Maintenance Manual

DR560 Serial Number 10346

4-11-2011

Sandvik Mining and Construction

13500 NW Country Road 235
Alachua, Florida 32616 - USA
Tel. (386) 462-4100
Fax. (386) 462-3247

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MAINTENANCE MANUAL (08/03/25) II

Getting Familiar…

There are 8 sections.

Sections have modules for

serviceable components.

Safety & Important Notices

Service Info
MAINTENANCE MANUAL (08/03/25) III

Planning your PM program…

Read Section 1 and 2.

Read the first page of each module.

Look at each page for 3 to 5 seconds.

Review the sample PM Program Forms.

Plan your PM Program.

TABLE OF CONTENTS (08/03/25) I

Finding the Information…

Table of Contents (10346)

Page
1.0 Introduction
1.1 Operating/Maintenance Safety 1-01-001
1.2 Safety Training Registration 1-02-001
1.3 Warranty & Claim Form 1-03-001

2.0 General Maintenance

2.1 Drill Assembly 2-01-001
2.2 Break-in Maintenance 2-02-001
2.3 PM Program 2-03-001
2.4 PM Schedules 2-04-001

3.0 Undercarriage
3.1 Track Adjustment 3-01-001
3.2 Final Drive 3-02-001

4.0 Feed Arrangement

4.1 Mast Feed System 4-01-001
4.2 Top Drive 4-02-001
4.3 Top Drive Motor 4-03-001
4.4 Breakout Wrench 4-04-001
4.5 Carousel Assembly 4-05-001
4.6 Expander Pin System 4-06-001
TABLE OF CONTENTS (08/03/25) II

5.0 Hydraulic System

5.1 Hydraulic Circuits 5-01-001
5.2 Hydraulic Symbols 5-02-001
5.3 Hydraulic Pump 5-03-001
5.4 Hydraulic Cylinders 5-04-001
5.5 Control Valves – On/Off Type 5-05-001
5.6 Manifold Blocks 5-06-001
5.7 Counterbalance Valves 5-07-001
5.8 Hydraulic Filtration 5-08-001
5.9 Proportional Valves 5-09-001

6.0 Drill Air Circuit

6.1 Air Schematic 6-01-001
6.2 Sullair Compressor 6-02-001
6.3 CAT Water Pump 6-03-001
6.4 Grease Injection 6-04-001

7.0 Electrical
7.1 Electrical Circuits 7-01-001
7.2 Electrical Components 7-02-001
7.3 On/Off Valve Activation 7-03-001
7.4 Types of Valves 7-04-001
7.5 Testing of Valve Solenoid 7-05-001
7.6 Testing On/Off Valves 7-06-001
7.7 Proportional Valves 7-07-001
7.8 Fault Monitoring System 7-08-001
7.9 Accra-Feed System 7-09-001
7.10 Operator Interface PanelView 1000 7-10-001
7.11 DR Canbus Electrical System 7-11-001
7.12 Software Updates 7-12-001
TABLE OF CONTENTS (08/03/25) III

8.0 Troubleshooting Guide

8.1 Troubleshooting the Tram Drive 8-01-001
8.2 Troubleshooting the Hydraulic System 8-02-001
8.3 Troubleshooting the Water Injection Pump 8-03-001
8.4 Troubleshooting the Air Driven Oil Injection 8-04-001
Pump
8.5 Troubleshooting the Air Driven Grease 8-05-001
Injection
8.6 Troubleshooting the Air Delivery System 8-06-001
8.7 Troubleshooting the Hammer 8-07-001
8.8 Troubleshooting the Drill Bit 8-08-001
8.9 Troubleshooting the Depth Laser 8-09-001

Appendix
Sauer Danfoss Hydraulic Pumps A
Caterpillar Undercarriage Owner’s Manual B
Cubex Tool Catalogue C
Hydraulic Schematic D
Air Schematic E
Electrical General Arrangement F
1.0 INTRODUCTION (08/03/25)

1.0 INTRODUCTION

This symbol warns of possible

danger. Proceed with caution.

Module Date (Year/Month/Day)

Page Number

Updating of Manual
Updated modules will be issued for revisions
and corrections as required.
Please keep your manuals updated.
Copyright © Sandvik Mining and Construction
1.1 OPERATING/MAINTENANCE SAFETY (08/03/25) 1-01-001

1.1 Operating/Maintenance Safety

When operating this machine, the safety of the operating crew and other workers in the area
must be the principal concern. All persons operating this machine must understand the
necessary safety precautions to help minimize the risk of accidents and injury. The operator
must ensure that all fire fighting equipment is in working order, inspect the condition of all
walkways, handrails, ladders, and guards.

Personal Protection Equipment

All safety equipment such as hardhat, steel cap boots, safety goggles, hearing protection,
gloves, etc., should be worn while operating this machine.
Snug fitting clothing should be worn by the operator in and around the drill so as not to be
caught up in any moving machinery.

Overhead and Buried Utilities

Special precautions must be taken by everyone when using a drill rig in the vicinity of electrical
power lines and other utilities. Underground electricity is as dangerous as overhead
electricity. Be aware and always suspect the existence of underground utilities such as
electrical power, gas, petroleum, telephone, sewer, and water.
Electricity can shock, burn, and cause death.
 Overhead and buried utilities should be located, noted, and emphasized on all hole-
boring location plans and hole-boring assignment sheets.
 When overhead electrical power lines exist at or near a drilling site or project, consider
all wires to be live and dangerous.
 Watch for sagging power lines before entering a site. Do not lift power lines to gain
entrance.
 Before raising the drill rig mast on a site in the vicinity of power lines, walk completely
around the drill rig. Determine what the minimum distance from any point on the drill
rig to the nearest power line will be when the mast is raised and/or being raised. Do
not raise the mast or operate the drill rig within a minimum of three (3) meters of any
electrical power line or other obstruction.
 Only move the drill rig with the mast down.
If there are any questions concerning the safety of drilling on sites in the vicinity of overhead
power lines, call your supervisor.

Copyright © Sandvik Mining and Construction

1.1 OPERATING/MAINTENANCE SAFETY (08/03/25) 1-01-002

Ask for Assistance

If a sign warning of underground utilities is located on a site boundary, do not assume that
underground utilities are located on or near the boundary or property line under the sign;
call the foreman and check it out. The underground utilities may be a considerable distance
away from the warning sign.
Always contact the foreman before drilling. Determine jointly, with utility personnel, the
precise location of underground utility lines. Mark and flag the location.

Copyright © Sandvik Mining and Construction

1.1 OPERATING/MAINTENANCE SAFETY (08/03/25) 1-01-003

1.1.1 Drill Operation and Maintenance Safety

Read all safety instructions provided here and those provided in the Operator’s Manual before
operating and servicing the drill. General safety and accident prevention regulations laid
down by local authorities must also be followed.

1.1.2 General Safety Instructions

1. Observe all safety procedures when operating and servicing the equipment.
2. Be completely familiar with the operating and maintenance procedures before inspecting,
operating, or servicing the drill or booster. You must read and understand all procedures
described in each manual.
3. Do not inspect or repair any components without properly shutting down the drill, water
pump, and air supply.
4. Keep all non-essential personnel away from the operator’s controls and the maintenance
area while service work is in progress.
5. Any modifications to controls or operating procedures must be noted clearly on equipment
and all operators must be advised of changes.
6. Inspect hoses, hose connection safety devices, fittings, and supply lines at frequent intervals
for indication of wear or damage. Repair or replace damaged components immediately.
7. Check all bolts, nuts, and adjustments frequently for proper tension. Check all fluids at
recommended intervals.
8. Do not stand under the mast at any time.
9. Disconnect the electrical power supply to the drill and booster before washing.
10. Wear protective gear when operating, diagnosing, or servicing the equipment.
11. Do not weld or grind near electrical wiring or supply lines.
12. Keep hands, clothing, rags, and tools away from moving parts.
13. Keep shields and guards in place. Do not operate equipment with the electrical panel door
open.
14. Keep safety and instruction decals clean. Replace them if they are not clearly legible.

Copyright © Sandvik Mining and Construction

1.1 OPERATING/MAINTENANCE SAFETY (08/03/25) 1-01-004

1.1.3 Safety Instructions for Driving and Operating

1. Do not move the drill if it is in potentially unstable conditions or if visibility is obscured in
any way.
2. Check for overhead restrictions and ground clearances before moving drill. Do not drive over
electrical cable or pressurized hoses or allow any vehicles to do so at any time.
3. Check that all controls on the drill are in off positions before connecting the electrical
power, mine air, and water supply line.
4. Check for any damage that might have occurred to the drill. Repair any damaged
components immediately, before starting the drill.
5. Check the water hose for damage or leakage before starting the pump.
6. Restrain the water hose to minimize vibration of the hoses.
7. Check that personnel are clear of the drill before starting system. High pressure leaks from
hydraulic, pneumatic, and water systems could result in injuries.

1.1.4 Safety Instructions for Servicing

1. Follow all service procedures at recommended intervals.
2. Before inspecting, disconnecting, or removing any hydraulic or mechanical components,
secure the mast by placing it on solid ground or floor. Move the top drive assembly to the
lowest position on the mast. Secure the mast with a hoist or restraining equipment. Follow
proper shutdown procedures.
3. Make sure that the servicemen are in a dry and safe position when working with electrical
circuits.
4. High-pressure leaks from hydraulic and pneumatic systems could result in injuries. Use
protective gear when inspecting leaks.
5. Secure all moving components with proper restraining devices before removing or loosening
any hydraulic components. This is to prevent components from shifting when hydraulic
components lose pressure.
6. Relieve pressure from track tensioning system before servicing. Unscrew relief plug slowly to
allow the high pressure grease to escape. Use extreme caution when working on tracks.
Keep fingers away from track shoes.

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1.1 OPERATING/MAINTENANCE SAFETY (08/03/25) 1-01-005

7. Tag the drill and pump to prevent accidental start-up. Signs must be clearly visible to alert
of service in progress.
8. Tag or mark hoses, wires, or components to assist in reinstallation.
9. Cap or plug all hydraulic or pneumatic connections immediately after removal.
10. Cap fluid ports to keep foreign material from entering components during servicing.
11. Clean grease fittings with a clean cloth before greasing.

Copyright © Sandvik Mining and Construction

1.1 OPERATING/MAINTENANCE SAFETY (08/03/25) 1-01-006

1.1.5 Warning, Caution, and Danger Decals

Warning, Caution, and Danger decals are affixed to the applicable components or appropriate
locations. Relevant safety instructions are written on the decals. Read these instructions
carefully. Some of the main decals are illustrated below, along with safety instructions.

Observe the following safety instructions on the decals shown below BEFORE
operating the drill:

Mast Function

Keep personnel away from the mast when positioning.

Keep personnel away when performing mast set-up
Decal is at control panel and valve functions.
controls.

Pinch Point

Stay clear while operating.

Decal is at slideover.

Rotating Drive Hazard

Stay clear while operating.

Do not operate without guard.
Decal is at rotating components.
Decal is at compressor drive.

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1.1 OPERATING/MAINTENANCE SAFETY (08/03/25) 1-01-007

Observe the following safety instructions on the decals shown below BEFORE
servicing the drill:

Danger!
Compressed Air!

Relieve pressure from receiver before servicing.

Decal is at booster air receiver/drain
valve.

Danger!
Keep flames and sparks away from battery.

Danger!
High pressure leaks may cause injury.

Danger!
Outriggers and mast stingers can cause serious
crushing injury – stand clear.

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1.1 OPERATING/MAINTENANCE SAFETY (08/03/25) 1-01-008

1.1.6 Fluid and Filter Notices:

Fill with Hydraulic Fluid Only

Decal is at hydraulic tank.

Fill with Rock Grease Only

Decal is at rock grease tank.

1.1.7 Safety Reminders:

Check that the drill is safe to work on.

Position mast on T-rest before moving drill.

Disengage torque hubs for towing.

Engage torque hubs to apply brakes.

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1.1 OPERATING/MAINTENANCE SAFETY (08/03/25) 1-01-009

Perform this Safety Check before welding:

Disconnect electrical panel before doing any welding.

Perform these Safety Checks when completing maintenance:

Check that all hose fittings are tight.

Check that all pressurized air hoses are secured with

hose connection safety devices.

Check that all controls are in the off position before

connecting the power supply.

Check that all valves are in the off position before

connecting the air system and power supply to the
drill unit.

Copyright © Sandvik Mining and Construction

1.1 OPERATING/MAINTENANCE SAFETY (08/03/25) 1-01-010
2.0 GENERAL MAINTENANCE (08/03/25)

2.0 GENERAL MAINTENANCE

READ INSTRUCTIONS BEFORE SERVICING

OR OPERATING!
2.1 DRILL ASSEMBLY (08/03/25) 2-01-001

2.1 Drill Assembly

Refer to the Parts Manual for part numbers, part descriptions, and parts locations.

WARNING!
Be familiar with the operating procedures before operating the drill.
2.1 DRILL ASSEMBLY (08/03/25) 2-01-002
2.2 BREAK-IN MAINTENANCE (08/03/25) 2-02-001

2.2 Break-in Maintenance

Preventative Maintenance Interval:
At the first 50 hours
The break-in maintenance is necessary to readjust some of the components after the initial
wear. It also includes the regular Preventative Maintenance (PM) checks as well as changing
the fluids.

WARNING!
Familiarize yourself with the PM procedures before performing the break-in
maintenance.

General Inspection
1. Clean and wash the drill.
2. Perform the general maintenance procedures as outlined in Fig 2.3.1
(Section 2.3).
3. Change pressure filter and return filter.
4. Check for hydraulic leaks.
5. Check the complete drill for unusual indications.
6. Change crankcase oil in water pump. Use hydraulic fluid.
7. Check bearing pre-load on top drive (see Section 4).
8. Open the control panel and inspect wires, terminals, and conduits.
9. Refer to engine and compressor service manuals.
10. Inspect carousel for proper operation.
11. Perform a 250 Hour Inspection.

Copyright © Sandvik Mining and Construction

2.2 BREAK-IN MAINTENANCE (08/03/25) 2-02-002

Copyright © Sandvik Mining and Construction

2.3 PM PROGRAM (08/03/25) 2-03-001

2.3 Preventative Maintenance Program

The PM program includes scheduled inspections and overhauling of drill components. Read this
section carefully. PM Schedules are enclosed ready for photocopying.

This section contains the following:

Lubrication Points and Intervals
Lubrication Types/System Capabilities
Lubrication Cross-over Table: Refer to this table for approved fluid types
Drill Filtration Points and Intervals
Bolt Torque Table: Refer to this table when no specific rating is given
Pipe Thread Grease Pump
PM Schedules: Service forms for 250, 500, 1000, and 2000 hours
DR Automatic Lubrication System

Copyright © Sandvik Mining and Construction

2.3 PM PROGRAM (08/03/25) 2-03-002

15
7
2 13

10 14
8

3 5

1
11 12 6 4

Fig 2.3.1 Lubrication Points

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2.3 PM PROGRAM (08/03/25) 2-03-003

2.3.1 Lubrication
Because of the severe operating conditions normally encountered in drilling
operations, lubrication is very important. See the information on the following
pages for lubrication instructions.

2.3.1.1 Rock Drill Grease

Rock drill grease is used in the grease injection system for lubricating the hammer.
Please refer to Section 6.4 Grease Injection for information on the rock drill
grease lubrication system.

2.3.1.2 Lubrication Points and Intervals

Refer to Fig 2.3.1 and the following table for lubrication points and intervals.

Table 1 Lubrication Points and Intervals

Key Component Type Interval/Hrs Service By

1 Water Pump Oil Esso NUTO 46 8 Operator
2 Rock Oil Tank Rock Oil 8 Operator
Rock Grease Tank Rock Grease 8 Operator
3 Top Drive Oil SAE 80W-90 8 Operator
4 Torque Hub SAE 80W-90 250 Maintenance
5 Air Swivel Extreme Pressure Grease 8 Operator
6 Track Tension Extreme Pressure Grease 250 Maintenance
7 Mast Boom Fittings Extreme Pressure Grease 8 Operator
8 Cab Boom Fittings Extreme Pressure Grease 8 Operator
9 Cylinder Pin Extreme Pressure Grease 50 Operator
10 Intake Valve – Comp. Extreme Pressure Grease 8 Operator
11 Osc. Pivot – Outside Extreme Pressure Grease 8 Operator
12 Osc. Cylinder Extreme Pressure Grease 8 Operator
13 Engine Esso XD3 Extra 15W-40 8 Operator
14 Compressor Mobil Rarus SHC 1024 8 Operator
15 Osc. Pivot – Inside Extreme Pressure Grease 8 Operator

Copyright © Sandvik Mining and Construction

2.3 PM PROGRAM (08/03/25) 2-03-004

2.3.1.3 Lubrication Types

The recommended lubricants and system capacities are listed below. Substitute lubricants
must meet these specifications. Mixing different types of gear lubrication should be
avoided.

Table 2 Lubrication Types/ System Capacities

Equipment Lubrication Capacities

Engine Oil SAE 5W-30 – low temperature 15.1 gal (57 ℓ)

SAE 15W-40 – high temperatures

Top Drive Gear Oil 80W-90 – low temperature 6.2 qts (6 ℓ)

SAE 140 – high temperatures

Grease Tank Esso AROX NM 000 22 gal (83 ℓ)

Hydraulic Tank Esso NUTO H46 70 gal (265 ℓ)

Torque Hubs Gear Oil SAE 80W-90 Half full 44 fl. oz. (1.3 ℓ)

Water Pump Esso NUTO H46 40 fl. oz. (1.2 ℓ)

Compressor Oil Mobil Rarus SHC 1024 42.3 gal (160 ℓ)

Triple Pump Drive Gear Lube SAE 80W90 4.2 qts (4 ℓ)

Copyright © Sandvik Mining and Construction

2.3 PM PROGRAM (08/03/25) 2-03-005

2.3.1.4 Lubrication Cross-over

Refer to this Cross-over Table for alternate suppliers. If these brands are unavailable, your
local supplier will be able to recommend alternatives using these specifications.

