove both lifting straps from drill pipe 18. Mechanic shall disembark from horizontal mast into the operator cabin 19. Clear all personnel from the mast area and rear of the machine 20. Drill operator shall raise mast to a vertical position and apply mast lock control 21. Drill operator use feed system and loader components as needed to load drill pipe into drill pipe loader

22. Drill operator index and lock the loader to new position for adding new drill pipe 23. Drill operator use feed system to raise rotary head to top of mast clear of the loader top plate

Sandvik Mining and Construction

Page 42

24. Drill operator lower mast to horizontal position 25. Repeat steps 4 through 24 as needed to load required number of drill pipe into the loader assembly Add drill tools according to required drilling method 1. Mechanic to place table bushing into table 2. Drill operator move the feed down so drill pipe is centered through the table bushing 3. Mechanic and operator connect customer supplied bit sub and rotary bit and/or hammer and drill bit to drill string under the dust hood 4. Connect the appropriate drill tools according to procedures noted in drill tool section of this manual

Safety must be expressed prior to and during the drill pipe and drill tool loading process.

All personnel must understand the dangers involved when working with heavy drill pipe and drill tools on any blasthole drill machine.

Load Drill Pipe Method 2 The drill supervisor and/or mine management have to approve of this method as it requires the mast to be raised and lowered numerous times during the drill pipe loading process.

This method does not require personnel to be in the mast during the drill pipe loading process.

Loading drill pipe from ground level is a safe means of installing drill pipe.

A top sub must be in the rotary head to perform this task.

Tools Required •

safety approved nylon lifting sling at least 2 inch (52 mm) wide or 1/2 inch wire rope in good service condition

•

service truck autocrane

•

mechanic and/or helper

•

drill machine operator

Two persons should be communicating during the drill pipe installation procedure.

Sandvik Mining and Construction Page 43

! WARNING All personnel must clear the mast and be in clear view of the drill operator prior to the operator raising or lowering the mast.

All personnel must wear appropriate PPE for the assigned task.

1. Start the machine 2. Operate at high idle speed 3. Level the drill machine frame

!

DANGER

Operating near or contacting a power line with any part of the machine can result in electrocution. Do not lower the drilling mast or operate the machine in the vicinity of electrical power lines without checking the minimum safe operating perimeter set by local, state or federal regulations 4. Have the operator raise the mast to a vertical position 5. Have the operator lower the rotary head to the bottom of the mast 6. Mechanic secure a single lifting strap to drill pipe at approximately 1/3 point of the drill pipe length 7. Mechanic use autocrane and lift the drill pipe 8. Remove the thread protector from the pin end of the drill pipe 9. Have the operator lower mast to a acceptable angle (approximately 40° + 5°) to allow proper drill pipe alignment through the mast table 10. Mechanic apply some koppercoat thread grease to the drill pipe threads 11. Mechanic position drill pipe angle to correspond with the mast angle 12. Mechanic position drill pipe through the dust hood and mast table being cautious not to damage dust hood or drill pipe threads NOTE! Do not use table bushing as it consumes the table opening diameter. The big table opening allows easier drill pipe maneuvering.

Sandvik Mining and Construction

Page 44

13. Drill operator set rotation torque control to minimum setting so not to over torque drill pipe threads during the threading process APPLY FEED DOWN TORQUE CONTROL MINIMUM

FEED PUMP ON 10%

PRESSURE CONTROL MINIMUM

ROTATION ON SLOW

14. Drill operator set pressure control to minimum setting during the drill pipe threading process 15. Drill operator place the feed pump on 10% 16. Drill operator move feed control to the down position NOTE! Assure top sub and drill pipe thread alignment is proper prior the connecting threads to minimize cross threading 17. Drill operator thread rotary head top sub onto pin end of drill pipe 18. Drill operator stop the rotation so not to wrap the lifting strap around the drill pipe with excess torque or rotation 19. Drill operator use slow feed to move feed up raising drill pipe box end above dust hood 20. Mechanic observe slow feed mode that drill pipe does not contact dust hood 21. Mechanic remove lifting strap from drill pipe 22. Drill operator shall raise mast to a vertical position and apply lock mast control 23. Drill operator use slow feed to raise drill pipe so box end clears drill pipe loader seat plate 24. Drill operator uses loader components to set drill pipe into open loader pocket

Sandvik Mining and Construction Page 45

25. Drill operator index and lock the loader to new position for adding new drill pipe 26. Repeat steps 4 through 25 as needed to load required number of drill pipe into the loader assembly Add drill tools according to required drilling method 1. Mechanic to place table bushing into table 2. Drill operator move the feed down so drill pipe is centered through the table bushing 3. Mechanic and operator connect customer supplied bit sub and rotary bit and/or hammer and drill bit to drill string under the dust hood 4. Connect the appropriate drill tools according to procedures noted in drill tool section of this manual.

PREDELIVERY CHECKS Fluids must be checked and grease points must be lubricated prior to machine commissioning. It is up to the local region and servicing dealer to provide the proper fluids necessary to maintain this machine in the working environment.

Refer to the factory fill spec page for compartment locations and quantity.

Lubricate the Central Grease Points There are two variations of grease systems. All require some form of maintenance.

Sandvik Mining and Construction

Page 46

Manual grease points Automatic timed cycle grease points Suggested tools •

Hand held grease gun

•

NLG1 or NLG2 series grease cartridges

Manual grease points for pins and bushings, rotating sprockets, rotating drive shafts, loader pivot shafts, power breakout tools and rotary head swivel bearings. There are as many as 34 points to lubricate as needed upon new machine commissioning.

In all lube applications there are 11 rotating or moving grease points that require initial grease, to be serviced by a hand held grease gun.

1. Inspect the four grease containers fixed to the carrier sprocket. Fill these containers with the hand held grease gun as needed, and at 250 hour intervals.

2. Drive shaft yoke and u joint zirks 3. Rotary head air swivel joint

Automatic grease systems are a timed cycle for grease injection at stationary lube points. It is suggested to adjust the timed lube cycle to minimum time during new machine commissioning period. Confirm all lube points receive grease then rest timed lube cycle to suit the ambient operating condition.

MANUAL TIMER SYSTEM

Sandvik Mining and Construction Page 47

CENTRAL GREASE TIMER

Refer to service literatur 006113-000 centralube system timer calibrations for setting grease cycles to meet local equipment lubrication requirements.

Grease adapters that were opened for transit (mast related grease points) may have air trapped in the lube line. The technician may need to purge air from the grease line during the commissioning process. All grease injectors have a manual lube point in order to address no lube situations.

Service Lubricator Reservoir (DTH Applications) Suggested tools •

2 each 5 gallon (20 liter) containers of rock drill oil

The lubricator is a timed cycle of oil injection for DTH hammer and bit lubrication. The timer is inside the operator station lower electric junction box.

Calibrate the timed cycle for 1 second on time and 6 to 8 seconds off time.

Sandvik Mining and Construction

Page 48

FILL LUBE TANK WITH CLEAN ROCK DRILL OIL

Rock drill fluid level is visible in the linear gauge and with the reservoir decal.

In some cases it may be necessary to purge the air and rock drill oil from the pump and lube line. Refer to service literature 011353-000 for details on lube pump calibrations.

1. Purge the air and oil from the pump at the vent port 2. Purge the air and oil at the air line check valve positioned on the mast air pipe connection Inspect Engine fluids Check engine oil level per engine dipstick level marks.

Check engine coolant level to be in site glass.

Inspect Compressor Oil Level Drain condensation from air receiver tank drain ball valve prior to starting the machine.

Compressor fluid level is noted on the air receiver reservoir decal.

If oil is required the machine must be stopped and receiver air pressure must be zero.

The fill plug is vented and sealed with a oring. Open the fill plug from the adapter port. Fill to appropriate level with appropriate, clean synthetic compressor oil.

Sandvik Mining and Construction Page 49

Inspect the hydraulic oil level Hydraulic fluid level is noted on the reservoir decal. Fluid is checked with leveling jack and mast raise cylinders in the retract mode.

There are two means of adding hydraulic oil to the machine. If hydraulic oil is required there is a #12 (3/4 inch) hose supplied with the accessory tools.

1. Install the hose to the hand pump and place the hose end into a supply of clean hydraulic oil. Adding hydraulic oil through the hand pump forces the oil through the machines return filtration.

2. Or place the service/lube connection onto the wiggins adapter at the service center. Adding hydraulic oil through the wiggins service center forces the oil through the machines return filtration.

Inspect Pump Drive Gearbox Fluid Levels 1. Remove the dip stick and wipe clean, reinstate the dip stick and remove it to see the fluid level.

Mineral and synthetic base gear oils of the proper grade for the operating environment are acceptable for pump drive gearbox fluids.

It is recommended to perform a initial pump drive gear oil sample and oil change at a 50 hour service interval.

Inspect Rotary Head Fluid Level Level machine frame and raise the mast. Lock mast in vertical position.

1. Rotary head shall be lowered to be accessible from mast table.

2. Open either plug on planetary cover.

3. Oil level to be at decal limit mid way between the planetary drive ring.

Mineral and synthetic base gear oils of the proper grade for the operating environment are acceptable for rotary head gearbox fluids.

Note overfilling the rotary head gearbox can lead to oil venting out of the breather vent during a drilling condition.

Sandvik Mining and Construction

Page 50

Inspect Final Drive Fluid Levels Start the machine and rotate the track so that the drain point is at the bottom position and the fill point will be at the 10 and 2 o’clock positions.

1. Remove the fill plug to verify oil level for each final drive assembly.

Inspect Winch Drum Fluid Level Operate the winch assembly so the winch drum site glass appears in the access hole.

Inspect Water Injection Pump Fluid Level 1. Remove the pump plug to inspect fluid level.

FACTORY FILL FLUIDS Lube oils listed here are factory fill fluids and compartment capacities are machine specific.

The fluids and capacities listed are for D55SP and D75KS applications.