Table 3 Lubrication Cross-over

Fluid Type Shell Oil Esso (Mobil) Petro-Canada Mohawk

XD3 Extra 15W-
40

Engine Oil
Spirax HD Mobil Gear Lube Gearlube
SAE 80W-90 HD 80W-90 80W-90 GL5 80/90 HP

Gear Oil
Darina XLEP2 Mobilux Precision EP2 N/A
EP102
Grease
Tellus T-37 Esso Harmony Mohawk
NUTO H46 HVI-36 V132

Hydraulic Oil
Madrela S46 or Mobil N/A N/A
SAE 10W RARUS 1024

Compressor Oil

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2.3 PM PROGRAM (08/03/25) 2-03-006

2.3.1.5 DR Automatic Lubrication System

The Automatic Lubrication system installed in the DR uses an air operated pump. Operation is
controlled by the DR’s PLC.
The system uses 59 SL32 and 10 SL1 injectors for grease delivery to lubrication points on the
unit. These injectors are mounted together in banks of 2 to 6 depending upon location and
the number of grease points in the area where the bank is mounted. Each injector is
individually set to deliver the correct amount of grease to the point it is servicing, which
depends on pin size and usage.
Refer to Fig 2.3.2 for injector bank location.
Lubricate all points every 8 hours.
Inspect pins and/or bushings at all points marked every PM (250 hours).

Mast

Mast Boom

Cab Boom

Grease Pump

Frame

Fig 2.3.2 Injector Bank Locations

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2.3 PM PROGRAM (08/03/25) 2-03-007

Asco Grease
Valve Pump

Asco Valve allows

air to the pump…

Grease flows from the pump to the mast boom and the frame…

Mast Boom Frame

and to the mast and the cab boom…

Mast Cab Boom

until the pre-set pressure has been reached, then the

pressure switch automatically shuts down the system.

Pressure Switch –
located on the mast

Fig 2.3.3 Auto-Lube operation

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2.3 PM PROGRAM (08/03/25) 2-03-008

Panelview Settings
The settings for the Auto-Lube system are through the Panelview display.
1. Touch the Config (configuration) button on any screen to access the Password screen. Refer
to Fig 2.3.4 and Fig 2.3.5.

Config
button

Fig 2.3.4 Config button on drilling screen

Press the
Password button

Fig 2.3.5 Password screen

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2.3 PM PROGRAM (08/03/25) 2-03-009

2. Press the Password button (see Fig 2.3.5); this will bring up two options, Config Password
and Admin Password. See Fig 2.3.6.

Press the Config

Password button

Fig 2.3.6 Config Password and Admin Password

3. Press the Config Password button and a keypad will appear on your screen. Enter 129124
and press the Accept button. 129124 is the standard password. Refer to Fig 2.3.7.

Password
display

Accept
button

Fig 2.3.7 Keypad

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2.3 PM PROGRAM (08/03/25) 2-03-010

4. Several new options will appear on the left side of the screen. For the Auto-Lube settings,
press the Lube/Grease/Water button. See Fig 2.3.8.

Press the
Lube/Grease/
Water button

Fig 2.3.8 New options

5. Once inside the Lube/Grease/Water screen, you can select from three Auto-Lube options;
Chassis Grease On Time, Chassis Grease Off Time, and Chassis Grease Settings. Press the
Chassis Grease Settings button to open the Auto Cycle and the One Cycle options. See Fig
2.3.9.
Pressing the Auto-Cycle button will cause the system to run automatically with the settings
provided in the Chassis Grease On Time and the Chassis Grease Off Time screens.
Pressing the One Cycle button will cause the system to run through one cycle only. This is
generally done for troubleshooting and maintenance purposes.
Other options are available in this screen; however only the Chassis Grease On Time, Chassis
Grease Off Time, and Chassis Grease Settings buttons relate to the Auto-Lube system.

Auto-Lube
options

Press the Chassis Grease Settings button to

open the Auto-Cycle and One Cycle options.

Fig 2.3.9 Lube/Grease/Water screen

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2.3 PM PROGRAM (08/03/25) 2-03-011

6. Press the Chassis Grease On Time button to set the maximum on time for the Auto-Lube
cycle. The keypad will open; use it to input your settings. See Fig 2.3.10.
Press the Chassis Grease Off Time to set the off time for the Auto-Lube cycle. Again, use the
keypad to input your settings. See Fig 2.3.11.
NOTE: The Chassis Grease On Time screen and the Chassis Grease Off Time screen are
virtually identical. Ensure you are in the correct screen for the time you are setting;
the active button will be outlined in green (refer to Fig 2.3.10 and 2.3.11).

Active button

Fig 2.3.10 Chassis Grease On Time screen

Active button

Fig 2.3.11 Chassis Grease Off Time screen

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2.3 PM PROGRAM (08/03/25) 2-03-012

Alarms
The Auto-Lube system uses a pressure switch to control the length of the grease cycle. Once
the pressure switch detects the system at the pre-set pressure, the system is automatically
shut down until the next cycle. If the pre-set pressure has not been reached by the
maximum on time (set in the Chassis Grease On Time screen – see Fig 2.3.10), the system
will shut down and your screen will show an error (the error button will be outlined in
red). See Fig 2.3.12.

Example – the
applicable error will
be outlined in red

Reset
button

Error button
outlined in red

Fig 2.3.12 Error indicated

Press the error button to open the error message screen. The applicable error will be outlined
in red.
Investigate and correct the error. Once completed, press the Reset button to resume normal
operations.

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2.3 PM PROGRAM (08/03/25) 2-03-013

Setting the Air Pressure for the Grease Pump

The air pressure that operates the grease pump is set at the factory to 60 psi (4.1 bar) to
correspond with the pressure switch setting (see Setting the Pressure Switch). The grease
pump runs at a 40:1 ratio. A regulator is located on the right side of the grease pump.
Turning the handle clockwise on the regulator will increase the pressure setting. The gauge
on top will display the pressure setting for the regulator.

Pressure Gauge
Regulator

Grease Pump

Fig 2.3.13 Grease Pump Regulator and Pressure Gauge

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2.3 PM PROGRAM (08/03/25) 2-03-014

Setting the Pressure Switch

The pressure switch for the Auto-Lube system is located at the bottom of the mast (see Fig
2.3.14).

Pressure Switch

Fig 2.3.14 Pressure Switch location

At the factory, the pressure switch is set to 2200 psi (151.7 bar) for use with Mobilith SHC007
grease (rated for -40°). Using thinner or thicker grease will require the pressure switch
setting to be adjusted. Refer to Fig 2.3.15 and Fig 2.3.16.

Switch is provided with scale

showing both psi and bar

Remove
protective cap

To adjust the pressure setting of the switch, turn

the self-locking adjustment screw clockwise (to
decrease) and counter-clockwise (to increase).

Fig 2.3.15 Step 1 Fig 2.3.16 Step 2

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2.3 PM PROGRAM (08/03/25) 2-03-015

Adjusting the SL1 Injectors

The locknut must be loosened to make the adjustment. Turning the adjustment screw in
(clockwise) will decrease the displacement of the injector (see Fig 2.3.17).
The SL1 injectors are located on the frame (see Fig 2.3.18). These injectors are set at one
turn out from the minimal setting, which displaces approximately 0.012 in3 of grease per
cycle.

Adjustment Screw
Locking Nut

Fig 2.3.17 SL1 Injectors

Fig 2.3.18 Injectors on Frame

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2.3 PM PROGRAM (08/03/25) 2-03-016

Adjusting the SL32 Injectors

The locknut must be loosened to make the adjustment. Turning the adjustment cap in
(clockwise) will decrease the displacement of the injector. Refer to Fig 2.3.19. Output
with the adjustment cap hand tightened is 0.001 in3. Maximum output is achieved with five
turns clockwise at 0.0014 in3 per turn.
The SL32 injectors are located on the mast, the mast boom, and the cab boom (see Fig
2.3.20, Fig 2.3.21, and Fig 2.3.22). These injectors are set at the maximum setting, which
displaces approximately 0.008 in3 of grease per cycle.

Adjustment Cap

Locking Nut

Fig 2.3.19 SL32 Injectors

Fig 2.3.20 Injectors on Mast Boom Fig 2.3.21 Injectors on Mast

Fig 2.3.22 Injectors on Cab Boom

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2.3 PM PROGRAM (08/03/25) 2-03-017

2.3.2 Bolt Torque

Use these ratings when no specific torque rating is specified.
Prevailing torque rating is the torque necessary to rotate a fastener after the mating
components are in full contact. These torque ratings are for dry threads.

Table 4 - BOLT TORQUE TABLE

Coarse and Fine Threads, Grade 8

Bolt Diameter Torque (ft-lbs) Torque (N-m)

1/4 - 20 12 16
1/4 - 28 14 19
5/16 – 18 24 33
5/16 – 24 27 37
3/8 – 16 44 60
3/8 – 24 49 66
7/16 – 14 70 95
7/16 – 20 78 106
1/2 – 13 105 142
1/2 – 20 120 163
9/16 – 12 155 210
9/16 - 18 170 230
5/8 – 11 210 285
5/8 – 18 240 325
3/4 – 10 375 508
3/4 – 16 420 570
7/8 – 9 605 820
7/8 – 14 675 915
1–8 910 1230
1 – 14 990 1340

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2.3 PM PROGRAM (08/03/25) 2-03-018

4
2 3

12
6

10

11
8

13 5 1

14 9

Fig 2.3.8 Drill Filtration

Copyright © Sandvik Mining and Construction

2.3 PM PROGRAM (08/03/25) 2-03-019

2.3.3 Drill Filtration Points and Intervals

Refer to Fig 2.3.8 and the following table for filtration points and intervals.

Table 5 Drill Filtration

Key Filter Type Intervals Service

Cummins Engine
1 Air Filter – Primary/Secondary (2) 250 Hours Maintenance
2 Engine Oil Filters (2) 250 Hours Maintenance
3 Fuel / Water Separators (2) 250 Hours Maintenance
4 Coolant Element 2000 Hours Maintenance
Compressor
5 Air Filter 250 Hours Maintenance
6 Main Fluid Filter 250 Hours Maintenance
7 Moisture Separator Filter 250 Hours Maintenance
Drain the moisture separator 8 Hours Operator
8 Oil Separator 250 Hours Maintenance
Hydraulics
9 Hydraulic Pressure Filters (3) 250 Hours Maintenance
10 Hydraulic Return Filter 250 Hours Maintenance
Cab Pressurizer
11 Air Filter – Primary 250 Hours Operator
Grease Injection
12 Moisture Separator Element 1000 Hours Operator
Air Conditioner
13 Clean or replace filter screens 2000 Hours Operator
Water Strainer (2)
14 Clean or replace strainer 2000 Hours Maintenance
NOTE: Water Strainer filters are different sizes (100 microns and 200 microns).

Copyright © Sandvik Mining and Construction

2.3 PM PROGRAM (08/03/25) 2-03-020

2.3.4 Pipe Thread Grease Pump

Preventative Maintenance Tasks

At the first 50 hours: Clean and inspect pump.

1000 Hour Intervals: Cleaning and visual inspection. Replace worn parts.

Grease Pump Specifications Pressure Ratio: 50:1

Air Pressure: Min 80 psi
Maximum Output Pressure: 4000 psi
Delivery Output: 0.55 cu.in. (8 ccm)/cycle

Fig 2.3.14 Pipe Thread Grease Pump

Copyright © Sandvik Mining and Construction

2.3 PM PROGRAM (08/03/25) 2-03-021

2.3.4.1 Safety
Adequate personal protection is recommended to prevent splashing of material on the skin or
in the eyes. ALWAYS disconnect air coupler from the pump when the pump is not being
used.

WARNING!
To reduce the risk of injury from splashing or static sparking when flushing the
pump with solvents, always hold a metal part of the dispensing valve firmly
to the side of a grounded metal pail and operate pump at lowest possible
fluid pressure.

Perform the following Pressure Relief Procedure before checking, servicing, installing,
cleaning or repairing any part of this system:
1. Disconnect the air supply to the pump.
2. Point the dispensing valve away from yourself and others.
3. Open the dispensing valve into an appropriate container until pressure is relieved.

WARNING!
Failure to heed the following warnings, including misuse, over-pressurizing,
modifying parts using incompatible chemicals and fluids, or using worn or
damaged parts, may result in equipment damage and/or serious personal
injury, fire, explosion, or property damage.

Do not exceed the stated maximum working pressure of the pump, or of the lowest
rated component in your system.
Do not alter or modify any part of this equipment.
Do not operate this equipment with combustible gas.
Do not attempt to repair or disassemble the equipment while the system is pressurized.
Make sure all grease connections are securely tightened before using this equipment.
Always read and follow the grease manufacturer’s recommendations regarding grease
compatibility, and the use of protective clothing and equipment.
Check all equipment regularly and repair or replace worn or damaged parts
immediately.
Never point the dispensing valve at any part of the body or at another person.

Copyright © Sandvik Mining and Construction

2.3 PM PROGRAM (08/03/25) 2-03-022

Never try to stop or deflect material from dispensing valve or leading connection or
component with your hand or body.
Always check equipment for proper operation before each use, making sure safety
devices are in place and operating properly.
Always follow the pressure relief procedure after shutting off the pump, when checking
or servicing any part of the system, and when installing, cleaning or changing any
part of the system.

2.3.4.2 Maintenance
An air line filter/regulator/lubricator is recommended for use with pump to remove harmful
dirt and moisture from your compressor air supply, and to provide automatic air motor
lubrication.
If an air line lubricator is not used, the following procedure should be performed daily:
1. Disconnect air coupler from air fitting.
2. Fill air coupler with No 10 SAE motor oil and reconnect to air fitting.
3. Operate pump to distribute lubricant.
To prevent water or air corrosion, never leave the pump filled with water or air. Flush the
pump first with a compatible solvent and then again with mineral spirits or oil based
solvent.
Repair is limited to replacement of listed service parts. Special procedures and tools are
required.

Copyright © Sandvik Mining and Construction

2.4 RECOMMENDED TOOLS (08/03/25) 2-04-001

2.4 Recommended Tools

 Standard Allen wrench set and metric Allen wrenches

 Pliers - needle nose, vise grip, channel lock, sidecutters
 Standard screwdrivers - 1 large, 1 small, 1 straight, and 1 Phillips
 Hammer
 Tape Measure
 Punch, chisel, pry bar
 14” Pipe wrench and 24” pipe wrench
 8” Crescent wrench
 12” Crescent wrench
 3/8 Drive ratchet set, sockets - 1/2, 9/16, 5/8, 3/4
 3/8 x 6 Extension
 1/2 Drive ratchet set, sockets - 9/16, 3/4, 15/16, 1-1/8
 1/2 x 6 Extension
 Multi-meter
 Combination wrench set - 7/16, 1/2, (2) 9/16, 5/8, 11/16, 3/4, 7/8, 15/16,
1-1/8, 1-1/4, 1-3/8, 1-1/2
 O-ring Pack
 Gasket scraper
 Knife
 Torque wrench
 Pre-load tool
 One of:

 CT16208-WH21 Saver Sub Breakout Wrench Holding Tool #21 Thread

 CT16208-WH24 Saver Sub Breakout Wrench Holding Tool #24 Thread
 CT16208-WH28 Saver Sub Breakout Wrench Holding Tool #28 Thread
 CT16208-WH30 Saver Sub Breakout Wrench Holding Tool RB30 Thread
2.4 RECOMMENDED TOOLS (08/03/25) 2-04-002
250 Hour Work Order # ______________________ Unit __________________________ Serial # _______________________

PM Schedule
DR560 Hour Meter ________________________ Date __________________________ By ___________________________

Main Assemblies / Actions: Service Codes: Service Codes:

General: Clean, wash Grease lubrication
Water pump coupling Extreme Pressure Grease
Track Assembly Cylinder pins Extreme Pressure Grease
Track tension Adjust: Feed extension pins Extreme Pressure Grease
Air swivel – top drive Extreme Pressure Grease
Drive Train
Hydraulic brakes Inspect: Seals Fluid Inspection
Test: Brakes Torque hubs Gear Lube SAE 80W-90
Tramming motor Inspect: Seals Hydraulic tank ESSO NUTO H46 or equal
Torque hub Inspect: Seals Compressor MOBIL 10W or equal
Engine See CAT/Cummins Manual
Gear Triple Gear Lube SAE 140 high temp
Mast 80W90 low temp
Mast boom Inspect: Bushings, pins
Mast connection Inspect: Bushings, pins Fluid Changes
Cab boom Inspect: Bushings, pins Top drive Gear Lube SAE 140 high temp
80W90 low temp
Jib boom Inspect: Pulleys, pivot joint Water pump ESSO NUTO H46 or equal
Chain Feed Inspect: Pulleys, bushings, chain Engine See CAT/Cummins manual
Carousel Inspect: Wear liner, bearings, bushings
Adjust: Arm, clamp pressure Miscellaneous
Wear guide Inspect: Under top drive mounting plate Control gauges Inspect: for proper operation
Sliders Inspect: Sliders and guide bars for wear
Adjust: @ Top drive mounting plate Electrical
@ Carrier block Electrical panels: Inspect wires, terminals, conduits,
joysticks
Lower Mast Inspect: Clevises, pins
Inspect: Cylinders, centralizer jaws Filter Changes
Top drive Adjust: Bearing pre-load QTY Description Part Number
Top drive motors Inspect: Seals 2 Engine Oil Filter Refer to
Centralizer Inspect: Remove debris 2 Primary Fuel Filter the Parts
Boom expander pins Inspect: 6 points; refer to Maint. Manual A/R Primary Engine Air Filter Manual
A/R Secondary Engine Air Filter
Hydraulic Circuit 1 Compressor Oil Filter
Hydraulic pump Inspect: Seals, hoses, fittings
Cylinders Inspect: Seals, rods

Air Circuit
Air hoses Inspect: Air hoses, fittings, hose safety
devices

Refer to manual sections or CAT/Cummins Engine Add service code to boxes: C – Completed
Appendix for: O – Okay not required
Sullair Drill Compressor
Tipton Dust Collector (if equipped) N – See Note
Comments (Continue on reverse):
500 Hour Work Order # _____________________ Unit _________________________ Serial # ______________________