COMPONENT

FLUID BRAND/GRADE

LOCATION

CAPACITY

ENGINE OIL

15X40 MOTOR OIL

CATERPILLAR 18 GALLONS 68 LITER OR CUMMINS QSK19 21 GALLONS 79.4 LITERS

ENGINE COOLANT

50% ETHYLENE GLYCOL 50% WATER MIXTURE

25 GALLONS 95 LITER

Sandvik Mining and Construction Page 51

DIESEL FUEL

NUMBER 2 DIESEL

600 GALLON 2274 LITERS

COMPRESSOR OIL

SHELL CORENA PAO 32

80 GALLONS 303 LITER

HYDRAULIC OIL

CITGO A/W ALL-TEMP 32

TANK REFILL 230 GALLONS 872 LITER SYSTEM REFILL 320 GALLONS 1213 LITERS

MAIN PUMP DRIVE GEARBOX

EP 90 SHC 75X90

Sandvik Mining and Construction

5.5 QUARTS 5.5 LITERS

Page 52

AUXILLIARY PUMP DRIVE GEARBOX

EP 90 SHC 75X90

7.75 QUARTS 7.3 LITERS

ROTARY HEAD

EP 90 SHC 75X90

5.5 GALLONS 21 LITER

FINAL DRIVE OIL

10W30

3.4 GALLONS 13 LITER

WINCH DRUM

EP 90

2 QUART 2 LITER

OVERHANG ADAPTER

SHELL CORENA PAO 32

12 OZ 355 ML

Sandvik Mining and Construction Page 53

POPPET INLET VALVE

SHELL CORENA PAO 32

12 OZ 355 ML

WATER INJECTION PUMP

SAE 30

1 QUART 1 LITERS

WATER TANK WITH DUST COLLECTOR

H2O

200 GALLONS 757 LITERS

WATER TANK WITHOUT DUST COLLECTOR

H2O

LUBRICATOR TANK

ISO 100 OR 220

LOW PRESSURE AIR SYSTEM

Sandvik Mining and Construction

SAME POINT AS ABOVE

400 GALLONS 1514 LITERS OR 550 GALLONS 2082 LITERS 10 GALLONS 38 LITERS OR 30 GALLONS 113.5 LITERS

Page 54

THREAD GREASE

KOPPERKOAT OR EQUIVELENT P/N 024178-003

5 GALLON 20 LITER

CENTRAL GREASE SYSTEM

NLGI 1 OR NLGI 2

30 OR 55 LB 13.6 OR 25 KG

CHAIN LUBE SYSTEM

SAE 20

30 GALLONS 113.5 LITERS

Sandvik Mining and Construction Page 55

COOLANT SPECIFICATIONS Always use a mixture of approved fill water, antifreeze and Cooling System Conditioner.

Refer to the engine manufacturer for detailed specifications, or Caterpillar® form SEBD0518.

FILL WATER Always add conditioner to coolant water. Never use plain water only in the cooling system.

Acceptable water for use in the preparation of ethylene glycol type antifreeze and water mixture is shown in the follow chart.

ACCEPTABLE WATER

Property

Maximum Limit

ASTM Test

Chloride (CL)

40 mg/L (2.4 grains/US gallon

‘D512’ ‘D4327’

Sulphate (SO4)

100mg/L (5.9 grains/US gallon)

‘D516’

Total Hardness

170 mg/L (10 grains/US gallon

‘D1126’

Total Solids

340 mg/L (20 grains/US gallon

‘D1888’

Acidity

pH of 5.5 to 9.0

‘D1293’

ppm = parts per million

Antifreeze For optimum performance a 1:1 (50/50) mixture of water/glycol solution is recommended.

Use ethylene glycol or propylene glycol to protect against freezing and boiling.

Concentration

Freeze Protection

Boil Protection

50 Percent

-36°C (-33°F)

106°C (223°F)

60 Percent (Ethylene Glycol Only)

-52°C (-62°F)

111°C (232°F)

Sandvik Mining and Construction

Page 56

Coolant Conditioner Elements Coolant conditioner elements should be used to maintain a 3 to 6% concentration of conditioner in the coolant. Use a precharge element when filling the system or changing coolant.

Install a new maintenance element after every 250 hours of service.

FUEL SPECIFICATIONS Caterpillar® manufactured diesel engines have the ability to burn a variety of fuels. These fuels are divided into two categories: Preferred or Permissible.

Preferred fuels provide maximum engine service life and performance. These fuels are distillate fuels and are commonly called; fuel oil, furnace oil, diesel fuel, gas oil or kerosene.

Permissible fuels are crude oils or blended fuels. Use of these fuels can result in higher maintenance costs and reduced engine service life.

Refer to form SEHS7067 from Caterpillar® for a detailed summary of preferred fuels and their specifications.

Cetane Requirement The cetane number of the fuel has an effect on the ability of the engine to start. Also, the cetane number has an effect on the interval of time before the engine runs smoothly. The minimum fuel cetane number recommended for this engine is 40.

Fuel Cloud Point The cloud point of the fuel is the temperature that allows some of the heavier components in the wax to solidify in the fuel. Wax in the fuel is not a contaminant, it is an important element of No.2 diesel fuel. Fuel waxing can plug the fuel filters in cold weather. Fuel heating attachments can minimize fuel filter waxing and are available from your Sandvik Mining and Construction or Caterpillar® dealer.

Fuel Sulphur Content The percentage of fuel sulphur content will affect the engine oil and filter change intervals (refer to the following chart).

Sandvik Mining and Construction Page 57

CRANKCASE OIL VISCOSITIES

Viscosity Grade

Minimum Temperature

Maximum Temperature

SAE 0W-20

-40°C (-40°F)

10°C (50°F)

SAE 0W-30

-40°C (-40°F)

30°C (86°F)

SAE 0W-40

-40°C (-40°F)

40°C (104°F)

SAE 5W-30

-30°C (-22°F)

30°C (86°F)

SAE 5W-40

-30°C (-22°F)

50°C (122°F)

SAE 10W-30

-18°C (0°F)

40°C (104°F)

SAE 10W-40

-18°C (0°F)

50°C (122°F)

SAE 15W-40

-9.5°C (15°F)

50°C (122°F)

SAE 30

0°C (32°F)

40°C (104°F)

SAE 30

5°C (41°F)

50°C (122°F)

NOTE !

The minmum Total Base Number (TBN) of the oil used must be 20 times the percentage of fuel sulphur (TBN as measured by the ASTM ‘D2896’ method). If the sulphur content is greater than 1.5%, choose and oil with the highest TBN that meets one of these classifications: API CF, API CF-4, API CG-4, API CH-4, or API CI-4 . Consult your Caterpillar® dealer or form SEBU6251 for correct engine oil recommendations.