PM Schedule
DR560 Hour Meter _______________________ Date _________________________ By ___________________________

Main Assemblies / Actions: Service Codes: Service Codes:

General: Clean, wash Grease lubrication
Water pump coupling Extreme Pressure Grease
Track Assembly Cylinder pins Extreme Pressure Grease
Track tension Adjust: Feed extension pins Extreme Pressure Grease
Air swivel – top drive Extreme Pressure Grease
Drive Train
Hydraulic brakes Inspect: Seals Fluid Inspection
Test: Brakes Torque hubs Gear Lube SAE 80W-90
Tramming motor Inspect: Seals Hydraulic tank ESSO NUTO H46 or equal
Torque hub Inspect: Seals Compressor MOBIL 10W or equal
Engine See CAT/Cummins Manual
Gear Triple Gear Lube SAE 140 high temp
Mast 80W90 low temp
Mast boom Inspect: Bushings, pins
Mast connection Inspect: Bushings, pins Fluid Changes
Cab boom Inspect: Bushings, pins Top drive Gear Lube SAE 80W90
Jib boom Inspect: Pulleys, pivot joint Water pump ESSO NUTO H46 or equal
Chain Feed Inspect: Pulleys, bushings, chain Engine See CAT/Cummins manual
Carousel Inspect: Wear liner, bearings, bushings
Adjust: Arm, clamp pressure Miscellaneous
Wear guide Inspect: Under top drive mounting plate Control gauges Inspect: for proper operation
Sliders Inspect: Sliders and guide bars for wear
Adjust: @ Top drive mounting plate Electrical
@ Carrier block Electrical panels: Inspect wires, terminals,
conduits, joysticks
Lower Mast Inspect: Clevises, pins
Inspect: Cylinders, centralizer jaws Filter Changes
Top drive Adjust: Bearing pre-load QTY Description Part Number
Top drive motors Inspect: Seals 2 Hydraulic Pressure Filter Refer to
Centralizer Inspect: Remove debris 2 Hydraulic Return Filter the Parts
Boom expander pins Inspect: 6 points; refer to Maint. Manual 2 Engine Oil Filter Manual
2 Primary Fuel Filter
Hydraulic Circuit 1 Engine Water Filter
Hydraulic pump Inspect: Seals, hoses, fittings A/R Primary Engine Air Filter
Cylinders Inspect: Seals, rods A/R Secondary Engine Air Filter
1 Compressor Oil Filter
Air Circuit 1 Moisture Separator Element Control Circuit
Air hoses Inspect: Air hoses, fittings, hose safety 1 Moisture Separator Element – Accessory Circuit
devices

Refer to manual sections or CAT/Cummins Engine Add service code to boxes: C – Completed
Appendix for: O – Okay not required
Sullair Drill Compressor
Tipton Dust Collector (if equipped) N – See Note
Comments (Continue on reverse):
1000 Hour Work Order # ____________________ Unit ________________________ Serial # _______________________

PM Schedule
DR560 Hour Meter ______________________ Date ________________________ By ____________________________

Main Assemblies / Actions: Service Codes: Service Codes:

General: Clean, wash Air Circuit
Air hoses Inspect: Air hoses, fittings, hose
safety devices
Track Assembly Rock oil pump Inspect: Seals
Track tension Adjust: Min press. valve Disassemble, replace worn parts

Grease lubrication
Drive Train Water pump coupling Extreme Pressure Grease
Hydraulic brakes Inspect: Seals Cylinder pins Extreme Pressure Grease
Test: Brakes Feed extension pins Extreme Pressure Grease
Tramming motor Inspect: Seals Air swivel – top drive Extreme Pressure Grease
Torque hub Inspect: Seals
Fluid Changes
Mast Top drive Gear Lube SAE 80W90
Mast boom Inspect: Bushings, pins Water pump ESSO NUTO H46 or equal
Mast connection Inspect: Bushings, pins Compressor MOBIL 10W or equal
Cab boom Inspect: Bushings, pins Engine See CAT/Cummins Manual
Jib boom Inspect: Pulleys, pivot joint Gear Triple Gear Lube SAE 140 high temp 80W90
low temp
Chain Feed Inspect: Pulleys, bushings, chain
Carousel Inspect: Wear liner, bearings, bushings Miscellaneous
Adjust: Arm, clamp pressure Control gauges Inspect: for proper operation
Wear guide Inspect: Under top drive mounting plate
Sliders Inspect: Sliders and guide bars for wear Electrical
Adjust: @ Top drive mounting plate Electrical panels: Inspect wires, terminals, conduits,
joysticks
@ Mast connection plate
@ Carrier block Filter Changes
Chain tensioners Inspect: Springs and bushings QTY Description Part Number
Lower Mast Inspect: Clevises, pins 2 Hydraulic Pressure Filter Refer to
Inspect: Cylinders, centralizer jaws slip 2 Hydraulic Return Filter the Parts
plate flats, drill table
Manual
Top drive Inspect: Bearing pre-load 2 Engine Oil Filter
Adjust: Bearing pre-load 2 Primary Fuel Filter
Torque: Mtg. Plate bolts 1 Engine Water Filter
Top drive motors Inspect: Seals A/R Primary Engine Air Filter
Torque: Motor Bolts A/R Secondary Engine Air Filter
Centralizer Inspect: Remove debris 1 Compressor Oil Filter
Boom expander Inspect: 6 points; refer to Maint. Manual 1 Moisture Separator Element Control Circuit
pins
1 Moisture Separator Element – Accessory Circuit
Hydraulic Circuit
Hydraulic pump Inspect: Seals, hoses, fittings
Cylinders Inspect: Seals, rods
Control valves Inspect: Seals
Refer to manual sections or CAT/Cummins Engine Add service code to boxes: C – Completed
Appendix for: Sullair Drill Compressor O – Okay not required
Tipton Dust Collector (if equipped) N – See Note
Comments (Continue on reverse):
2000 Hour Work Order # ____________________ Unit __________________________ Serial # ________________________

PM Schedule
DR560 Hour Meter ______________________ Date __________________________ By _____________________________

Main Assemblies / Actions: Service Codes: Service Codes:

General: Clean, wash Cylinders Inspect Seals, rods
Control valves Inspect Seals
Track Assembly Check For proper installation
Track links Link wear
Track rollers Track roller Air Circuit
Idler wheel Idler wear Air hoses Inspect Air hoses, fittings, hose safety
devices
Drive sprocket Sprocket wear Water Pump Perform Pressure test clean strainer
Track tension Adjust Rock Oil Pump Inspect Seals

Drive Train Grease lubrication

Hydraulic brakes Inspect Seals Water pump coupling Extreme Pressure Grease
Test Brakes Cylinder pins Extreme Pressure Grease
Tramming motor Inspect Seals Feed extension pins Extreme Pressure Grease
Torque hub Inspect Seals Air swivel – top drive Extreme Pressure Grease

Mast Fluid Changes

Mast boom Inspect Bushings, pins Hydraulic tank ESSO NUTO H46 or equal
Mast connection Inspect Bushings, pins Top drive Gear Lube SAE 80W90
Cab boom Inspect Bushings, pins Water pump ESSO NUTO H46 or equal
Jib boom Inspect Pulleys, pivot joint Compressor Mobil 10W or equal
Chain Feed Inspect Pulleys, bushings, chain Engine See CAT/Cummins Manual
Carousel Inspect Wear liner, bearings, bushings, Gear Triple Gear Lube SAE 140 high temp
drive 80W90 low temp
Adjust Arm, clamp pressure
Wear guide Replace Under top drive mounting plate Miscellaneous
Sliders Inspect Sliders and guide bars for wear Control gauges Inspect: for proper operation
Adjust @ Top drive mounting plate
@ Mast connection plate Electrical
@ Carrier block Electrical panels: Electrical panels:
Chain tensioners Inspect Springs and bushings
Lower Mast Inspect Cylinders, centralizer jaws slip
plate flats, drill table
Replace Clevises, pins Filter Changes
Top drive Inspect Bearing pre-load QTY Description Part Number
Adjust Bearing pre-load 2 Hydraulic Pressure Filter Refer to the
Torque Mounting Plate bolts 2 Hydraulic Return Filter Parts
2 Engine Oil Filter Manual
Top drive motors Torque Motor Bolts 2 Primary Fuel Filter
Inspect Seals 1 Engine Water Filter
Centralizer Inspect Remove debris A/R Primary Engine Air Filter
Boom expander Inspect: 6 points; refer to Maint. Manual A/R Secondary Engine Air Filter
pins
1 Compressor Oil Filter
Hydraulic Circuit 1 Moisture Separator Element Control Circuit
Hydraulic pump Inspect Seals, hoses, fittings 1 Moisture Separator Element – Accessory Circuit
Inspect Operating pressure 1 Receiver Tank Separator Element
Standby pressure
Refer to manual sections or Appendix CAT/Cummins Engine Add service code to boxes: C – Completed
for: Sullair Drill Compressor O – Okay not required
Tipton Dust Collector (if equipped) N – See Note
Comments (Continue on reverse):
3.0 UNDERCARRIAGE (08/03/25)

3.0 UNDERCARRIAGE

USE PROPER LIFTING EQUIPMENT!

Copyright © Sandvik Mining and Construction

Copyright © Sandvik Mining and Construction
3.1 TRACK ADJUSTMENT (08/03/25) 3-01-001

3.1 Track Adjustment

Track tension is maintained by pressurizing the track-tensioning cylinder with grease. Adjust
the track tension every 250 hours as follows:
1. Move drill to level ground and position track links as shown in Fig 3.1.1.
2. Place straight edge on middle section of track assembly and measure sag.
3. Add extreme pressure grease to fill valve until sag is 3/8" to 1/2" (10 - 12 mm).
WARNING!
Use relief plug to discharge pressure in track tensioning cylinder before
removing or servicing any track components.

Relief Plug

Fill Valve

Fig 3.1.1 Track Adjustment

Copyright © Sandvik Mining and Construction

3.1 TRACK ADJUSTMENT (08/03/25) 3-01-002

Copyright © Sandvik Mining and Construction

3.2 FINAL DRIVE (08/03/25) 3-02-001

3.2 Final Drive

For information on the Caterpillar Final Drive, refer to the Caterpillar Industrial Products, Inc.
Support Literature Owner’s Manual (located in the Appendix).

Fig 3.2.1 Final Drive

Copyright © Sandvik Mining and Construction

3.2 FINAL DRIVE (08/03/25) 3-02-002

Copyright © Sandvik Mining and Construction

4.0 FEED ARRANGEMENT (08/03/25)

4.0 FEED ARRANGEMENT

DANGER!
Keep personnel away from drill while
operating!!
Copyright © Sandvik Mining and Construction
4.1 MAST FEED SYSTEM (08/03/25) 4-01-001

4.1 Mast Feed System

PM Tasks
A visual inspection of the cylinder rods is necessary to locate pitting or damage to the surfaces.
Damaged rod surfaces collect foreign matter that enters the hydraulic system.
Adjustment of the sliders on the top drive mounting plate, mounting plate and carrier block are
required to eliminate excessive play.

50 Hour Intervals:  Inspect slider adjustment; zero clearance is required

250 Hour Intervals:  Adjust sliders at top drive mounting plate and carrier block
 Inspect cylinder rods for wear indications
 Inspect wear guides
1000 Hour Intervals:  Adjust sliders on mast connection plate and carrier block
 Torque top drive mounting bolts
 Inspect chain tensioners and bushings
 Inspect guide bars
 Inspect wear guides
2000 Hour Intervals:  Check feed cylinder for by-pass
 Replace wear guide
 Inspect chain tensioners, bushings, and idlers

WARNING!
Secure or support the mast before removing any components or loosening
hydraulic fittings.

Copyright © Sandvik Mining and Construction

4.1 MAST FEED SYSTEM (08/03/25) 4-01-002

Top Drive Mounting Plate

¾ NC Hex Capscrew
Inspect gap and Torque to 375 ft-lbs
clearance (508 N-m)

½ NC Hex Capscrew
Torque to 105 ft-lbs
(142 N-m)

Inspect wear guide

under mounting
Inspect gap and plate
clearance

¾ NC Setscrew

Tighten bolts every

250 hours

Mast Connection Plate

Guide Bar

Inspect gap and Triple Jaw

clearance Breakout
(TJBO)

Fig 4.1.1 Mast Feed System

Copyright © Sandvik Mining and Construction

4.1 MAST FEED SYSTEM (08/03/25) 4-01-003

4.1.1 DR Feed Chain Adjustment

1” to 2” of sag
from centerline of
mast

Fig 4.1.2 Feed Chain Tension

To achieve proper tension of the feed chains, both must be adjusted so there is 1” to
2” of sag in each chain at mid point on the mast (as shown above). This is
accomplished by adjusting the tension of each chain with its corresponding tension
block. Ideally, the tension adjustment should be made evenly across both tension
adjusters. This is to prevent over-tensioning of the adjusters and collapsing the
springs, which are needed to cushion the feed chain.
NOTE: Under normal operating conditions the chain will stretch over time. Once
the chain has stretched beyond the limit of the adjusters, individual links can
be removed from either chain to bring them back to a normal adjustable
length.

Copyright © Sandvik Mining and Construction

4.1 MAST FEED SYSTEM (08/03/25) 4-01-004

4.1.1.1 Top Chain Adjustment

Refer to Fig 4.1.3
1. Move top drive to bottom of mast.

WARNING!
Make sure equipment is shut off before making adjustments.

2. Back off locking nut.

3. Turn adjusting nut clockwise to tighten chain.
4. Do not collapse tension springs completely as they are needed to cushion the
chain.
5. If more chain tension is required, it can be made up with the other tension
adjuster. The adjustment should be made evenly between both tension
adjusters.
6. Tighten locknut against adjusting nut once proper chain tension is achieved.

Remove
access
plate

Locknut
Adjusting screw

Fig 4.1.3 Top Chain Adjustment

Copyright © Sandvik Mining and Construction

4.1 MAST FEED SYSTEM (08/03/25) 4-01-005

4.1.1.2 Bottom Chain Adjustment

Refer to Fig 4.1.4
1. Move top drive to bottom of mast.

WARNING!
Make sure equipment is shut off before making adjustments.

2. Back off locking nut.

3. Turn adjusting nut clockwise to tighten chain.
4. Do not collapse tension springs completely as they are needed to cushion the
chain.
5. If more chain tension is required, it can be made up with the other tension
adjuster. The adjustment should be made evenly between both tension
adjusters.
6. Tighten locknut against adjusting nut once proper chain tension is achieved.

Adjusting screw Locknut

Copyright © Sandvik Mining and Construction

4.1 MAST FEED SYSTEM (08/03/25) 4-01-006
Fig 4.1.4 Bottom Chain Adjustment

Copyright © Sandvik Mining and Construction

4.1 MAST FEED SYSTEM (08/03/25) 4-01-007

4.1.2 Slider Adjustment

Periodic adjustments of the sliders is required to keep the top drive mounting plate, mast
connection plate and carrier block parallel to the guide bars. The purpose of these
adjustments is to maintain zero clearance between the sliders and the guide bars by
adjusting the setscrews.
Refer to Fig 4.1.5

Procedures for top drive mast connection plate

1. Rotate mast to vertical position. Move top drive mounting plate and mast
connection plate to bottom of mast. Ensure that these are in lowest position.
2. Inspect gap settings as shown below, at all four corners of plate assembly.
3. Turn all setscrews an equal amount until no clearance exists between sliders and
guide bars. Ensure that mounting plate is parallel to guide bars.
4. Turn all setscrews 1/4 turn to create a snug sliding fit. Tighten lock nuts.
5. Torque top drive mounting bolts to 375 ft-lbs (508 N-m).
6. Move top drive mounting plate and mast connection plate up and down. Inspect
sliders for zero clearance.

Wear Guides
At the specified intervals, inspect and replace the wear guides, which are located
under the top drive mounting plate.

¾” set screws Wear Guide

Equal gaps at Equal gaps at

left, right, top, left, right, top,
and bottom and bottom

Guides

Slider

Fig 4.1.5 Wear Guides

Copyright © Sandvik Mining and Construction

4.1 MAST FEED SYSTEM (08/03/25) 4-01-008

4.1.3 Carrier Block

Refer to Fig 4.1.6
1. Bring the mast to horizontal position and align the carrier block with the opening
on the mast.
2. Inspect gaps between sliders (item 6) and adjuster wedges (item 4).
3. Turn the setscrews (item 18) on equal amount until no clearance exists between
sliders and guide bars.
4. Move the carrier block back and forth by cylinder for few times. Inspect the gaps
again and tighten the screws if necessary. Tighten the lock nuts.

Section of slider housing

Fig 4.1.6 Carrier Block

Copyright © Sandvik Mining and Construction

4.1 MAST FEED SYSTEM (08/03/25) 4-01-009

4.1.4 Feed Chain Block

Periodic inspection of the feed chain, idlers, and pins are required as shown in Fig 4.1.7.
INSPECT EVERY 250 HOURS UNLES NOTED.
Refer to Fig 4.1.7

Check idler, pin, and guides

Check spring,
bushing, and chain
tension
Carrier Block Tighten as required

Check spring,
bushing, and chain
tension
Tighten as required

Feed Cylinder

Check idler, pin, and guides

Every 8 hours, clear cuttings and debris from idler

Fig 4.1.7 Feed Chain Block

Copyright © Sandvik Mining and Construction

4.1 MAST FEED SYSTEM (08/03/25) 4-01-0010

4.1.5 Jib Boom

Inspect the jib boom every 250 hours.
Refer to Fig 4.1.8

1. Inspect cylinder pins

and cylinder rods
2. Apply grease to nipple;
check for excessive leaking
Arm

3. Inspect sheaves
and spacer washers

4. Apply grease to nipple;

check for excessive leaking

5. Check for excessive

play in swivel joint by
wiggling arm

6. Inspect winch cable;

replace as required

Fig 4.1.8 Jib Boom

Copyright © Sandvik Mining and Construction

4.1 MAST FEED SYSTEM (08/03/25) 4-01-011

4.1.6 Triple Jaw Breakout (TJBO)

PM Tasks
The Triple Jaw Breakout (TJBO) requires minimal servicing but the cylinders and clevis pins
need to be inspected.