LUBRICANT SPECIFICATIONS General The classifications listed below follow S.A.E. J183 classifications. The MIL specifications are USA Military Specifications. The following definitions will be of assistance in purchasing lubricants. The specific classifications for this machine are found on the Lubricant Chart.

Engine Oils (CH) Only use oils that meet Engine Service Classification CH (MIL-L-2104D).

At the factory, this machine was filled with BP 15W - 40. Consult the Caterpillar form SEBU5939 for a listing of CH oil brands.

Sandvik Mining and Construction

Page 58

NOTE! The engine oil and filter should be changed after the first 50 hours of service on new and reconditioned engines.

Compressor Oils (COMP) As with any oil Do not mix different types of oils. Contamination of synthetic oils with ATF or mineral based fluids may lead to excessive foaming and lubrication/cooling problems.

When operating between 80 and 100°F (27 and 38°C) and with relative humidity above 80%, a synthetic hydrocarbon type fluid is recommended. Currently, Shell Corena PAO 32 is used as the factory fill compressor oil unless the receiver tank decal indicates otherwise.

NOTE! Compressor oil change intervals will change depending on the type of oil used. The oil manufacturers recommendations supersede the recommended interval suggested in this manual.

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

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

Sandvik Mining and Construction Page 59

AMBIENT TEMPERATURE

CHANGE INTERVAL

ISO

LUBRICANT DESCRIPTION

-40°F to +95°F (-40°C to +35°C)

1000 Hours

32

Mobil SHC-624, 924 & 1024

-40°F to +100°F (-40°C to +38°C)

500* Hours

32

Mobil Rarus 424

-40°F to +100°F (-40°C to +38°C)

1000 Hours

32

Chevron HiPerSYN

-40°F to +100°F (-40°C to +38°C)

1000 Hours

32

Chevron Tegra Synthetic

-40°F to +100°F (-40°C to +38°C)

1000 Hours

32

Shell Corena PAO

-40°F to +100°F (-40°C to +38°C)

1000 Hours

32

Royco 432

-40°F to +100°F (-40°C to +38°C)

1000 Hours

32

Conoco Syncon R&O

-40°F to +100°F (-40°C to +38°C)

1000 Hours

32

Texaco Cetus PAO

-40°F to +100°F (-40°C to +38°C)

1000 Hours

32

Valvoline Syn Guard CP

-40°F to +100°F (-40°C to +38°C)

1000 Hours

32

Petro-Canada Super SCF32

+30°F to +100°F (-1°C to +38°C)

1000 Hours

46

Chevron HiPerSYN

+30°F to +100°F (-1°C to +38°C)

1000 Hours

46

Citgo CompressorGuard

+30°F to +100°F (-1°C to +38°C)

1000 Hours

46

Conoco Syncon R&O

+30°F to +100°F (-1°C to +38°C)

500* Hours

46

Mobil Rarus 425

+30°F to +100°F (-1°C to +38°C)

1000 Hours

46

Petro-Canada Super SCF46

+30°F to +100°F (-1°C to +38°C)

1000 Hours

46

Royco 446

+30°F to +100°F (-1°C to +38°C)

1000 Hours

46

Texaco Cetus PAO

+30°F to +100°F (-1°C to +38°C)

1000 Hours

46

Valvoline Syn Guard CP

+80°F to +120°F (+27°C to +49°C)

1000 Hours

68

Conoco Syncon R&O

+80°F to +120°F (+27°C to +49°C)

1000 Hours

68

Mobil SHC-626, 926 & 1026

High and Low Pressure Compressors When operating between +80 and 100°F (+27 and 38°C) with a relative humidity above 80%, synthetic hydrocarbon type fluid Mobil SHC or equivalent as recommended above should be used. * 1000 Hours with low pressure compressors All lubricant recommendations are based on 1200 rpm maximum WARM-UP speed.

Sandvik Mining and Construction

Page 60

Hydraulic Oils (HYDO) Use Engine Service Classification CC (MIL-L-2104B), CC/SF (MIL-L-46152B), CD (MIL-L2104D) or industrial-type hydraulic oils that are certified by the oil supplier to have anti-wear,foam, -rust, and -oxidation additive properties for heavy duty usage.

At the time of shipment this machine was filled with Citgo 32 AW hydraulic oil.

Refer to Sandvik Mining and Construction oil specifications approved by our pump supplier for use in piston and vane pump assemblies. Equivalent manufacture and brand name fluids are noted with ISO grades applicable to operating conditions.

Equivalent Hydraulic Oils

LUBRICANT BRAND NAME

MANUFACTURER

ISO 22

ISO 32-46-68

ISO 100 X

ACCITE HIDRAULICO MH

PETROLEOS MEXICANOS

X

AMOCO AW OIL

AMOCO OIL CO.

X

AMOCO RYDON OIL MV

AMOCO OIL CO.

X

ANTECH

EXXON/ESSO

X

ASHLAND VG

ASHLAND OIL CO.

32

BARTRAN HV

BP OIL CO.

BRESLUBE VG

BRESLUBE LTD.-CANADA

X

X

CANADIAN OIL MOXY T

OIL CANADA

X

X

CANVIS AW

BP OIL CO.

X

X

CHAMPION SUPER GRADE

LOWE OIL

X

CHEVRON AW

CHEVRON

X

CITGO AW

CITGO

X

D-A WEAR GUARD II VG

D-A LUBRICANT CO.-USA

X

DECOL ANTI-WEAR

SHELL CANADA

X

DTE 24-25-26

MOBIL OIL CORP.

X

DURO AW

ARCO

X

EAL SYNDRAULIC

MOBIL OIL CO.

X

ELF OLNA DS

ELF/ANTAR

X

ENERGOL HLP-HD SERIES

BP OIL CO.

X

EPPCO UNIVIVERSAL GP

EPPERT OIL CO.

X

GULF HARMONY AW

GULF R&D

X

GULF SYNFLUID SL H__AW

GULF USA

X

HIDRALUB EP

MARAVAN S.A.

X

X

HARMONY AW

GULF CANADA LTD.

X

X

ISO 150

X

46 & 68

X

X

X

X

X

X

X

Sandvik Mining and Construction Page 61

LUBRICANT BRAND NAME

MANUFACTURER

ISO 22

ISO 32-46-68

ISO 100

ISO 150 X

HYDRAFLOW

PETRO CANADA

X

X

HYDRALUBE AW

LUSCON IND.

X

X

HYDRELF DS

ELF

HYSPIN AWS-AD

CASTROL INC.

X

HYTAC

DISTAC LUBRICANTS

X

X

KENOIL R&O AW

KENDALL REFINING CO.

X

X

LUSCON HD

LUSCON IND.

X

X

MARATHON MULTI. VG

MARATHON PETROLEUM

X

X

MOBIL HYD. OIL NZ

MOBIL OIL CO.

X

MOBIL HYD. OIL ZF

MOBIL OIL CO.

X

MYSTIK AW/AL

CATO OIL & GREASE CO.

X

X

NERVOL FLUID SH2

NERVOL

X

X

X

NUTO-H

EXXON/ESSO

X

X

X

NUTO-HP

EXXON/ESSO

32 & 46

NUTO-H PLUS

EXXON/ESSO

X

NYCO HYD. OIL

NYCO LUBRICANT CORP.

X

ORLY AGENA

ORLY INTERNATIONAL

X

ORLY GALA

ORLY INTERNATIONAL

X

ORLY HYDRO

ORLY INTERNATIONAL

X

PACER POWER V

PACER LUBRICANT INC.

X

X

X

PARADENE ANTI-WEAR AW

DRYDEN OIL CO. - USA

X

X

X

PEAK HYDRA AW SERIES

PEAK OIL CO.

46 & 68

X

PEN PREMIUM EP

PENTAGON CORP.

32 & 68

X

PENNZBELL AW

PENNZOIL PROD. CO.

X

X

PENNZOIL AW

PENNZOIL PROD. CO.

X

X

PENNZOIL AWX

PENNZOIL PROD. CO.

X

X

RANDO OIL HD

TEXACO INC. - USA

X

ROL ANTELITTERAM HVI

ROL RAFFINERIA

X

ROYAL AW

EPPERT OIL CO.

X

ROYAL PREMIUM VG

EPPERT OIL CO.

X

RYKON OIL

AMOCO OIL CO.

X

SELCO SF 330

SELCO

X

SHARLU HYDROFLUIDS AW

SHARJAH NATIONAL LUBE OIL CO. LTD.

X

SHOSEKI W-R

SHOWA OIL LTD.-JAPAN

STAR PREMIUM VG

EPPERT OIL CO.

Sandvik Mining and Construction

46 & 68

X

X

32, 46 & 56 X

Page 62

X

X

X

X

LUBRICANT BRAND NAME

MANUFACTURER

ISO 22

ISO 32-46-68

ISO 100

ISO 150

SUNVIS 8__ WR

SUNCOR or SUNTECK

X

X

X

SUPER BLUE HYD. OIL

AUTOLINE OIL CO.

X

X

X

SUPER HYD. OIL VG

CONOCO

X

X

TELLUS

SHELL CANADA LTD.

X

X

TELLUS

SHELL CO. - USA

X

X

TERRAPIN IND. OIL

AUTOLINE OIL CO.

X

X

TOTAL AZOLI A ZS

J.W.LANE

46 & 68

X

TRC HYD. OILS VG

TEXACO REFINERY

X

UNION UNAX AW VG

UNION OIL - USA

32 & 46

X

UNIVIS N

EXXON/ESSO

X

X

UNIVIS N PLUS

EXXON/ESSO

X

X

UNIVIS SHP

EXXON/ESSO

32 & 46

YUKONG SUPERVIS

YUKONG LTD.

X

X

X

X

Sandvik Mining and Construction Page 63

MINIMUM PERFORMANCE STANDARDS FOR HYDRAULIC OILS The following are typical properties of hydraulic oils for use in severe duty applications of axial piston and vane pumps. Any oil which meets these or similar properties or which is listed in the approved list of Equivalent Hydraulic Oils may be used.

32 (32AW)

46 (46AW)

68 (68AW)

100 (100AW)

ASTM Viscosity Grade No. (Saybolt)

150

215

315

465

Gravity: API

31.1

30.3

29.5

28.9

Viscosity, Kinematic: cSt 104°F (40.0°C) 212°F (100.0°C)

30.04 5.26

42.70 6.57

62.9 8.43

96 11.03

Viscosity, SSU 100°F (37.8°C) 210°F (98.9°C)

155 43.9

220 48.2

325 54.6

500 64

Viscosity Index, ASTM D 2270

106

105

104

99

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

31

31

31

32

Flash, P-M: °F (°C)

400 (205)

405 (208)

450 (233)

465 (241)

Flash, OC: °F (°C)

425 (219)

430 (222)

470 (244)

490 (255)

Fire, OC: °F (°C)

455 (235)

470 (244)

500 (260)

545 (285)

Pour: °F (°C)

-25 (-32)

-25 (-32)

-20 (-29)

+5 (+15)

Color, ASTM D 1500

L0.5

L0.5

L1.0

L1.5

Carbon Residue, Ramsbottom:%

0.30

0.30

0.36

0.37

Rust Preventive Test, ASTM D 665 Procedure A, 24 hr Procedure B, 24 hr.