250 Hour Intervals:  Inspect cylinders

 Remove debris from centralizer tube
 Inspect centralizer jaws and inserts
1000 Hours Intervals:  Inspect cylinder clevises and pins
 Inspect centralizer jaws and inserts
 Inspect drill table

Breakout
Jaws
Vise
Jaws
Centralizer
Jaws

Fig 4.1.9.a Triple Jaw Breakout (TJBO) Fig 4.1.9.b Triple Jaw Breakout (TJBO)

Capscrew Jaw,
Breakout

Tong Jaw, Capscrew Tong

Die Breakout Die

Fig 4.1.10 Jaw Assembly Fig 4.1.11 Jaw Assembly from above

Copyright © Sandvik Mining and Construction

4.1 MAST FEED SYSTEM (08/03/25) 4-01-012

4.1.6.1 Overhaul procedure

Servicing the TJBO is limited to checking and repairing the hydraulic cylinders and replacing
the cylinder pins.
Refer to Fig 4.1.9 to Fig 4.1.12
1. Dismantle the assembly as illustrated in Fig 4.1.12.
2. Inspect centralizer jaws and replace as required.
3. Inspect the inserts and replace as required.
4. Overhaul the hydraulic cylinders as required.
5. Reassemble the lower masts in reverse order.

Fig 4.1.12 Triple Jaw Breakout

Copyright © Sandvik Mining and Construction

4.1 MAST FEED SYSTEM (08/03/25) 4-01-013

Copyright © Sandvik Mining and Construction

4.2 TOP DRIVE (08/03/25) 4-02-001

4.2 Top Drive

PM Tasks
The top drive requires minimal maintenance; however, certain precautions must be taken to
ensure long life of the unit. The top drive is exposed to severe vibration and shock loading.
The frequency of rebuilding the top drive assembly depends on the drilling conditions as
well as maintenance of the unit.
It is essential to check the pre-load of the bearings after the first 50 hours of service as well as
every 250 service hours, adjusting as required. This will prevent movement of the
driveshaft when the bearings have excessive play. The movement will damage the oil seals
and possibly damage the driveshaft wear sleeve and seal housings, causing loss of oil and
eventual failure of the top drive.
NOTE: A special tool is required to check the bearing pre-load. Order the tool from
Cubex (CT16208-WH24) or manufacture it from an old drill pipe (see Fig 4.2.1).
Daily:  Check oil level
 Check for oil leaks
250 Hour Intervals:  Bearing Pre-load Adjustment
 Change gear oil
1000 Hour Intervals:  Torque bolts on rotation motors
 Torque bolts at mounting plate

2000 Hour Intervals:  Inspect top drive and rebuild as required

WARNING!
Disconnect electrical power, mine air, water supply and relieve pressure in
air receiver before servicing.
Support mast before removing or loosening hydraulic components or fittings.

Technical Specifications: Lubricant: Gear Lube SAE 140 - High temp.

SAE 80W-90 - Low temp.
Capacity: 6.2 qts (6 l)
Weight: 780 lbs (350 kg)

Copyright © Sandvik Mining and Construction

4.2 TOP DRIVE (08/03/25) 4-02-002

4.2.1 Using the Right Equipment

When working on a 6240 top drive, it is recommended that the correct stand is used to hold the
unit while working on it. This stand must be capable of rotating the top drive 360° and
securely holding it in the required position as shown in Fig 4.2.1.
Also required will be a bearing warmer (see Fig 4.2.1).

Top
Drive

Bearing
Warmer

Stand

Fig 4.2.1 Stand

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4.2 TOP DRIVE (08/03/25) 4-02-003

4.2.2 Checking Bearing Pre-load

NOTE: This procedure is for Preventative Maintenance.
A special tool is required to check the bearing pre-load. Order the tool from Cubex (CT16208-
WH24) or manufacture it from an old drill pipe (see Fig 4.2.2).
It is critical to maintain the correct pre-load on the drive shaft bearings. The test is to
determine the force required to rotate the driveshaft. The pre-load is adjusted by adding or
removing shims, installed under the bearing cap.
1. Move top drive to a comfortable working position and drain oil. Rotate mast until
top drive motors are facing down.
WARNING!
Secure full load of mast and top drive.
Disconnect electrical power, mine air, water supply and relieve pressure in air
receiver before proceeding.
2. Remove top drive motors and cap hydraulic lines.
3. Install Pre-load Checking Tool into drive shaft sub. Place torque wrench on nut,
and measure torque required to rotate drive shaft. Torque must be between 65 -
75 ft-lbs (88 - 102 N-m).
NOTE: If pre-load is within limits, remove Pre-load Checking Tool and
reassemble top drive. Otherwise proceed with Adjusting Bearing Pre-load.

Alternative Field Method for Checking Pre-load

1. Move the top drive to a comfortable working position and drain the oil.
2. Install the Pre-load Checking Tool into the driveshaft saver sub. Using a torque
wrench rotate the driveshaft and read the torque required to turn it. Torque
must be between 100 – 110 ft-lbs (136 - 150 N-m) rolling torque (torque must be
read while turning the driveshaft).
NOTE: If the pre-load is within limits, remove the Pre-load Checking Tool.
Otherwise, proceed with Adjusting Bearing Pre-load.

Fig 4.2.2 Pre-load Checking Tool (CT16208-WH24)

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4.2 TOP DRIVE (08/03/25) 4-02-004

4.2.3 Adjusting Bearing Pre-load

Normal wear tends to reduce the pre-load. Shims, placed under the bearing cap, must be
removed to compensate for wear. The shims are available in 2 sizes - 0.005” (0.127 mm) -
clear and 0.010” (0.254 mm) – white, with both being found under the cap.
NOTE: This procedure is continued from "Checking Bearing Pre-load"; therefore the air
pressure is already relieved.
1. Remove bearing cap. Remove one shim, bolt bearing cap back in place and
torque bolts (30) to 375 ft-lbs (508 N-m). Turn driveshaft two full revolutions.
NOTE: When removing the bearing cap, care must be taken to insure that there
are no burrs on the wear sleeve that might damage the seal as the cap is
being removed.
2. Recheck bearing pre-load by measuring rotation torque. Repeat step 1 and
recheck bearing pre-load until correct torque is achieved.
3. Remove Pre-load Checking Tool. Reassemble top drive and reconnect power.
Rotate mast until air swivel is up, and check oil level in top drive.

4.2.4 Removing Top Drive

The top drive can be removed with the mast in the horizontal or vertical position.
1. Break saver sub before removing top drive from mast. To break and install saver
sub, follow the instructions given in Section 4.2.8.
WARNING!
Disconnect electrical power, mine air, water supply and relieve pressure in air
receiver before servicing.
2. Drain the oil into a suitable container.
3. Support weight of top drive using crane or suitable restraining device.
4. Disconnect air hoses and hydraulic hoses, capping all lines.
5. Remove 8 of the ¾” retaining bolts and lift off the top drive.
6. Clean and wash exterior of top drive.
7. Install the top drive on a suitable holding device.
8. Proceed with disassembly instructions.

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4.2 TOP DRIVE (08/03/25) 4-02-005

4.2.5 Disassembly Procedure

NOTE: Use bearing warmer or press to remove and install bearings and sleeves.
Refer to Fig 4.2.4
1. Remove the hydraulic motors.
2. Remove the splined piston (if your model is so equipped).
3. Remove the upper seal housing bolts and then remove the housing by turning in
the previously installed set screws.
4. Remove the oil seal from the housing and discard.
5. Remove the gear housing top plate.
6. Remove the driveshaft bearing cup and pinion bearings from the plate.
7. Remove the driveshaft assembly from the gear housing using a suitable lifting
device.
8. Remove the bearing cones, sleeves, and bullgear from the driveshaft using a
suitable press. Avoid damaging the driveshaft surfaces.
9. Remove both pinion gears and lower pinion bearings from the gear housing. It
may be necessary to remove 4 of the 1/8” pipe plugs from the bottom of the
gear housing and use a pin punch to push the bearings out.
10. Remove the bottom bearing cap bolts and the bottom bearing cap. It may be
necessary to use the two set screws previously installed in the cap.
11. Remove the bearing cup from the gear housing.
12. Clean and inspect all parts, replacing any worn components.

Fig 4.2.3 Disassembly

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4.2 TOP DRIVE (08/03/25) 4-02-006

4.2.6 Assembly Procedure

The top drive assembly has been split into four parts: Lower Gear Housing assembly, Upper Gear
Housing assembly, Driveshaft assembly, and Final assembly.
NOTE: The Lower Gear Housing and Upper Gear Housing assemblies can be completed while
warming the bearings during the Driveshaft assembly.

4.2.6.1 Lower Gear Housing Assembly

1. Install pinion bearings onto pinion gear (2 sets).

Pinion Gear

Pinion Bearing

Fig 4.2.4.a Fig 4.2.4.b

2. Install bearings and gear into the lower gear housing. The lower gear housing should
have previously been installed on the appropriate stand (see Section 4.2.1).
Use a rubber mallet and/or brass punch to ensure the bearings are seated all the way
to the bottom (edge should be below housing edge).

Bearing edge below

Lower Gear Housing housing edge

Fig 4.2.5.a Fig 4.2.5.b

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4.2 TOP DRIVE (08/03/25) 4-02-007

4.2.6.2 Upper Gear Housing Assembly

1. Install pinion bearings in upper gear housing.0
Use a rubber mallet and/or brass punch to ensure the bearings are seated all the
way to the bottom (edge should be below housing edge). See Fig 4.2.6

Pinion Bearing
Pinion Bearing
Bearing edge below
housing edge

Upper Gear Housing

Fig 4.2.6
2. Install the outer ring from bearing assembly CX001423 (see Fig 4.2.7.a and Fig
4.2.7.b) into upper gear housing.
Use a rubber mallet/brass punch to ensure the outer ring is seated all the way to the
bottom (edge should be bottomed out). See Fig 4.2.8.a and Fig 4.2.8.b

Outer Ring

Fig 4.2.7.a Fig 4.2.7.b

Outer Ring

Fig 4.2.8.a Fig 4.2.8.b

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4.2 TOP DRIVE (08/03/25) 4-02-008

4.2.6.3 Driveshaft Assembly

CAUTION!
Use gloves whenever you are removing items from the bearing warmer. Parts can
be extremely hot.
1. Using a bearing warmer, heat CX001442 spacer. When warm, install on driveshaft
CX004939 (not on threaded end).

Driveshaft
Spacer

Threaded end
of driveshaft

Fig 4.2.9.a Fig 4.2.9.b

2. Heat large CX001423 bearing assembly on bearing warmer (can take up to 30
minutes; be sure to rotate the bearings on the warmer to heat evenly). Use a
temp stick (rated for 250°F) to check on bearing temperature; check 3 spots to
ensure it’s heated evenly.
NOTE: It is during this step and during step 10 (warming bearings) that the Lower
Gear Housing and the Upper Gear Housing assemblies can be completed.

Bearings Temp
Stick

Fig 4.2.10.a Fig 4.2.10.b

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4.2 TOP DRIVE (08/03/25) 4-02-009

3. When the bearings are heated, drop onto the driveshaft on top of the spacer
(remember to use gloves). Ensure the bearing ring is touching the spacer.

Bearing Assembly

Spacer

Driveshaft

Threaded end
of driveshaft

Fig 4.2.11

4. Heat and install upper CX001433 spacer sleeve on top of bearing assembly. Ensure it
is seated all the way down.

Spacer
Sleeve

Fig 4.2.12.a Fig 4.2.12.b

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4.2 TOP DRIVE (08/03/25) 4-02-010

5. Heat and install upper wear sleeve CX001425 on top of spacer sleeve. Ensure
tapered edge is facing up.

Tapered edge

Tapered edge
Upper Wear
Sleeve

Fig 4.2.13.a Fig 4.2.13.b

6. Invert (turn over) driveshaft so threaded end is up. Determine thread direction. If
threads are circling to the right, unit is left hand rotation and vice versa.

Thread direction

Rotation direction
(marked on driveshaft
by assembler)

Fig 4.2.14

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4.2 TOP DRIVE (08/03/25) 4-02-011

7. Install bullgear on the driveshaft. Place the bullgear on the driveshaft properly (up
for L/H rotation, etc) using the rotation direction determined in step 6. “Up” is
toward the threaded end. See Fig 4.2.16
NOTE: Bullgear has “up for L/H rotation” and “up for R/H rotation” inscribed on
either side. See Fig 4.2.15.a and Fig 4.2.15.b

Fig 4.2.15.a Fig 4.2.15.b

Fig 4.2.16

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4.2 TOP DRIVE (08/03/25) 4-02-012

8. Install collector cups on bullgear (both sides – top and bottom). The open end of the
collector cup MUST BE facing the direction of rotation. The collector cups gather oil
and direct it to the bearings.

Collector Cup

Open end facing

rotation direction

Collector Cup
(underneath)
Rotation
Open end facing
direction
rotation direction

Fig 4.2.17

9. Warm and install bottom spacer CM16216 on top of bullgear. Both sides are
tapered, so it can be installed either way.

Bottom Spacer

Fig 4.2.18.a Fig 4.2.18.b

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4.2 TOP DRIVE (08/03/25) 4-02-013

10. Heat bearing cone CP16205 on the bearing warmer. Install on top of the bottom
spacer. Ensure it is seated all the way to the bottom.

Bearing Cone

Fig 4.2.19.a Fig 4.2.19.b

11. Heat and install the lower spacer sleeve on top of bearing cone.

Lower Spacer
Sleeve

Fig 4.2.20

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4.2 TOP DRIVE (08/03/25) 4-02-014

12. Heat and install lower wear sleeve (tapered edge outward) on top of the lower
spacer sleeve. Ensure it’s seated at the bottom.

Tapered edge

Lower Wear Sleeve

Fig 4.2.21

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4.2 TOP DRIVE (08/03/25) 4-02-015

4.2.6.4 Final Assembly

1. Invert driveshaft (turn over: threaded end at bottom). Using a crane or other
hoisting equipment, install driveshaft assembly into lower gear housing.

Fig 4.2.22.a Fig 4.2.22.b

2. Using Loctite 518, apply to surface of lower gear housing. Install gasket on lower
gear housing. Apply Loctite 518 to surface of gasket.

Loctite 518 (red) Gasket (green) Loctite 518 (red)

Fig 4.2.23.a Fig 4.2.23.b Fig 4.2.23.c

3. Apply Lubriplate No. 105 Motor Assembly Grease (white) to the interior of the upper
gear housing (outer ring of bearing assembly) and to the bearing assembly.

Lubriplate

Fig 4.2.24.a Fig 4.2.24.b

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4.2 TOP DRIVE (08/03/25) 4-02-016

4. Install upper gear housing on to the lower gear housing. It may be necessary to use a
rubber mallet to seat housing firmly on gasket. Ensure the pinion gears are fitting
into the pinion bearings in the upper gear housing.

Pinion Bearings

Fig 4.2.25.a Fig 4.2.25.b

5. Install 16 (sixteen) bolts (3/4-10 UNC Hex Hd. Bolt, 2.5 lg.) and washers (3/4” Lock-
washer) into the upper gear housing. Use Loctite 243 (blue threadlock) on bolt
threads. Using a torque wrench, torque bolts to 250 ft lbs.
NOTICE: Do not install the oil seals at this time. The repeated removal during pre-
load setting can damage seals.

Loctite 243 (blue)

Bolts (16)

Torque bolts
to 250 ft lbs

Fig 4.2.26.a Fig 4.2.26.b

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4.2 TOP DRIVE (08/03/25) 4-02-017

6. Invert top drive on stand (threaded end up). Apply Lubriplate grease to bearing
cone CP16205 and bearing cup CP16204. Use rubber mallet to seat the bearing cup
approximately ½” above the housing level.
NOTICE: It is very important NOT to push the bearing cup as far as it will go.
Pushing it too far can prevent the bearings from rolling freely. Instead, allow
the pressure of the bearing cap installation (steps 8 and 9) to seat the bearing
cup properly.

Lubriplate on Lubriplate on interior

bearing cone of bearing cup

Fig 4.2.27.a Fig 4.2.27.b

Bearing Cup -
Seated approx. ½”
above the housing
level.

Fig 4.2.27.c

7. Add several shims (exact number to be determined during pre-load setting) to the
housing. Discard the thickest shims from shim set CX001438.

Shims

Fig 4.2.28

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4.2 TOP DRIVE (08/03/25) 4-02-018

8. Install bearing cap CX001410 onto housing. Ensure the fill plug is facing forward
from the mounting side. It may be off-center depending on the position of the bolt
holes.

Mounting side
(side attached
to stand)

Fill Plug Bearing Cap

Fig 4.2.29

9. Install 6 (six) bolts (3/4-10 UNC Hex Hd. Bolt, 2.5 lg.) and washers (3/4” Lock-
washer) into the bearing cap. Torque bolts to 250 ft-lbs.
NOTE: DO NOT use Loctite 243 on the bolt threads at this time. Bearing cap and
bolts may need repeated removing during pre-load setting.

Bolts and Washers

Torque to 250 ft lbs

Fig 4.2.30

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4.2 TOP DRIVE (08/03/25) 4-02-019

10. Setting the bearing pre-load:

a. Insert the pre-load tool into the threaded end of driveshaft. Tighten.
b. Use a torque wrench to check rolling torque (needs to be approx. 80 ft-lbs).
c. If rolling torque is outside limits: Remove bearing cap, add (to lower torque) or
remove (to raise torque) shims, re-install bearing cap and bolts, and recheck
rolling torque until it is within limits.
*IMPORTANT: Always re-torque bolts to 250 ft-lbs before checking pre-load.
d. Once you have reached the correct rolling torque, remove bolts and apply
Loctite 243 to the bolt threads. Re-install bolts and torque to 250 ft-lbs.
e. Remove pre-load tool.

Pre-load tool
See also Fig
4.2.2

Fig 4.2.31.a Fig 4.2.31.b

11. Lubricate seal CX001436 and wear sleeve contact surfaces. Install seal with
spring/open side down. NOTE: Spring can bend; if bent, it will not seal correctly.
BE CAREFUL. Use rubber mallet and/or level to seat the seal evenly.