Passes Passes

Passes Passes

Passes Passes

Passes Passes

Neutralization No. ASTM D 974 Total Acid No.

0.68

0.68

0.68

0.68

Oxidation Test, ASTM D 943 Time Oxidized Hr. to 2.0 Acid No.

2000+

2000+

2000+

1500+

Emulsion, FTMS 791 3201, 180°F Dist. Water: Minutes

40-40-0 (3)

40-40-0 (3)

40-40-0 (4)

40-40-0 (6)

Aniline Point, ASTM D 611: °F (°C)

217 (103)

220 (105)

228 (109)

234 (113)

ISO VISCOSITY GRADE

Sandvik Mining and Construction

Page 64

Multipurpose - Type Gear Lubricant (MPL) Use Gear Lubricant Classification GL-5 (MIL-L-2105B) EP140. Use SHC 75 x 90 in cold ambient conditions and SHC 5 x 90 in arctic conditions.

Lubricating Grease (MPGM) Use only multi-purpose grease (MPGM) which contains 3 to 5% molybdenum disuphide.

NLGI No, 2 Grade is suitable for most temperatures. Use NLGI No. 1 or No. 0 Grade for extremely low temperatures.

Refrigeration Oil (REF) Use an ISO 100 refrigeration oil. If the system is completely evacuated use 3.5 lb of 134a refrigerant.

Sandvik Mining and Construction Page 65

DRILL STRING AND DRILL TOOLS Drill string kits available from Sandvik Mining and Construction include all tools required to start drilling blastholes. Note the difference between rotary and down the hole drill applications.

What type of drilling medium will be used?

Sandvik Mining and Construction

Page 66

CHUCK ADAPTER API THREAD

DTH

RETAINING RINGS

DRILL BIT

API THREAD

ROTARY

Install Top Sub The top sub may be installed at the factory which require no prestart preparation.

If the top sub is supplied locally the top sub may need to be prepared and installed into the rotary head API thread.

It is recommended to follow 011201 service literature for proper top sub installation procedures. If available apply a small wrap of twine string onto the top sub thread. Then apply a thin layer of thread grease onto the top sub threads.

Install Table Bushing Prepare the mast table adapter for new bushing installation as the surfaces may be dirty from transit.

Sandvik Mining and Construction Page 67

HOLDING WRENCH

The holding wrench must be fully retracted so the new table bushing will fit into the adapter.

Table bushings are shipped inside the accessory crate. There are three variations of bushings built for specific drilling applications.

•

1 piece rotary bushing (fixed insert) for rotary drilling

•

1 piece rotary bushing (barber bushing) for rotary drilling

•

2 piece hammer bushing with insert for DTH hammer drilling

Place the bushing into the table adapter so the flat joints align.

Purge New Drill Pipe It is recommended to blow air through new drill pipe prior to placing the drill tools in service.

The purpose is to clean the drill pipe of any foreign substance prior to connecting expensive drilling tools such as down the hole hammers and drill bits.

! WARNING THIS PROCESS GENERATES MOMENTARY NOISE PERSONNEL PROTECTIVE EQUIPMENT REQUIRED UNNECESSARY PERSONNEL MUST BE CLEARED FROM THE WORK AREA DURING THIS PROCESS

This task must be performed with drill pipe connected to the rotary head and the machine operating at low idle speed. Momentarily turn the air on for a short burst of air to blow through the open drill pipe. Turn the air off.

Sandvik Mining and Construction

Page 68

Install Bit Sub and Bit Remove thread protectors from bit sub and drill bit. Inspect threads, and apply a liberal amount of quality thread grease on all thread joints. Sandvik Kopper thread grease part number 024178-003 is available in 5 gallon (20 liter) containers.

Rotary application: The operator and the assembler will be communicating to connect drill tools to the drill string.

PPE is required for this task.

1. Place the drill bit on solid ground under the drill table.

2. Operate feed down so bit sub and drill pipe are passing through the table bushing 3. Stop the feed down mode as the bit sub threads engage the drill bit threads 4. Slow rotate the bit sub and drill bit threads together so the two shoulders contact taking necessary steps not to cross thread the drill tools.

DTH application: The operator and the assembler will be communicating to connect drill tools to the drill string.

PPE is required for this task.

1. Place the new drill bit onto the blank bit breakout plate, mark the bit diameter on the breakout plate, cut the breakout plate to suit the dimension of the bit, a welder with cutting tools will be required to cut the breakout plate 2. Remove the chuck adapter from the hammer case 3. Lubricate the new drill bit splines and the chuck adapter threads with a thin coating of thread grease

Sandvik Mining and Construction Page 69

4. Place the chuck adapter onto new drill bit 5. Place retaining rings with a new oring onto the drill bit above the chuck adapter

#1

#3-4-5

6. Install the chuck adapter and drill bit into the hammer case and hand tighten 7. Lubricate the hammer API threads with thread grease 8. Prep the hammer by pouring 1 quart (1/2 liter) of clean rock drill oil into the hammer case, the check valve may need to be opened to prelube the internal hammer components #8

#9-10-11-12

9. Place the hammer and bit on solid ground under the drill table.

10. Operate feed down so the drill pipe passes through the hammer bushing 11. Stop the feed down mode as the drill pipe threads engage the hammer threads

Sandvik Mining and Construction

Page 70

12. Slow rotate the drill pipe and hammer threads together so the two shoulders contact taking necessary steps not to cross thread the drill tools.

NOTE! Drill bits, chuck adapters and hammer threads will tighten as the drilling cycle commences.

Rotary drill bits, hammers and hammer bits are consumable items that wear according to ground conditions. Operators must inspect the drill tools on a regular basis to assure they are in good operating conditions.