Lubricate wear Use level to seat

Spring
sleeve surfaces seal evenly

Fig 4.2.32.a Fig 4.2.32.b Fig 4.2.32.c

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4.2 TOP DRIVE (08/03/25) 4-02-020

12. Install cover plate CX001444 with Loctite 518 and gasket, using 3 (three) bolts
(3/8-16 UNC Hex Hd. Bolt, 3/4 lg.) and washers (3/8” lock-washer). Also plug the
hole in the side with a bolt.

Bolt example

Cover Plate
Bolt in side Loctite and Gasket

Fig 4.2.33.a Fig 4.2.33.b

13. Install 4 (four) pipe plugs (1/8-27 NPT) into holes in casting. Use Loctite 587.

Pipe
Plugs
Pipe
Plugs

Fig 4.2.34

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4.2 TOP DRIVE (08/03/25) 4-02-021

14. Invert (turn over) top drive on stand. Apply Lubriplate grease to seal CX001435 and
wear sleeve contact surfaces. Install seal with spring/open side down. NOTE:
Spring can bend; if bent, it will not seal correctly. BE CAREFUL. Use rubber
mallet and/or level to seat the seal evenly.

Lubriplate on wear
sleeve surface

Fig 4.2.35

O-ring installed
Seal installed

Fig 4.2.36
15. Install o-ring CP16001 onto driveshaft using Lubriplate grease. Refer to Fig 4.2.36

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4.2 TOP DRIVE (08/03/25) 4-02-022

16. Install Labyrinth Cap, Upper (CX004944); use mallet to seat as far as it goes.

Labyrinth
Cap, Upper

Fig 4.2.37.a Fig 4.2.37.b

17. Install second o-ring CP16001 into upper labyrinth cap, using Lubriplate grease.

O-ring installed

Fig 4.2.38

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4.2 TOP DRIVE (08/03/25) 4-02-023

18. Fit air swivel CX004940 onto the upper labyrinth cap, aligning the bolt holes. Use
8 (eight) bolts (1/2-13 UNC Hex Hd. Bolt, 2 1/2 lg. gr.8+) and washers (1/2” lock-
washer). Apply Loctite 243 to the bolt threads and fasten the air swivel to the
upper labyrinth cap. Torque bolts to 70 ft-lbs.
NOTE: Air swivel must have threaded part facing forward (same as the fill plug in
step 8). Tighten bolts.

Air Swivel
Threaded hole

Bolts and washers

Fig 4.2.39
19. Install pinion locking tools (CT16208-WS) into pinion gear. This prevents
components from turning while tightening the saver sub.

Install Pinion Locking

Tool here (both sides)

Pinion
Locking
Tool

Fig 4.2.40.a Fig 4.2.40.b

CAUTION!
After installation of the pinion locking tools, do not engage the drill’s rotation
either forward or reverse, as damage to the top drive may occur.

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4.2 TOP DRIVE (08/03/25) 4-02-024

20. Hand-tighten the saver sub onto the top drive.

Saver sub

Fig 4.2.41

21. Move top drive to breakout bench and secure with bolts. Using the breakout
wrench (CT16208-W), torque the top drive to 1550 psi.

Secure top drive to

bench with bolts

Saver sub breakout

wrench

Breakout bench

Fig 4.2.42

22. Once torqued, remove the top drive from the breakout bench and move to table.
Remove the pinion locking tools.

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4.2 TOP DRIVE (08/03/25) 4-02-025

23. Using bolts (1/2-13 UNC 12 point Bolt, 3/4 lg.) and washers (1/2” High collar lock-
washer), with Loctite 243 on the bolt threads, attach motors to top drive. NOTE:
Placement is important, as one motor has side ports and another has bottom
ports. Tighten as much as possible.

Side Ports (yellow) Bottom Ports (yellow)

Fig 4.2.43.a Fig 4.2.43.b

24. Install Lower Labyrinth Cap CX001409. Insert and tighten cap screw with allen key.

Lower Labyrinth Cap Cap screw

Fig 4.2.44.a Fig 4.2.44.b

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4.2 TOP DRIVE (08/03/25) 4-02-026

25. Install fill plugs to oil drain/fill holes (both sides).

Install fill plug

Install fill plug

Fig 4.2.45.a Fig 4.2.45.b

26. Using silicone adhesive/sealant, seal holes in top drive. Allow to dry.
27. Top up oil to proper level.

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4.2 TOP DRIVE (08/03/25) 4-02-027

4.2.7 Top Drive Installation

1. Place the spacer over the t-bar and onto the top drive mounting plate with the 8
holes aligned.
2. Hoist the top drive onto the spacer with the large shaft facing the bottom of mast
and the 8 holes aligned.
3. Install eight 3/4” bolts with 3/4” lock washers through the top drive and spacer and
into the top drive mounting plate.

NOTE: Mast and spacer on your model of drill

may be different than those shown here.
However, installation is the same.

Fig 4.2.46

Ref No. Part No. Qty Description

1 Refer to Parts Manual 1 6230/6240 Top Drive Assembly

2 CQ66403-2 1 Spacer – Top Drive

3 BHC0750 8 3/4-10 UNC Hex HD. Bolt, 2.75” LG.

4 WLR0750 8 3/4” Lock Washer

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4.2 TOP DRIVE (08/03/25) 4-02-028

4.2.8 Saver Sub Field Procedures

4.2.8.1 Removal
1. Lower the top drive to the bottom of travel and support the mast safely to
remove the hydraulic motors.
2. Clean the top of the top drive to prevent debris from entering the top drive,
which will cause premature wear.
3. Remove both hydraulic motors from the top drive assembly; cap all hydraulic
lines to prevent contamination of the hydraulic system.
4. Install the pinion locking tools (CT16208-WS) and secure each with four bolts.
Refer to Fig 4.2.47.a and Fig 4.2.47.b
CAUTION!
After installation of the pinion locking tools, do not engage the drill’s rotation
either forward or reverse, as damage to the top drive may occur.

Pinion Locking Tool

Pinion
Prevents the
Locking
driveshaft from
Tool
turning during
saver sub removal

Fig 4.2.47.a Fig 4.2.47.b

5. Raise the top drive so the saver sub is at the same height as the breakout
cylinder.

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4.2 TOP DRIVE (08/03/25) 4-02-029

6. Install the saver-sub breakout wrench (CT16208-W) on the saver-sub, then install
the appropriate wrench holding tool and connect to the breakout cylinder with
the cylinder in the extended position. Refer to Fig 4.2.48

Saver sub
Breakout cylinder connected in breakout
the extended position to allow wrench
movement for breaking saver
sub

Fig 4.2.48

7. Retract (if cylinder is mounted on the left side of mast) or extend (if cylinder is
mounted on right side of mast) the breakout cylinder until the joint is broken.
WARNING!
To prevent possible injury, do not stand in the path of the wrench while
breaking the joint.

Breakout cylinder
retracted; saver sub
joint loosened

Fig 4.2.49

8. After the joint is broken, remove the saver sub retainer and wrench, and remove
the saver sub by hand.

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4.2 TOP DRIVE (08/03/25) 4-02-030

4.2.8.2 Installation
1. Thread the saver sub onto the driveshaft by hand. Ensure the threads have been
coated with anti-seize.
2. Remove the pinion locking tools.
3. Reinstall top drive motors and all hydraulic lines. Torque motor bolts to 105 ft-lbs.
4. Reduce forward rotation torque to minimum by turning the needle valve labeled
“Forward Rotation Torque” counter-clockwise.
5. Install the breakout wrench onto the saver sub then install the appropriate wrench
holding tool.
6. Rotate the top drive forward until the wrench contacts the right edge of the mast,
keeping all personnel clear of area.

With wrench against

the mast, apply 2500
psi forward rotation
to tighten the saver
sub to the shaft

Wrench Holding
Tool

Fig 4.2.50

7. Push the high rotation torque button; check gauge to ensure a pressure of 2500 psi.
8. Release the button to return to 1600 psi after making up the saver sub; check the
pressure gauge to ensure the pressure has reduced.
9. Relieve the forward pressure with the joystick to remove the breakout wrench.
10. Remove the breakout wench holding tool and breakout wrench.

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4.2 TOP DRIVE (08/03/25) 4-02-031

4.2.9 Air Swivel Field Procedures

PM Tasks
50 Hour Intervals:  Check for external leaks, lubricate grease nipple

2000 Hour Intervals:  Remove and disassemble air swivel, inspect seals and O-rings

4.2.9.1 Removing Air Swivel

Refer to the beginning of the section if the top drive needs to be removed.
1. Lower the top drive to a comfortable working position to remove the air swivel.
2. Clean the top of the top drive to prevent debris from entering the top drive,
which will cause premature wear.

3. Remove the anti-rotation bracket (bolted on) from the top drive mounting plate.
4. Remove the main air supply line from the air swivel.
5. Remove air swivel from top drive by undoing and removing bolts, then lift off the
air swivel.
NOTE: If the air swivel is to remain off the top drive for any length of time, the
drive shaft should be covered to prevent any debris from entering the top
drive.

Main air supply

line

Anti-rotation
Bracket

Fig 4.2.51.a Fig 4.2.51.b

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4.2 TOP DRIVE (08/03/25) 4-02-032

4.2.9.2 Installation of Air Swivel

1. Clean and examine the threads of both the saver-sub and drive shaft for any
damage i.e. burrs, nicks, damage to the threads and replace the o-ring on the air
swivel.
2. Lubricate the o-ring. Refer back to Fig 4.2.38 for location of o-ring.
3. Install the air swivel wrench on the top drive and install bolts and washers, using
Loctite 243 on the bolt threads.

Air Swivel

Bolts and washers

Fig 4.2.52

7. Install the main air supply line from the air swivel.
8. Install the anti-rotation bracket from the top drive mounting plate.

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4.2 TOP DRIVE (08/03/25) 4-02-033

4.2.9.3 Dismantling Air Swivel

Refer to Fig 4.2.53.a and Fig 4.2.53.b

1. Remove upper cover plate and bolts. The bearings directly under the upper cover
plate will come off with it.

2. Loosen the bolts on the lower cover plate.

3. Remove the outer tube from the air swivel.

Upper Items removed

Cover Plate
and Bolts

Outer
Tube

Fig 4.2.53.a Fig 4.2.53.b

4.2.9.4 Assembly Procedure

Re-assemble in reverse order.

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4.2 TOP DRIVE (08/03/25) 4-02-034

4.2.9.5 Inspection of Parts

50 Hour Intervals
1. Inspect the air swivel for air leaks from the vent holes. An air leak indicates that
the seals inside the air swivel require replacement.

Vent
Holes

Fig 4.2.54

2000 Hour Intervals

1. Remove and disassemble air swivel; inspect all seals, bearings, and O-rings.

Lower
bearings

O-rings
(shown
Upper
in blue)
bearings

Fig 4.2.55 Fig 4.2.55 Fig 4.2.55

NOTE: All seals and bearings should be replaced at time of rebuild.

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4.2 TOP DRIVE (08/03/25) 4-02-035

4.2.10 Cushion Sub

The cushion sub assembly CX008698 is designed to be installed on rotary drills below the top
drive as a shock absorbing, thread saving, and maintenance reducing device.
In tension or compression, the transmission of axial vibrations created by the bit or DTH
hammer is minimized.
The cushion sub offers the following benefits:

 Minimum maintenance required.

 100% transmission of torque and breakout forces.
 No air restriction through the body.
 Field re-buildable with an inexpensive seal and cushion kit.
 No modifications to the drill are required.
 Acts as a shock dampener.
 Reduces shock transmission to the rotary gearbox, promoting longer
bearing life and reduced maintenance.
 No loss of horsepower to the drill string or bit, positive displacement.

Fig 4.2.56 Cushion Sub

Copyright © Sandvik Mining and Construction

4.2 TOP DRIVE (08/03/25) 4-02-036

4.2.10.1 Maintenance
The cushion sub should be lubricated every 8 hours. The lubricant can be a
general purpose grease of the same type used to lubricated bearings or other
drill components.
The grease fitting is located in the approximate center position of the body.
Grease should be installed when the sliding spindle is in the retracted (up)
position. The operator should pump in five to ten strokes of the handle to
maintain lubrication of the components.
If, at any time, the sliding spindle will not retract or extend from the housing,
there could be too much grease in the housing cavity. If this happens, remove
the grease fitting and cycle the spindle up and down a couple of times to
remove excess grease and then re-install the fitting into the lower cover plate.
Wait one shift before beginning the lubrication cycle over again and reduce the
amount of grease being used.
It will be necessary to periodically change the seals and wear rings in the
assembly. The frequency of this maintenance will depend on the drilling
application and the amount of lubrication the unit receives during its operating
cycle. If, at any time during the drilling operation, air or fluids are being blown
out the lower end past the seals and spindle, the cushion sub should be
removed immediately from the drill to have a new seal kit installed.
Under average drilling conditions, a preventative maintenance inspection should
be performed at six month intervals or approximately every 1000 hours.

NOTICE!
Under no circumstances should any welding or wrenching be done on the
chrome surface of the spindle.

Copyright © Sandvik Mining and Construction

4.2 TOP DRIVE (08/03/25) 4-02-037

4.2.10.2 Operating Parameters

The cushion sub was developed primarily to reduce shock and vibration
introduced by the rotary bit or DTH hammer bit. Typically the pin up, box
down threaded configuration machined into the upper cap and piston will suit
drills and drill string combinations without any modifications to the drill.
The spline drive system that transfers the torque from the rotary spindle by
means of drive pins provides 100% displacement to the drill string and the bit.
Located within the housing cavity are upper and lower cushions that absorb the
shock displaced into the piston from the drill string when the piston is at either
the upper or lower limits of its stroke within the housing. Drilling fluids or air
are isolated from the housing by means of a washpipe and seal arrangement
that prevent corrosion from taking place on the internal components.
The severity of the drilling application will determine the cycle time in which the
cushion sub will be required to have a rebuild performed. The following are
some visual indicators as to when the cushion sub should be removed from
service and a rebuild performed:
1. If air or drilling fluid is being blown out around the wiper seal at the lower
end of the assembly around the piston (cause – leaking seal at the
washpipe).
2. If the piston seems to have more extension than when the cushion sub was
originally installed on the drill (when new, the chrome section on the
piston when fully extended will protrude approximately 0.250” below the
lower cap – if this length exceeds 1.25”, the lower cushion should be
replaced as soon as possible).
3. If there is backlash in the piston and housing between the time the rotary
spindle starts to rotate and the time the drill steel starts to rotate (the
splines in the piston and the housing will eventually start to wear due to
the torsional pressure being applied during the drilling process from the bit
and also from making up and breaking out of threads – when the free play
exceeds ½” (0.500) – the piston and/or body may need to be replaced. To
check this, mark a position on the piston and the lower cap parallel with
each other, rotate the drive in the opposite direction and measure the
distance now between the lines).

Copyright © Sandvik Mining and Construction

4.2 TOP DRIVE (08/03/25) 4-02-038

4.2.10.3 Disassembly
Refer to Fig 4.2.56
1. Clamp the cushion sub in a horizontal position.
2. Remove cap screws (10) from the lower cap (9).
3. Remove lower cap from body (8).
4. Remove lower cushion (5) from the body.
5. Using a lift nubbin, pull the piston (12) out of the body.
6. Remove upper cushion (3) from the body.
7. To remove the washpipe (14), first remove the spacer (4).
8. Using snap-ring pliers, remove retaining ring (6).
9. Remove washpipe from the upper cap.
10. Remove seal from the upper cap.
11. Remove seals and guide rings from piston and lower cap.
12. Clean all parts with cleaning fluid and inspect for wear – deburr any parts and
remove sharp edges prior to assembly.
13. Seals, guide rings, and cushions are available in a seal and cushion kit –
contact your representative to order.
The seal and cushion kit contains items 3, 4, 5, 6, 10, 11, 16, 17, and 19.

4.2.10.4 Assembly
1. Place one seal (16) in the seal location fit of the upper cap (1). Install the o-
ring of the seal against the shoulder of the fit.
2. Insert the washpipe (14) in the location fit.
3. Install the retaining ring into the groove (be sure it is properly seated).
4. Install spacer over the washpipe to seat in the location fit.
5. Install the upper cushion over the washpipe.
6. Install the piston after replacing the seals and guide ring.
7. Lubricate the drive pins and body (Unirex Moly H grease or equivalent).
8. Install lower cushion (5) into the body until it is seated on the drive pins.
9. Install the lower cap (9) into the location fit of the body (line up bolt holes).
10. Install hi-collar lockwashers on the cap screws and install into the lower cap.
The cap screws provided can be torqued to 210 ft-lbs.
NOTE: The upper cap (1) does not need to be removed to rebuild the cushion
sub, however, it is advised to re-torque the cap screws to 210 ft-lbs.

Copyright © Sandvik Mining and Construction

4.2 TOP DRIVE (08/03/25) 4-02-039

4.2.10.5 Removal
1. Remove the hydraulic motors and install the pinion locking tools in those
locations. Refer to Section 4.2.6.4, step 19 for more information on the pinion
locking tools.

Fig 4.2.57

2. Once the saver sub is engaged in the TJBO, close the jaws and break the
connection between the saver sub and the cushion sub. Remove the saver sub.

Fig 4.2.58

Copyright © Sandvik Mining and Construction

4.2 TOP DRIVE (08/03/25) 4-02-040

3. Place the cushion sub tool into the TJBO and close the jaws.

Fig 4.2.59 Fig 4.2.60

4. Slowly lower the cushion sub into the cushion sub tool. Rotate the top drive to
align the cushion sub with the tool. Rotate the centralizer jaws to break the
joint between the cushion sub and the top drive.