Change drill bits as needed with proper breakout tools. Breakout tools are a necessary item to loosen threads and the drill bit from bit subs or hammer cases. Breakout tools must be accessible to the operator.

In some cases removing drill bits requires a second person.

Breakout Tools Break out tools are required to remove drill bits and hammers from the drill string. Stow breakout tools in a safe location until they are needed.

The pipe tong will be used on drill pipe and sub connections.

The petol wrench and chain attachment will be used on down the hole hammers.

Bit baskets are blank plates to be cut to fit a customer supplied drill bit diameter. The bit basket fits into the mast table and the bit will fit and lock into the basket for removal.

J WRENCH TONG WRENCH PETOL WRENCH AND CHAIN

DTH BIT BREAKOUT

ROTARY BIT BREAKOUT

Do not use the tong wrench on hammer cases as the squeezing action of the tong pipe dies can damage the circumference of hammers.

Sandvik Mining and Construction Page 71

Follow manufacture recommendations for hammer lubrication, maintenance, disassembly, repair and assembly.

SANDVIK MINING AND CONSTRUCTION BLASTHOLE WARRANTY A package of commissioning documents will be sent to the local Region and/or Servicing dealer that is responsible for the equipment order.

Submit commissioning documents to the respective regional Sandvik Mining and Construction office.

Submit Engine, Compressor and Undercarriage documents thru vender supplied electronic database or a standard local dealer representative.

Fire suppression warranty is administered at a local level within the final destination country.

Verify commissioning documents with actual component serial numbers

The machine data plate offers 1.

2.

3.

4.

manufacture address machine model 6 digit machine serial number patent numbers

Equipment serial numbers may be located • operator station - console • right rear leveling jack hanger • front mast rest frame The engine data plate offers 1.

2.

3.

4.

5.

Sandvik Mining and Construction

Page 72

engine serial number arrangement number horsepower fuel specification maximum altitude calibration

The compressor data plate offers 1. compressor model number 2. compressor serial number 3. manufacture date High pressure compressor shown

The track frame data plate offers 1.

2.

3.

4.

5.

left side model number right side model number left side serial number right side serial number manufacture dates

Engine The engine must be registered on Caterpillar web page at www.cat.com. Go to the tab marked ‘Engines’ and then ‘Service & Support’ then go to ‘Engine Warranty Registration’ and complete the form.

Engine specific numbers are located on the engine cylinder head or valve cover.

You are encouraged to read the complete ‘Caterpillar Limited Warranty’ from Caterpillar. It details terms and conditions which must be met in order to qualify under the warranty.

Undercarriage The undercarriage must be registered with Caterpillar OEM Solutions Group. The warranty registration may be completed by visiting www.componentsformoems.com Undercarriage specific numbers are located on the left and right track side frame.

You are encouraged to read the complete ‘Caterpillar Warranty’ from Caterpillar. It details terms and conditions which must be met in order to qualify under the warranty.

Compressor The compressor warranty will be administered by Sandvik Mining and Construction upon return receipt of the machine start up documents.

Sandvik Mining and Construction Page 73

Compressor specific numbers are located on the housing or gearbox.

Sandvik Mining and Construction Equipment Start Up Inspection Document Machine start up documents are to be filed within the first 30 days of new machine commissioning.

Machine specific numbers are located on the operator console or right rear leveling jack hanger.

A copy of a equipment start up document is provided as a reference guide.

Complete all fields in the original Equipment Start Up Inspection form.

Note repairs and adjustments in the repair, adjustments remarks field.

Quality Checklist Fill in all fields of the quality check list.

Grade the quality of the machine with a score between 5 to 1 according to the condition of the machine as received during the machine commissioning process.

Sandvik Mining and Construction

Page 74

DRILLING EQUIPMENT START-UP INSPECTION IMPORTANT: Warranty claims for this product will not be processed until this form is completed and returned to the factory Customer Name

Address

Worksite Address

City,State,Zip

Phone

Contact Person

Phone

Phone

Distributor Name

Address

City, State, Zip

Drill Model

Drill Serial No.

Delivery Date

GO THROUGH WITH CUSTOMER'S OPERATOR/CONTACT PERSON Contents of Operator's Manual Operation, service and maintenance instructions Spare Parts manual All greasing points All filter element locations

All drill controls and operation Brake system and towing (crawlers) Guards, protective devices and warning decals Quality checklist completed All warranty documents completed

CHECK WITH CUSTOMER'S OPERATOR/CONTACT PERSON All fluid compartment levels Track tension and adjustment (crawlers) Function of controls and instruments Operation of all systems and accessories Drill string consumables Spare parts

Drain condensed water from fluid compartments Grease all lubrication points Tighten any loose fittings or fasteners Prestart check list (owner operator manual) 50 hours service

GIVE TRAINING TO CUSTOMER'S OPERATOR/CONTACT PERSON Starting, levelling drill, and raising mst Loading drill stem Operating drill stem loader Drilling and drill performance Safe operating practices

Operation of accessories Proper instrument readings Driving or moving drill Shut down procedures

REPAIRS, ADJUSTMENTS, REMARKS

EXAMPLE FORM The product described above was received by the customer in satisfactory condition and the customer acknowledges that the Driltech Mission warranty is hereby accepted as part of the sales agreement for this product. The customer has received a thorough briefing on correct operation, and proper maintenance and service procedures for this product.

CUSTOMER REPRESENTATIVE

TITLE

DATE

TITLE

DATE

NAME DISTRIBUTOR REPRESENTATIVE NAME

Sandvik Mining and Construction Page 75

Fire Suppression Factory installed fire suppression systems require local representation at new machine commission time. Upon inspection of the fire equipment the local representatives are responsible to certify the system and submit the proper warranty documentation.