Fig 4.2.61 Fig 4.2.62

Copyright © Sandvik Mining and Construction

4.2 TOP DRIVE (08/03/25) 4-02-041

5. Place a sling through the cushion sub and place a pin through the sling,
ensuring the cushion sub is secure.

Fig 4.2.63 Fig 4.2.64

6. Carefully lift and remove the cushion sub using the sling.

Fig 4.2.65 Fig 4.2.66

Copyright © Sandvik Mining and Construction

4.2 TOP DRIVE (08/03/25) 4-02-042

7. Open the TJBO jaws and remove the cushion sub tool.

Fig 4.2.67

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4.2 TOP DRIVE (08/03/25) 4-02-043

4.2.10.6 Installation
1. Place the cushion sub tool into the TJBO (Triple Jaw Breakout) and close the
jaws.

Fig 4.2.68 Fig 4.2.69

2. Install the cushion sub using a sling and gently place into the cushion sub tool.

Fig 4.2.70 Fig 4.2.71

Copyright © Sandvik Mining and Construction

4.2 TOP DRIVE (08/03/25) 4-02-044

3. Remove sling and pin. Ensure the cushion sub is fully resting in the cushion sub
tool.

Fig 4.2.72 Fig 4.2.73

4. Transfer the seal cover from the top drive and place onto the cushion sub.
Apply anti-seize to the cushion sub threads.

Fig 4.2.74 Fig 4.2.75

Copyright © Sandvik Mining and Construction

4.2 TOP DRIVE (08/03/25) 4-02-045

5. Using a chain wrench, thread the cushion sub into the top drive, making sure to
fully engage threads. Once the cushion sub is fully threaded onto the top drive,
set the top drive to high torque mode (2500 psi). Close the jaws on the TJBO
and torque the cushion sub using forward rotation of the top drive.

Fig 4.2.76

6. Once the cushion sub is properly torqued, remove the cushion sub tool.
7. Apply anti-seize to the threads on the saver sub.

Fig 4.2.77

Copyright © Sandvik Mining and Construction

4.2 TOP DRIVE (08/03/25) 4-02-046

8. Partially thread the saver sub into the cushion sub.

9. Once the saver sub is partially threaded onto the top drive, set the top drive to
high torque mode (2500 psi). Close the jaws on the TJBO and torque the saver
sub using forward rotation of the top drive.

Fig 4.2.78 Fig 4.2.79

Copyright © Sandvik Mining and Construction

4.3 TOP DRIVE MOTOR (08/03/25) 4-03-001

4.3 Top Drive Motor

PM Tasks
Replacing seals and O-rings is routine maintenance but a complete overhaul is time-consuming.
Motor replacement is recommended.

250 Hour Intervals:  Inspect seals

NOTE!
Rebuilding the hydraulic pumps is recommended for qualified maintenance
technicians only.

Motor Specifications:

Top Drive Motor CP17014-6

Displacement: 12.1 in3/rev (198 cm3/rev.)
Continuous Pressure: 2800 psi (193.5 bar)
Continuous Flow: 20 gpm (76 l/min.)
Speed: 0 - 349 rpm
Weight: 36 lbs (16.3 kg)

Copyright © Sandvik Mining and Construction

4.3 TOP DRIVE MOTOR (08/03/25) 4-03-002

Fig 4.3.1 Top Drive Motor

Fig 4.3.2 Rotor Clearance

Copyright © Sandvik Mining and Construction

4.3 TOP DRIVE MOTOR (08/03/25) 4-03-003

4.3.1 Dismantling Top Drive Motor

Remove the top drive motors from the top drive assembly, plug the hose fittings, and proceed
as outlined below.
Refer to Fig 4.3.1
1. Clean the outside of the motor and drain the fluid. Clean all parts, except seals,
in petroleum-based solvent, then dry them with compressed air. Keep parts
separate to avoid nicks and burrs.
2. Place motor in a vise with coupling shaft facing down and jaws gripping housing
flange.
3. Draw an alignment mark down the outside of the motor from cover (2) to housing
(18) to assist orientation when assembling the unit.
4. Remove bolts (1), end cover (2) and seal ring (4). Discard seal ring. Inspect end
cover (2) for operating conditions. A polished pattern is normal wear created by
commutator assembly.
Discoloring indicates excessive fluid temperature, thermal shock or extreme speeds.
If discoloring exists, inspect items 2, 5, and 8 for scoring or distortion.
5. Remove commutator ring (6) and inspect it for cracks or burrs.
6. Remove commutator (5). Remove seal from commutator, using an air hose
blowing air into the ring groove until the seal (3) is lifted out. The seal (3) must
be discarded after removal.
NOTE: Item 5 and commutator ring (6) are sold as matched sets.
7. Remove manifold (7) and inspect it for cracks or surface scoring. Replace it if
required. A polished pattern on the ground surfaces from commutator or rotor
rotation is normal. Remove and discard seal rings (4) from both sides.
NOTE: The manifold is constructed of bonded plates and cannot be dismantled
any further. Compare configuration of both sides of the manifold to ensure
that the same surface is reassembled against the rotor set.
8. Remove rotor set (8) and wear plate (9) together, keeping rotor set in its
assembled form. Then, mark the position to allow installation in the same
location. Keeping the original position increases the service life of the torque
motor. Remove and discard seal ring between item 9 and item 8.
NOTE: Some motors may have a rotor set with two stator halves with a seal ring
(4) between them and two sets of vanes. Discard the seal ring if the stator
halves become disassembled.

Copyright © Sandvik Mining and Construction

4.3 TOP DRIVE MOTOR (08/03/25) 4-03-004

9. Check rotor vane clearance as follows: Place the rotor set (8) and wear plate (9)
on a flat surface then rotate the rotor as illustrated in Fig 4.3.2. Measure the
clearance between the vane and rotor lobe. Replace the rotor set if the
clearance is more than 0.005" (0.13 mm). If this motor is equipped with two sets
of stators, repeat above procedure on other side.
10. Inspect drive link (10) for damaged splined. No noticeable lash should be
apparent between mating spline parts.
11. Remove seal ring (4) from item 18. Remove thrust bearing (11) from coupling
shaft (12) and inspect it for wear.
12. Remove coupling shaft (12) and check it for wear. Replace it if the two
diameters show wear in excess of 0.020" (0.51 mm).
13. Remove inner thrust bearing (13) to inspect condition. Remove item 16, and
item 17. Remove seal (20) using a seal puller.
14. Remove bearing (19) using a suitable bearing puller.

4.3.2 Assembly Procedure

1. Reassemble in reverse order including the additional steps below.
2. Pack bearing (19) with grease as it is not lubricated with hydraulic fluid.
3. Apply grease to all seal rings (4). Install two studs that are 0.50" (13 mm) longer
than bolts (1) into item 18 to guide external parts during installation.
4. Install bolts (1) and torque to 24 ft-lbs (32 N-m).

Copyright © Sandvik Mining and Construction

4.4 BREAKOUT WRENCH (08/03/25) 4-04-001

4.4 Breakout Wrench

PM Tasks
Clean and replace components as required. The knurled inserts require replacement more
frequently.
250 Hour Intervals:  Visual inspection
 Cleaning assemblies

Fig 4.4.1 Breakout Wrench

Service Procedure
Servicing the wrench is limited to replacing chain components, pins, and springs. Consult the
Parts Manual for replacement parts.
1. Dismantle the assemblies as illustrated in Fig 4.4.1.
2. Replace worn inserts and parts as required. Clean chains and replace them when
necessary.
3. Assemble in reverse order.

Copyright © Sandvik Mining and Construction

4.4 BREAKOUT WRENCH (08/03/25) 4-04-002

Copyright © Sandvik Mining and Construction

4.5 CAROUSEL ASSEMBLY (08/03/25) 4-05-001

4.5 Carousel Assembly

PM Tasks
The carousel requires frequent lubrication and inspection.
8 Hour Intervals:  Lubrication of grease nipples; operators must check that drill
pipes align with top drive

250 Hour Intervals:  Visual inspection of bearings, pins, and pipe guides
2000 Hour Intervals:  Repeat 250 Hour Inspection; inspect carousel drive; check
hydraulic cylinders and motor

WARNING!
Secure or support mast before inspecting or servicing drill. Drill pipe may
move if pipe clamping pressure is set incorrectly.

4.5.1 Check Pipe Alignment Every 50 Hours

1. Check that the pipe clamps have sufficient force to hold drill pipes.
2. Check drill pipes align with top drive.

Fig 4.5.1 Pipe Alignment

Copyright © Sandvik Mining and Construction

4.5 CAROUSEL ASSEMBLY (08/03/25) 4-05-002

4.5.2 Carousel Inspection at 250 Hours

1. Inspect top wear liner.
2. Inspect washers for wear.
3. Inspect bearings.
4. Inspect cylinder pins and clamp pins.
5. Inspect bushings inside clamp and washers.
6. Inspect cylinder bearing.
7. Repeat steps 4 and 6.
8. Repeat steps 2 and three.
9. Inspect bottom wear liner.

Fig 4.5.2 Carousel Inspection

Copyright © Sandvik Mining and Construction

4.5 CAROUSEL ASSEMBLY (08/03/25) 4-05-003

4.5.3 2000 Hour inspection

1. Inspect and shim bearing as required.
2. Inspect driven indexer and washer.
3. Inspect drive indexer.
4. Inspect hydraulic motor for leaks.

Fig 4.5.3 2000 Hour Inspection

Copyright © Sandvik Mining and Construction

4.5 CAROUSEL ASSEMBLY (08/03/25) 4-05-004

4.5.4 Carousel Adjustment

The carousel requires adjustment when the drill pipes do not align with the top drive or when
the clamping force of the pipe clamp is insufficient.
You must also perform these adjustments when replacing carousel components. Tighten screws
to torque values shown in Table 4 Bolt Torque Table.

4.5.4.1 Pipe Clamp Adjustment

Adjusts clamping jaws. Perform lower and upper adjustment simultaneously.
1. Load drill pipe into clamps and tighten pipe into top drive.
2. Turn lock-nut counterclockwise to unlock cylinder rod adjustment. Release the
clamping pressure on the drill pipe by turning the cylinder rod into the cylinder
eye (clockwise). Turn the cylinder rod until there is no more clamping pressure.
This will give a starting point for tightening the clamps.
3. Adjust cylinder rod until clamp grips drill pipe firmly, by turning the cylinder rod
out of the clevis (counter-clockwise). Open pipe clamp and turn the cylinder rod
two more revolutions out of the clevis (counter-clockwise) to make final
adjustment to clamping pressure. Tighten lock nuts. Remove drill rod from drill
table.

Load drill pipe into clamps and

tighten pipe into top drive

Pipe Clamp
Cylinder

Lock-nut

Clamp Cylinder Rod

Fig 4.5.4 Pipe Clamp Adjustment

Copyright © Sandvik Mining and Construction

4.5 CAROUSEL ASSEMBLY (08/03/25) 4-05-005

4.5.4.2 Clamp Arm Adjustment

Adjusts drill pipe with top drive location. Perform lower and upper adjustment
simultaneously.

The adjustment of the pipe clamp

Pipe Clamp Shaft Adjustment shaft will change the position of
the pipe clamps in and around
the carousel around the pipe
shaft clamp axis.

Adjusting
Bolts Lock-nuts

Lock-nut

Cylinder
Rod

The adjustment of the cylinder

will change the position of the
carousel arm assembly around Carousel Arm Assembly
the indicated axis. Cylinder Adjustment

Fig 4.5.5 Lower Carousel Adjustment

Copyright © Sandvik Mining and Construction

4.5 CAROUSEL ASSEMBLY (08/03/25) 4-05-006

Pipe Clamp Shaft Adjustment

Lock-nuts Adjusting
The adjustment of the pipe clamp Bolts
shaft will change the position of
the pipe clamps in and around
the carousel around the pipe
shaft clamp axis.

Lock-nut

Cylinder
Rod

Carousel Arm Assembly

Cylinder Adjustment The adjustment of the cylinder
will change the position of the
carousel arm assembly around
the indicated axis.

Fig 4.5.6 Upper Carousel Adjustment

Copyright © Sandvik Mining and Construction

4.6 EXPANDER PIN SYSTEM (08/03/25) 4-06-001

4.6 Expander Pin System – Mast Boom

The expander pin system is used in the mast boom of your drill. The Expander System consists of
an axle that is tapered at both ends, expansion sleeves, pressure washers, and fastening
elements. The parallel expansion of the sleeves eliminates play in the pivot lugs. This was
introduced to the DR series of drills to reduce the amounts of maintenance and repairs
required on the main pivot and swing cylinder of the boom assembly.
IMPORTANT!
Re-torque is an intricate part of the installation and crucial to the success of
the repair. Make sure to follow the Torque Schedule in Table 7.
Check the torque at regular service intervals. Apply appropriate torque
according to Table 6. Tighten until the torque wrench “clicks out” on
setting.
Proper greasing of your machine pivots is crucial for the functioning and
durability of the Expander System. It is strongly recommended that grease
with 3-5% molybdenum disulfide be used, as it allows much less wear and
gives increased load carrying capability.

Fig 4.6.1 Expander System

Copyright © Sandvik Mining and Construction

4.6 EXPANDER PIN SYSTEM (08/03/25) 4-06-002

4.6.1 Expander pin metric bolt size reference

Fig 4.6.2 Expander pin metric bolt size reference

Fig 4.6.3 Pin CX002332

Copyright © Sandvik Mining and Construction

4.6 EXPANDER PIN SYSTEM (08/03/25) 4-06-003

4.6.2 Torque and Maintenance Intervals

4.6.2.1 Torque Recommendations

Table 6
Bolts and Specialty Fasteners
UNIT M12 M14 M16 M20 M24 M30 M36 M42
N-m 70 115 175 350 500 600 700 900
Lb-ft 52 85 129 258 369 443 516 664

Nuts, Standard Height

UNIT M12 M14 M16 M20 M24 M30 M36 M42
N-m 65 115 175 250 350 500 600 700
Lb-ft 48 85 129 184 258 369 443 516

Nuts, Low Height

UNIT M12 M16 M20 M24 M30
N-m 60 125 200 275 350
Lb-ft 44 92 148 203 258

Spanner Nuts
UNIT M17 M25 M35 M45 M55 M65 M75 M85
N-m 50 120 250 500 600 700 800 900
Lb-ft 37 89 184 369 443 516 590 664

Copyright © Sandvik Mining and Construction

4.6 EXPANDER PIN SYSTEM (08/03/25) 4-06-004

4.6.2.2 Torque Schedule

Re-torque according to Table 7.

Table 7
Hours of Operation

After 1 hour * When you re-torque and the wrench “clicks out” on setting
without adding additional torque, you have successfully seated
After 3 hours
the expansion sleeves.
After 10 hours or 1 day*
If the expansion sleeves have not seated within one week of
After 40 hours or 4 days* operation, call your representative.

4.6.2.3 Mounting/Dismounting Tools

Most Expander System assemblies do not need any special tools for installation and dismounting.
If special tools are needed, they will be supplied with the assembly. If excessive force is
needed or if space is limited, we recommend the use of Expander Mounting/Dismounting
Tools (sold separately).

4.6.2.4 Installation
1. Prior to installation, ensure there are no existing structural damages (i.e. cracks,
severely bent lug ears, etc) that would affect the alignment of the pivot lugs. If
damage exists, it may result in the Expander System not functioning properly.
Repair structural damage before proceeding with installation.
2. Double check the minimum and maximum wear points of the lug holes to ensure
that you have the correct size expansion sleeve for each side of the pin. Each
expansion sleeve expands to a maximum of 2.0 mm (0.08 in). If the maximum wear
diameter of the lug hole is more than 2.0 mm (0.08 in) larger than the diameter of
the sleeve, contact your representative to order the correct oversize expansion
sleeve.
NOTE: If you attempt to install the expander system with improperly sized
expansion sleeves, the installation will not be successful.
3. Visually inspect the bore surface of the mounting lugs. Remove any ridges or other
irregularities.
If the lug hole has more than 1.5 mm (0.06 in) difference between the minimum and
maximum wear, the hole must be bored or ground out to a difference of les than
1.5 mm (0.06 in).

Copyright © Sandvik Mining and Construction

4.6 EXPANDER PIN SYSTEM (08/03/25) 4-06-005

4. Lubricate the expander pin and the expansion sleeves with bearing grease for easy
insertion. First, insert only the expander pin into the bore, then install the sleeves,
tension washers, and fastening elements. Be sure not to damage the thread or the
tapered ends of the expander pin. Refer to Fig 4.6.4.

Fig 4.6.4

5. Hand-tighten the assembly centered (or positioned as required) in its final position
in the pivot.
6. Before tightening the system, find the appropriate torque value for the
corresponding fastening element in Table 6. Torque the fastening elements
alternately in order to maintain an equal clearance between the tension washers
and the mounting lugs on both sides of the expander system. Tighten until the
torque wrench “clicks out” on setting. Refer to Fig 4.6.5.

Fig 4.6.5 Tightening the System

Copyright © Sandvik Mining and Construction

4.6 EXPANDER PIN SYSTEM (08/03/25) 4-06-006

WARNING!
The tension washer located between the fastening element and the end of the
expander pin should NEVER come in contact with the pivot lug. If this occurs on
only one side of the pin, begin again at step 4.
If either tension washer comes in contact with the lug (A) or the end of the expander
pin (B), the expansion sleeve is incorrectly specified. See Fig 4.6.6. The system
must be fitted with a larger oversize expansion sleeve.

Fig 4.6.6 Tension Washer Fitting

7. Lubricate the pivot using grease with 3-5% molybdenum disulfide before operating
the machine. Proper lubrication maintenance will greatly extend the life of the
expander system.
8. Once the initial torque regiment and pivot lubrication have been completed, start
the machine and move the unit back and forth. Tighten again until torque wrench
“clicks out” on settings. This procedure ensures that the expansion sleeves have
properly seated.

Copyright © Sandvik Mining and Construction

4.6 EXPANDER PIN SYSTEM (08/03/25) 4-06-007

4.6.2.5 Dismounting
1. Unscrew the fastening elements on both sides of the assembly and remove the
washers. See Fig 4.6.7.

Fig 4.6.7

2. Tap the expander pin body alternately on both sides until the expansion sleeves
come loose. Use a piece of plumbing pipe between the expander pin and the
mallet/hammer in order to not damage the threads. Make sure that the pipe does
not come in contact with the expansion sleeve. See Fig 4.6.8.

Fig 4.6.8

3. Remove the expansion sleeves with channel lock pliers or a similar tool. See Fig
4.6.9.

Fig 4.6.9

4. Remove the expander pin.

Copyright © Sandvik Mining and Construction

4.6 EXPANDER PIN SYSTEM (08/03/25) 4-06-008

Copyright © Sandvik Mining and Construction

5.0 HYDRAULIC SYSTEM (08/03/25)

5.0 HYDRAULIC SYSTEM

WARNING!
Wipe up spills immediately!
WARNING!
Before servicing any hydraulic components or loosening hose fittings,
secure the mast as follows:
1. Place the mast on solid ground or floor.
2. Move the top drive assembly to the lowest position on mast.
3. Support the mast with hoist or restraining equipment.
5.1 HYDRAULIC SYMBOLS (08/03/25) 5-01-001

5.1 Hydraulic Symbols

Symbols Description

Filter or strainer

Variable Displacement Pump with One Direction Flow

Fixed Displacement Pump

Check Valve

Ball Valve

Pressure Relief Valve

Shuttle Valve

Internal Orifice
Control Valve, 3-position, solenoid with spring return,
manual lever control

Flow Direction

Reservoir Return

Pilot Line

Hydraulic Line

Fig 5.1.1 Hydraulic Symbols

5.1 HYDRAULIC SYMBOLS (08/03/25) 5-01-002

5.1.1 Hydraulic Schematic

Fig 5.1.2 Hydraulic Schematic

5.2 HYDRAULIC CIRCUITS (08/03/25) 5-02-001

5.2 Hydraulic Circuits

An open-loop, hydraulic system is used with a variable displacement, pressure compensating
supply pump. The load sensing function strokes the pump up when flow is required, and
destrokes when the system is idle.

PM Tasks
The hydraulic system requires limited maintenance. The filter elements and hydraulic fluid
must be replaced at the recommended intervals.
Keep all cylinders, motors and valves clean. The cylinder rods are the main source where
contamination may enter into the hydraulic system. Replace damaged components
immediately. Investigate all leaks, using extreme caution. Worn or damaged hoses must be
replaced without delay.
All maintenance should be performed in a clean, well-lit work area. Extreme cleanliness is
required when servicing hydraulic components.

250 Hour Intervals:  See Section 5.8 Hydraulic Filtration; inspect system for leaks

1000 Hour Intervals:  Change hydraulic fluid

WARNING!
High pressure oil leaks can penetrate the skin and cause injury. Use extreme
caution and proper protective gear when investigating hydraulic leaks.
After installing hydraulic components and hoses, check that hydraulic
actuators are operating in direction as indicated on controls.
5.2 HYDRAULIC CIRCUITS (08/03/25) 5-02-002

Hydraulic Circuits
Operating Temperature: 100° to 150°F (38° to 65°C)
Fluid Type: Esso NUTO 46
System Capacity: 80 gal. (303 L)

Pump Specifications
Pump supplies Feed, Left Tram, Drilling Valves

Rotation: Right Hand

Capacity: 6.1 cin (100 cc) 47 gpm (178 l/min) @ 1800 rpm

Filling Volume: 0.4 gal (1.6 l)

Weight: 73 lbs (33 kg)

Pump supplies Rotation, Right Tram, Set-up Valves

Rotation: Right Hand

Capacity: 6.1 cin (100 cc) 47 gpm (178 l/min) @ 1800 rpm

Filling Volume: 0.4 gal (1.6 l)

Weight: 73 lbs (33 kg)

Pump supplies Rad Fan

Rotation: Right Hand

Capacity: 6.1 cin (100 cc) 47 gpm (178 l/min) @ 1800 rpm
Stroke limited to 5.5 cin (90 cc) 42 gpm (160 l/min) @ 1800 rpm
5.2 HYDRAULIC CIRCUITS (08/03/25) 5-02-003

Pressure and Flow Settings P-1 Pump Circuit (Feed, etc) P-2 Pump Circuit (Rotation, etc)
System (Operating) Pressure: 4000 psi (276.4 bar) 4000 psi (276.4 bar)
Stand-by Pressure: 400 psi (27.6 bar) 400 psi (27.6 bar)
Relief Valve: 4400 psi (304.0 bar) 4400 psi (304.0 bar)
Pressure Reducing Valve: 3300 psi (227.5 bar) Not equipped

Pressure and Flow Settings P-3 Pump Circuit (Fan)

System (Operating) Pressure: 4200 psi (289.6 bar) - 1450 RPM (Max Cooling)
Oil Cooler Fan: 2600 psi (179.3 bar) – 1300 RPM
Rad Fan: 1600 psi (110.3 bar) - 2100 RPM
Stand-by Pressure: 400 psi (27.6 bar)

5.2.1 Adjustment Sequence

The hydraulic adjustments are preset and require setting only after servicing the pump or the
control valve or when a change in performance is noticed. When overhauling the pump and
valves at the same time, follow this adjustment sequence.
1. System (Operating) Pressure: Located on the pump’s control valve.
2. Standby Pressure: Located on the pump’s control valve, this is the minimum
pressure when the pump is running idle.
3. Pressure Reducing Valve: Mounted before inlet sections of drilling valves.
4. Relief Valve: Located on the inlet cover in each valve bank.
5. Valve Pressure: Located in the set-up and drilling valve sections, allowing
independent settings for both valve ports.
6. Valve Flow: Located in each valve section, allows independent settings
for both valve ports. See Section 5.5 Control Valves for
individual pressure and flow settings.
5.2 HYDRAULIC CIRCUITS (08/03/25) 5-02-004
5.3 HYDRAULIC PUMP (08/03/25) 5-03-001

5.3 Hydraulic Pump

This model of pump is designed for open-loop, closed center, or load-sensing hydraulic systems.
Flow is proportional to the drive speed and the displacement. By adjusting the position of
the swashplate, it is possible to smoothly vary the flow.
The “Load Sense” type of control registers the load at a point away from the pump. In the case
of your drill, a pilot line from the hydraulic control valves sends the pressure signal back to
the pump. The pump control then tries to keep the output pressure above the load
requirements by the standby or differential pressure (pressure compensation). The
differential pressure is generally in the area of 400 psi.

Principals of Operation
The displacement mechanism of this series of pumps operates via two stroking pistons (large
and small) which adjust the position of the swashplate. The smaller of the two stroking
pistons (1) works in conjunction with its spring (2) to always try to move the swashplate to
maximum angle, and therefore the pump, to maximum displacement. High pressure oil is
continually routed from the outlet (pressure) port to the small stroking piston via the control
oil drilling (3). Working in opposition to this on the opposite of the swashplate is the larger
stroking piston (4). If pressurized fluid is routed to the larger stroking piston (4), it will exert
a force to de-stroke the pump to a lower displacement value. Since piston (4) has a larger
area than piston (1), the pump will de-stroke with pressure on both cylinders. It is therefore
possible to control the pump displacement by changing the pressure applied to the larger of
the two stroking pistons. All the pump controls work on the same principal of controlling the
pressure on this large stroking piston (4) in order to vary the pump’s displacement.

Fig 5.3.1 Hydraulic Pump

5.3 HYDRAULIC PUMP (08/03/25) 5-03-002

NOTICE!
Rebuilding hydraulic pump is recommended for qualified maintenance
technicians only.
When reinstalling pump, ensure that pump housing is filled with hydraulic fluid
before starting.

5.3.1 Installation

5.3.1.1 Pre Start-up

1. When you are installing a new pump because of a failure or gradual decrease in
performance, it is important that you change the pressure and return elements in
the system. The entire hydraulic system requires flushing and installation of new
hydraulic oil.
2. Be sure the hydraulic oil level in the tank is sufficient.
3. Remove the case drain fitting and fill the case with clean hydraulic oil. Reconnect
the line when full.
4. Loosen the suction line at the pump to allow air to bleed from the line. When oil
starts to run out, reconnect the line.
5. Place a 4000 psi gauge at the pump outlet for testing.

5.3.1.2 Start-up
1. With a wrench, remove the protective nuts from the set screws for the
differential pressure and compensator control adjusters. Loosen the jam nuts and
unscrew both adjustments until you no longer feel any resistance from the control
springs. Be sure not to screw them all the way out. This will allow the pump to
start at minimum pressure.
2. If the pump is diesel driven, very slightly loosen off the outlet pressure hose or a
downstream hose connection. Bump the starter for 2 to 3 second periods to allow
air to escape from the line and pump cavity. When oil starts to leak at the
connection you loosened, retighten the fittings.
3. If the pump is driven with an electric motor, jog the starter for the motor and
follow the same procedure as described for a diesel motor. After you tighten the
fitting you used to bleed out the air, run the electric motor. If the pump is noisy,
“crack” the fitting again to bleed of the air. Air is probably still in the suction line
or pump.
4. Once the pump runs quiet, adjust the differential (standby) pressure setscrew
clockwise until the pressure on the outlet of the pump is at the required standby
pressure. Once you have set the pressure, lock the jam nut and replace the
protective nut on the differential pressure adjustment.
5.3 HYDRAULIC PUMP (08/03/25) 5-03-003

5. Next, set the compensator control adjustment to the recommended setting. To

achieve this, you will have to bottom out a control at the valve bank where the
load sense pilot line was connected. This is done to provide a signal back to the
pump to determine a setting for the compensator. Once the compensator is set,
tighten the jam nut and replace the protective nut.
5.3 HYDRAULIC PUMP (08/03/25) 5-03-004

5.3.2 Adjustments

5.3.2.1 System (Operating) Pressure Adjustment

The system pressure is set at the pump’s control valve, mounted at the rear of the pump (see
Fig 5.3.1). If the drill is not equipped with a system pressure gauge, connect a gauge on the
inlet side of the pressure filter. Install a T-fitting and cap the line if the gauge is to be
removed later.
1. Remove the protective cap and loosen the lock-nut on the system pressure
adjustment. Check that personnel are away from the drill and start pump.
2. Set pressure to 4000 psi (278 bar) for a DR drill by turning the setscrew with a 4
mm allen key. Turn it counter-clockwise to reduce pressure. One turn creates a
pressure change of approximately 725 psi (50 bar).
3. Reinstall the protective cap and torque to 15 ft-lbs (21 N-m).

5.3.2.2 Stand-by Pressure Adjustment

The stand-by pressure is the minimum pressure maintained during zero pump load. It is set at
the control valve mounted at the rear of the pump.
1. Install pressure gauge on inlet side of pressure filter.
2. Remove the protective cap and loosen the lock-nut on the stand-by pressure
adjustment. Check that personnel are away from the drill and start pump.
3. Set pressure to 400 psi (27.6 bar) by turning the setscrew.
4. Reinstall the protective cap and torque to 6 ft-lbs (8.1 N-m).
5.3 HYDRAULIC PUMP (08/03/25) 5-03-005

5.3.3 Testing the Pump

The condition of a pump can be determined by checking the flow.
Install a flow meter in series with a restrictor valve on the discharge line of the
pump (make sure the restrictor valve is large enough to handle the flow from the
pump). Run this line back to the tank. Make sure the load sense line is included in
the circuit.
While the pump is running, slowly restrict the flow with the valve you installed. As
the flow is restricted, it should actually increase due to the load sense of the
pump. The flow increase should continue until the pressure reaches 80 to 90 % of
the compensator pressure. At this point, the flow will drop off as the pressure
reaches 100 % of the compensator pressure, at which point the flow will be zero.
See Table 5.3.A to determine the expected flow from your pump at 1750 rpm.

Restrictor Valve
Flow Meter

Return back to tank

Load Sense Line

Fig 5.3.3 Test Circuit

Pump Size Acceptable Pump Flow

71 cc 27.5 to 31 gpm

100 cc 39 to 44 gpm

Table 5.3.A
5.3 HYDRAULIC PUMP (08/03/25) 5-03-006

The approximate condition of a pump can also be determined by the flow produced
from the case drain. No more than 10 to 12 percent of the pump output should be
coming from the case drain.

NOTE: For a case drain leakage test, it is recommended that you DO NOT use a
flow meter. This is because piston pumps are very sensitive to case drain
pressure. Using a flow meter in most cases causes a certain back pressure that
could damage the pump. Instead, use the manual method of directing the case
drain into a pail of known volume while measuring the time and calculating
the flow.
5.3 HYDRAULIC PUMP (08/03/25) 5-03-007

5.3.4 Troubleshooting the Pump

Problem Cause Explanation Corrective Action

Hydraulic system is Standby pressure is A low standby pressure Check the differential
not performing as set too low. setting will cause the pressure setting.
it should. For pump to destroke too
example the drill soon, preventing the
has lost required flow from
performance. reaching the hydraulic
system.

Pump is bypassing. The pump has been Check the pump’s

contaminated, condition. If the
cavitated, aerated, or pump does not pass
otherwise worn. standards, replace.

Loss of load sense The load sense line has Check the load sense
signal. become disconnected line for leakage at
or obstructed and the fitting, breakage, or
signal is not getting an obstruction.
back for the pump to
compensate.

The case drain of Pump is worn. If the pump is Check the acceptable
the pump contaminated, its pump performance
generates efficiency will as outlined in
excessive heat. deteriorate and Section 5. Change
manifest itself as a pump out as
case drain leak. necessary.

Pump is noisy. Pump is cavitating / If a piston pump is being Shut the system down.
aerating. starved of oil or has air
Make certain the inlet
trapped in the oil
to the pump is not
(aeration), it will
restricted.
sound noisy when
running. Make certain there are
no kinks, twists, or
obstructions in the
suction line.
5.3 HYDRAULIC PUMP (08/03/25) 5-03-008

5.3.5 Factors Affecting the Pump’s Life

The weak link of swashplate piston pumps is the slipper pad arrangement and there are a
number of conditions that may detrimentally affect the life of the pump by damage in this
area. Essentially there are five possible conditions which may contribute to a failure in this
area. These conditions are contaminated fluid, too high a vacuum at the pump’s inlet,
excessive case pressure, too low of an operating pressure, and cavitation/aeration.

5.3.5.1 Contaminated Fluid

Besides the obvious accelerated wear caused by contaminated fluid, in extreme cases
contaminants can also plug the lubrication passages in the piston/slipper pad area. The
principle of the slipper pad design is that the hydraulic force, which pushes the piston
towards the swashplate is counteracted by a pressure force acting in the opposite direction.
High-pressure oil in the piston chamber is routed via a drilling through the piston knuckle
and slipper pad to a recess between the slipper and swashplate. This area is designed to
have an effective area, which precisely balances the pressure forces caused by the piston.

1. If this passage becomes plugged with contamination…

2. Lubrication and hydrostatic balancing are lost here…

3. Which causes slipper pad failure.

Fig 5.3.4 Contamination

The relatively small drillings keep the leakage low and the volumetric efficiency in the pump
high. If the system has a high level of contamination it is possible that these drillings can
become plugged. This would lead to an accelerated failure of the slipper pad since both
lubrication and balancing forces would be lost.
5.3 HYDRAULIC PUMP (08/03/25) 5-03-009

5.3.5.2 Too High of Vacuum Condition

The piston/slipper assemblies are connected together via a crimp connection. This type of
connection is excellent under compression but cannot stand high tensile forces. During the
suction process, the piston is drawn back out of the bore because of the retaining plate
pulling on the slipper pad. If the vacuum at the pump’s inlet is too high it will oppose this
motion and the tensile force will increase to a point where two modes of failure occur.
1. The retaining plate flexes and allows the slipper to lose contact with the
swashplate. On the pressure side of the pump’s rotation, the slipper is once again
brought to contact as the high-pressure oil forces the piston back. At this point, the
slipper is damaged due to rounding of the slipper corners from uneven re-seating
contact. Repetition of this process will damage the slipper to a point where it can
no longer retain its lubricating pool of oil and the pump will fail.
2. The high vacuum forces the slipper pad to simply be pulled off the piston knuckle if
the tensile strength of the connection is overcome.
NOTE!
Unfortunately, it is difficult to detect this failure by listening to the operation
of the pump and the pump will keep running until it is destroyed.

1. Too much vacuum here…

2. Or too high a case pressure here…

3. Will cause slipper pad lift-off and
slipper/piston serration.

Fig 5.3.5 Too High of Vacuum Condition

5.3 HYDRAULIC PUMP (08/03/25) 5-03-010

5.3.5.3 Excessive Case Pressure

Excessive case pressure has the same effect on the piston/slipper assembly, as does the too
high of vacuum condition. As can be seen in Fig 5.3.6, the two areas actually work together
to force the piston to the left, causing a high tensile force in the piston/slipper connection.
Because of this, a marginal suction condition and a marginal case pressure condition may
work together to cause a failure of this type.

Fig 5.3.6 Excessive Case Pressure

In order to avoid damage by either of the above two conditions, the suction line and drain line
should be optimized. This means that the pump should always have a flooded suction
(mounted below the oil reservoir oil level) and there should be limited resistance in the
suction line itself. Therefore, the amount of bends should be minimized and only full area
shut-off valves should be used if required. The case drain should be full sized and as short as
possible back to the reservoir. It is not advisable to tee the case drain line in with any other
return lines and each pump case should be routed individually back to the reservoir.
5.3 HYDRAULIC PUMP (08/03/25) 5-03-011

5.3.5.4 Too Low an Operating Pressure

The running area between the slipper pad and the swashplate relies on high pressure oil for
lubrication. If the pressure at the outlet of the pump is too low (i.e. the pump outlet is
unloaded to tank), excessive wear will occur in this area causing premature pump failure.

5.3.5.5 Cavitation/Aeration
Cavitation results when air, which is typically entrained or dissolved in the hydraulic fluid, is
allowed to expand because of a low-pressure situation. This occurs in pump inlets, which by
nature have a low-pressure condition. The expanded gas bubbles at the inlet collapse with
considerable force as the pumping chamber is exposed to system pressure. This collapsing
action results in rapid energy losses in the form of heat and noise. This energy level is also
high enough to cause serious damage to the lens plate and/or the cylinder barrel of the
pump.
Aeration is somewhat different than cavitation, however the resulting noise and damage to the
pump is nearly identical. Aeration occurs when there are air bubbles present in the reservoir
fluid at atmospheric pressure (typically caused by excessive foaming or vortexing at the
pump inlet). These air bubbles are then drawn into the inlet line of the pump and ultimately
cause of the same damage as described in cavitation.