Cab mounted manual/automatic actuator shown without the LT-5-R cartridge Install one LT-5-R cartridge into the actuator prior to machine commission LT-5-R cartridge is filled with nitrogen and provides the pressure required to activate the connected system Manual test and reset control Red button on right is test Black pin on left is reset If the manual test button is engaged the machine will shutdown and will not start Fire suppression system

Nozzles positioned and aimed at high risk or enclosed hot areas

Sandvik Mining and Construction

Page 76

Recommended Torque Values For Standard Hardware - UNC

This table applies to Sandvik Mining and Construction part numbers: 001554-___ CAPSCREW, Hex hd Gr. 5 005486-___ CAPSCREW, Hex hd Gr. 8 001559-___ CAPSCREW, Socket hd Gr. 8 001570-___ SCREW, Flat hd socket Gr. 8 001577-___ NUT, Hex - regular Gr. 5 001575-___ NUT, Hex - heavy Gr. 5 001562-___ NUT, Hex - self-locking Gr. 5 Coarse Thread (UNC) Size (Diameter in Inches)

Torque Grade 5 Ft.Lb. (Kg/M)

Torque Grade 8 Ft.Lb. (Kg/M)

1/4

6 (.8)

9 (1.2)

5/16

12-14 (1.5)

17-19 (2)

3/8

22-24 (3)

31-34 (4.5)

7/16

36-39 (5)

50-55 (7)

1/2

54-59 (8)

76-84 (11)

9/16

77-85 (11)

110-120 (15-16.5)

5/8

107-118 (15-16)

153-166 (21-23)

3/4

190-210 (26-29)

270-292 (37-40)

7/8

280-310 (38-43)

437-475 (60-66)

1

425-460 (59-63)

650-710 (90-98)

1-1/8

570-620 (79-86)

930-1000 (128-138)

1-1/4

810-870 (112-120)

1310-1410 (181-195)

1-3/8

1060-1140 (146-157)

1730-1850 (239-256)

1-1/2

1410-1510 (195-209)

2290-2460 (316-340)

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

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

Sandvik Mining and Construction Page 77

Recommended Torque Values For Standard Hardware - UNF This table applies to Sandvik Mining and Construction part numbers: 001555-___ CAPSCREW, Hex hd Gr. 5 005487-___ CAPSCREW, Hex hd Gr. 8 001560-___ CAPSCREW, Socket hd Gr. 8 001571-___ SCREW, Flat hd socket Gr. 8 001578-___ NUT, Hex - regular Gr. 5 001576-___ NUT, Hex - heavy Gr. 5 001563-___ NUT, Hex - self-locking Gr. 5 Fine Thread (UNF) Size (Diameter in Inches)

Torque Grade 5 Ft.Lb. (Kg/M)

Torque Grade 8 Ft.Lb. (Kg/M)

1/4

7 (1)

10-11 (1.5)

5/16

14-16 (2)

20-22 (3)

3/8

25-28 (3.5)

35-39 (5)

7/16

39-43 (6)

55-61 (8)

1/2

63-69 (9)

86-94 (12)

9/16

87-95 (12-13)

123-134 (17-18.5)

5/8

126-138 (17-19)

171-187 (24-26)

3/4

213-233 (30-32)

300-328 (42-45)

7/8

312-338 (43-46)

480-520 (66-72)

1

466-504 (64-70)

715-770 (99-106)

1-1/8

640-695 (89-96)

1040-1120 (144-155)

1-1/4

900-960 (124-133)

1460-1560 (202-216)

1-3/8

1210-1300 (167-180)

1970-2100 (272-290)

1-1/2

1585-1700 (167-180)

2570-2750 (272-290)

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

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

Sandvik Mining and Construction

Page 78

CONVERSION FACTORS The following conversion factor chart is for reference purpose. It is based in US standards for metric conversions and may be administered in system calculations.

MULTIPLY

FACTOR

TO OBTAIN

ATMOSPHERES

1.011325

BAR

ATMOSPHERES

29.9213

IN OF HG @ 32 F

ATMOSPHERES

101.325

KILOPASCALS

ATMOSPHERES

14.6960

PSI

BAR

1.1097

ATMOSPHERE (TECH)

BAR

14.504

PSI

CENTIMETERS

0.3937

INCHES

CUBIC FEET

0.02832

CUBIC METERS

CUBIC FEET

7.48052

GALLONS

CUBIC FEET

28.32

LITERS

CUBIC INCHES

16.39

CC

CUBIC YARDS

0.7646

CUBIC METERS

FEET

0.3048

METERS

FOOT-POUNDS

1.356

NEWTON METERS

GALLONS

231

CUBIC INCH

GALLONS

3.785

LITERS

INCH

2.54

CENTIMETER

INCH

25.40

MILLIMETER

KILOGRAMS

2.20462

POUNDS

KILOMETERS

0.6214

MILES

KILOWATTS

1.341

HORSEPOWER

LITERS

61.02

CUBIC INCH

LITERS

0.2642

GALLONS

METERS

100

CENTIMETER

METERS

39.37

INCHES

MILLIMETERS

0.03937

INCHES

MILLIMETERS

0.1

CENTIMETERS

POUND PER SQUARE INCH (PSI)

0.06895

BARS

POUND PER SQUARE INCH (PSI)

6.89476

KILOPASCALS

TONS (SHORT)

2000

POUNDS (LBS)

TONS (SHORT)

0.90718

TONS (METRIC)

Sandvik Mining and Construction Page 79

Sandvik Mining and Construction

Page 80