Damage caused by
cavitation and / or
aeration

Fig 5.3.7 Cavitation / Aeration

5.3 HYDRAULIC PUMP (08/03/25) 5-03-012
5.4 HYDRAULIC CYLINDERS (08/03/25) 5-04-001

5.4 Hydraulic Cylinders

All cylinders are double acting.

PM Tasks
The cylinder rods are the main source where contamination enters the hydraulic system. Any
surface damage on the cylinder rods hold foreign matter that is absorbed into the hydraulic
fluid. Keep the cylinders clean and in good condition. If premature cylinder failure is
suspected, perform the cylinder inspection noted below.

250 Hour Intervals:  Wash and inspect cylinder rods, rod wipers
1000 Hour Intervals:  Wash and inspect cylinder rods, rod wipers
 Inspect cylinder operation

NOTE: Washing cylinder rods extends seal life.

5.4 HYDRAULIC CYLINDERS (08/03/25) 5-04-002

5.4.1 Double Acting Cylinders

1. Dismantle each double acting cylinder separately. Clean and degrease all parts
and tools contacting seals.
2. Deburr sharp edges that may contact seals.
3. Use hydraulic fluid on parts and seals before installation.

5.4.2 Cylinder Inspection

Perform a cylinder inspection if premature cylinder failure is suspected.
1. Improper installation of seals is apparent when cuts or nicks in seals are noticed.
This is the most frequently occurring problem.
2. Break-down or softening of seals may indicate incompatible seal types.
3. Physical damage of seals may indicate fluid contamination. Most external
contamination enters the system during rod retraction. Look for scratched rod
and cylinder surfaces.
4. Hardening of seals may indicate hot running conditions.

5.4.3 Cylinder Overhaul

Seal types must be compatible with the fluid and temperature range. Refer to the Parts Manual
for service kits.
1. Clean, inspect, and replace all parts. Lubricate seals and all parts that contact
seals.
2. Referring to Parts Manual, reassemble cylinder in reverse order.
5.5 CONTROL VALVES – ON/OFF TYPE (08/03/25) 5-05-001

5.5 Control Valves – On/Off Types

The control valves are load-sensing types. Valves, which control cylinders, are equipped with
closed center spools. Valves, which operate motors, are fitted with open center spools.
Proportional models are used where variable flow is required and On-Off types are installed
in the remaining applications (see next page). Depending on the drill’s options, the valves
are manually or electrically operated. Refer to the Troubleshooting Section and Electrical
Section when determining operating problems.

PM Tasks
Periodic maintenance is limited to external inspections. Overhauling the control valves includes
replacing O-rings, seals, and setting the pressure and flow. See Valve Specifications (next
page) for these settings. If additional parts need servicing, it may be more economical to
replace the individual valve sections.
1000 Hour Intervals:  Visual inspection

2000 Hour Intervals:  Visual inspection; operate controls to check for proper
operation

WARNING!
After installing hydraulic components and hoses, check that hydraulic
actuators are operating in direction as indicated on controls.
CAUTION!
Two types of valves are used: On/Off and Proportional.
5.5 CONTROL VALVES – ON/OFF TYPE (08/03/25) 5-05-002

Controls Valve Type Flow Rating Pressure Setting Flow Setting

Upper Breakout Clamp On/Off 26.4 gpm (100 l) Note 1 Wide open

Lower Breakout Clamp On/Off 26.4 gpm (100 l) Note 1 Wide open

Cab Tilt On/Off 1.3 gpm (5 l) Note 1 Note 2

Cab Swing On/Off 1.3 gpm (5 l) Note 1 Note 2

Oscillation On/Off 1.3 gpm (5 l) Note 1 Wide open

Winch On/Off 10.6 gpm (40.1 l) 1500 psi (103 bar) Note 2

Breakout On/Off 2.6 gpm (9.8 l) Note 1 Wide open

Centralizer On/Off 6.6 gpm (25 l) 1500 psi (103 bar) Wide open

Air On/Off 1.3 gpm (5 l) 1000 psi (68.9 bar) Wide open

Diverter On/Off 2.6 gpm (10.0 l) Note 1 Wide open

Carousel Arm On/Off 10.6 gpm (40.1 l) 2800 psi (193 bar) Note 2

Carousel Clamp On/Off 10.6 gpm (40.1 l) 2800 psi (193 bar) Wide open

Carousel Motor On/Off 2.6 gpm (10.0 l) Note 1 Note 2

Notes:
Note 1: Not applicable.
Note 2: Adjust to a speed that feels comfortable to the operator.

Relief Valve Setting:

See schematics.

NOTE: On/Off valves are equipped with black connectors.

5.5 CONTROL VALVES – ON/OFF TYPE (08/03/25) 5-05-003

5.5.1 Control Valves

The valve banks consist of five major components, which are the valve section, lever assembly,
end plate, inlet section, and solenoid (see Fig 5.5.1). Malfunctioning of the control valves
could be a mechanical, hydraulic or electrical problem. Therefore, each criterion needs to
be checked. Refer to the Troubleshooting Section when determining operating problems.

Fig 5.5.1 Valve Adjustment

5.5 CONTROL VALVES – ON/OFF TYPE (08/03/25) 5-05-004

5.5.2 Relief Valve Adjustment

Each valve bank has its own internal relief valve that needs to be adjusted when the control
valves are serviced. The relief valve is located in the inlet section (see Fig 5.5.2).
NOTE: Operating pressure in hydraulic pump must be set correctly before performing this
adjustment.
1. Remove protective cap on inlet section for relief valve.
2. Move cylinder to full stroke.
Block movement of any small cylinder to build up pressure.
WARNING!
Check that blocking does not move when force is applied.
3. Open control valve to blocked cylinder and observe hydraulic pressure gauge.
Adjust relief valve setting to 3200 psi (221.1 bar). Reinstall cap and remove
blocking. Reset pump pressure to specification (max pressure).

5.5.2 Relief Valve Adjustment

5.5 CONTROL VALVES – ON/OFF TYPE (08/03/25) 5-05-005

5.5.3 Valve Pressure Adjustment

The valves do not require any periodic adjustment after the initial setting. After servicing the
valves, set the pressure adjustment for both ports as shown in Fig 5.5.1 using the pressure
setting listed in the Valve Specifications.
NOTE: On rotation valve, reverse pressure is much higher than forward pressure to allow
for breaking of tool joints.
1. Block movement of any small cylinder to build up pressure.
WARNING!
Check that blocking does not move when force is applied.
2. Remove caps at valve section. Refer to pressure settings listed in Valve
Specification at the beginning of Section 5.5.
3. Adjust both ports independently while observing pressure gauge at control panel.
A 6 mm allen key is required. Each rotation of 360° creates a pressure change of
1400 psi (96.7 bar).
4. Reinstall caps and remove testing equipment.

5.5.4 Valve Flow Adjustment

The flow adjustment screws are located on the handle section, as illustrated in Fig 5.5.2. The
upper setting screw controls port ‘B’ and the lower setting screw controls port ‘A’.
1. Loosen lock nuts. Note flow setting listed in Valve Specifications at the beginning
of Section 5.5.
2. Adjust both ports independently, using allen key.
NOTE: Water pump is run proportionally.
3. Tighten lock nuts at flow adjustment and remove testing equipment.

5.5.5 Valve Overhaul

Overhauling any of the five valve components requires replacing of seals and O-rings. Work on
each section separately to avoid mixing of parts with other valve sections. Wash the body
and parts in solvent, and dry with compressed air. Inspect moving parts for wear and replace
as required. Lubricate moving parts and O-rings with hydraulic fluid. When ordering
replacement parts, specify the serial number and model of the drill.
5.5 CONTROL VALVES – ON/OFF TYPE (08/03/25) 5-05-006
5.5 CONTROL VALVES – ON/OFF TYPE (08/03/25) 5-05-007

5.5.6 Valve Sections

All O-rings must be replaced between each valve section (see Fig 5.5.3).

1. Remove nuts (1) and studs (3) to disassemble valve sections.

2. Replace O-rings 4, 5, 6, and 7. Reassemble in reverse order and torque nuts (1)
to 200 in-lbs (23 N-m).

5.5.7 Solenoid
The solenoid is not serviceable and must be replaced when malfunctioning. A special
adjustment procedure may be required for the rotation and feed valves. Refer to Solenoid
Adjustment in this section if the joystick movements produce uneven speeds in both
directions.
1. Remove solenoid as shown in Fig 5.5.4.
2. Replace filter (7) and O-rings (8 and 9).
3. If electrical connector is damaged, replace it with connector of same color for
ease of identification (See Valve Specifications).
4. Reassemble in reverse order and torque capscrew (2) to 70 in-lbs (8 N-m).

5.5.8 Lever Section

The handle section does not require frequent servicing (see Fig 5.5.5).
1. Replace damaged parts as well as O-rings (9 and10) located between handle
section and valve.
2. Reassemble and torque items 2, 4, 5, and 7 to 70 in-lbs (8 N-m).
3. Set Flow Adjustments, as outlined previously in this section.
5.5 CONTROL VALVES – ON/OFF TYPE (08/03/25) 5-05-008
5.5 CONTROL VALVES – ON/OFF TYPE (08/03/25) 5-05-009

5.5.9 Valve Assembly

Fig 5.5.6 is a general assembly diagram and may show some additional parts. Therefore, it is
critical to specify the model and serial number when ordering replacement parts. Work on
one valve section at a time, to avoid mixing of parts.
1. Dismantle valve section as shown.
2. Install required parts, making sure that new parts are identical to existing ones.

3. Torque fasteners as follows:

Item 17 and 19 360 in-lbs (40 N-m)
Item 3 220 in-lbs (25 N-m)
Item 15 70 in-lbs (8 N-m)
4. Set Pressure Adjustment, as outlined previously in this section.

5.5.10 Inlet Section

The inlet section contains the relief valve. Fig 5.5.7 is a general assembly diagram and may
show some additional parts. Therefore, it is critical to specify the model and serial number
when ordering replacement parts.
1. Dismantle inlet section as shown. Inspect, clean and replace parts as required.
2. Torque fasteners as follows:
Item 3 360 in-lbs (40 N-m)
Item 13 and 15 220 in-lbs (25 N-m)
Item 6 and 23 70 in-lbs (8 N-m)
3. Assemble and install complete valve bank into drill.
4. Start hydraulic pump and adjust relief valve in inlet section, as outlined
previously in this section.
5.5 CONTROL VALVES – ON/OFF TYPE (08/03/25) 5-05-010
5.6 MANIFOLD BLOCKS (08/03/25) 5-06-001

5.6 Manifold Blocks

The Accra-Feed manifold (see Fig 5.6.1) contains cartridge valves that control the Accra-Feed
functions.
The Pipe Arm Sequence manifold (see Fig 5.6.3) contains cartridge valves that control the pipe
arm sequence functions.
The TJBO manifold (see Fig 5.6.4) contains cartridge valves that control the triple jaw
breakout functions.

5.6.1 Servicing Cartridge Valves

Cartridge valves are basic service items; they are easily removed from their mounting in the
cavity for cleaning or replacement. It is not necessary to remove an entire cartridge valve
assembly, i.e. cartridge/body assembly, from the circuit piping or solenoid valve stack.
Simply unscrew the cartridge valve from its mounting configuration for troubleshooting or
replacement.
Ensure that all loads are adequately supported and the system is depressurized before
performing any service work.
While considered service items, cartridge valves are not designed to be disassembled in the
field. If, for any reason, a cartridge valve does not perform as required, follow the trouble
shooting steps that follow. If the cartridge still does not function, it should be replaced.

5.6.2 Troubleshooting Cartridge Valves

The most common cause of failure of a cartridge valve is contamination in the hydraulic fluid,
which can then lodge in the working parts of the cartridge and interfere with their
operation. If necessary, the following cartridge valves can be easily cleaned without
altering their settings: RP**, RV**, RS**, PB**, PP**, FX**, LP**, and LR**.
1. First secure any moving elements associated with the equipment and ensure that all loads
are adequately supported.
2. Carefully de-pressurize the hydraulic system.
3. Remove the cartridge from its cavity.
4. Inspect the cartridge for visible contaminants and, if found, carefully remove any obvious
particles.
5. Through the nose of the cartridge, manually operate the inner working parts several times.
Use a piece of plastic tubing to avoid damaging soft seats, sharp edges, finished surfaces or
the screen protecting the pilot orifice. All parts should move freely. If possible, this
inspection should be done with the cartridge submerged in clean mineral spirits.
6. After flushing, blow-dry the cartridge with clean, filtered air.
7. Replace any seals that are worn or damaged, using the appropriate seal kit.
5.6 MANIFOLD BLOCKS (08/03/25) 5-06-002

Accra-Feed Manifold
Air Pressure
Transducer
Rotation
Pressure Switch
(not installed
in this picture) Low
Compressor
Oil Switch

Tram High/Low
Pressure Reducing
Valve

Carousel Pressure
Tram High/Low Reducing Valve
Selector Valve

Fig 5.6.1 Accra-Feed Manifold and surrounding components

Accra-Feed Manifold located behind the panel

Fig 5.6.2 Accra-Feed Manifold location

5.6 MANIFOLD BLOCKS (08/03/25) 5-06-003

8. Dip the cartridge in clean hydraulic fluid, and then reinstall the cartridge and tighten to the
specified torque and retest.
9. If this procedure does not eliminate the operational problem, replace the malfunctioning
cartridge with a new, factory-tested cartridge valve.

Pipe Arm Sequence Manifold

located on the mast

Fig 5.6.3 Pipe Arm Sequence Manifold

5.6 MANIFOLD BLOCKS (08/03/25) 5-06-004

5.6.3 Installation Torque Values

When installing cartridge valves, torque to values shown in Table 8.

Table 8 Cartridge Valve Torque Values

Series Torque (ft-lbs) Hex Thread Cavities
Z 100-120 (lb-in) 3/16” 3/8” – 24 UNF T-382A
P 25 – 30 7/8” M16 T-8A, T-9A
0 25 – 30 3/4” M16 T-162A, T-163A
T-10A, T-11A,
1 30 – 35 7/8” M20 T-13A, T-21A,
T-31A, T-61A
T-2A, T-3A,
2 45 – 50 1 1/8” 1”-14UNS T-5A, T-22A,
T-32A, T-62A
T-16A, T-17A,
3 150 – 160 1 1/4” M36 T-23A, T-33A,
T-63A
T-18A, T-19A,
4 350 – 375 1 5/8” M48 T-24A, T-34A,
T-64A

TJBO Manifold located on

the mast

Fig 5.6.4 TJBO Manifold location

5.7 COUNTERBALANCE VALVES (08/03/25) 5-07-001

5.7 Counterbalance Valves

Counterbalance valves with pilot assist combine two valves; a check valve and a relief valve.
The check valve allow free flow from the directional valve (port 2) to the load (port 1)
while a direct acting, pilot-assisted relief valve controls flow from port 1 to port 2. Pilot
assist at port 3 lowers the effective setting of the relief valve at a rate determined by the
pilot ratio.

Fig 5.7.1 Counterbalance Valve

5.7 COUNTERBALANCE VALVES (08/03/25) 5-07-002

The counterbalance valve will be one of the most difficult valves you will have to ‘set’ on a
piece of equipment. It is difficult to determine the setting of the valve while in the circuit
in the usual manner. Because of this, the counterbalance valve has to be ‘bench set’ off the
machine with a special block for this purpose.
You will need the following items to set the counterbalance valve:

 A pressure gauge that is suitable for the pressure involved

 A Sun Hydraulics P/N BCJ/S body with a T-2A cavity (test block)
 A hydraulic hand pump
 Miscellaneous hoses and fittings
See Fig 5.7.2 for set-up.

5.7.1 Making Adjustments

Before removing the counterbalance valve, ensure machines and loads (i.e. top drive) are
mechanically held in position or at rest. Also make sure that the valve is not under pressure
at the time of removal.
1. Remove the counterbalance valve and install into testing block.
2. Loosen lock-nut on counterbalance valve.
3. Insert an allen key into the adjusting screw and turn out (counter-clockwise) to
increase the pressure setting or in (clockwise) to reduce the pressure setting.
4. While looking at gauge, pump up test system pressure with hand pump and set
valve to relieve at recommended setting. See Fig 5.7.1 for location of setting on
valve.
5. Repeat several times to ensure the consistency of the setting.

Fig 5.7.2 Test Gauge

5.7 COUNTERBALANCE VALVES (08/03/25) 5-07-003

5.7.2 Troubleshooting
The most common cause of failure of a counterbalance valve cartridge is seal failure or
contamination in the hydraulic fluid, which can then lodge in the working parts of the
cartridge and interfere with their operation. The major symptom of a failed counterbalance
valve is ‘creeping’ in the cylinder.
1. Before removing the counterbalance valve, ensure machines and loads (i.e. top
drive) are mechanically held in position or at rest. Also make sure that the valve
is not under pressure at the time of removal.
2. Remove the cartridge from its cavity.
3. Inspect the cartridge for visible contaminates, if found, carefully remove any
obvious particles.
4. Flush the cartridge in clean mineral spirits and blow dry with clean dry air.
5. Replace any seals that are worn or damaged.
6. Dip the cartridge in clean hydraulic fluid and re-install the cartridge tightening to
the specified torque.
7. If this procedure does not eliminate the operational problem, replace the
malfunctioning cartridge with a new, factory tested cartridge.
5.7 COUNTERBALANCE VALVES (08/03/25) 5-07-004
5.8 HYDRAULIC FILTRATION (08/03/25) 5-08-001

5.8 Hydraulic Filtration

Change the hydraulic fluid at the recommended intervals to get maximum service life.

PM Tasks
250 Hour Intervals:  Change filters
 Check filter indicators for proper operation
2000 Hour Intervals:  Change filters
 Change hydraulic fluid
 Clean pressure filter indicators

Filter Types: Pressure filter: Cartridge (3 micron)

Return filter: Cartridge (10 micron)

WARNING!
Disconnect power supply and mine air before servicing drill.
High pressure jet leaks may cause injury.
5.8 HYDRAULIC FILTRATION (08/03/25) 5-08-002

5.8.1 Change Hydraulic Fluid Every 2000 Hours

1. Drain hydraulic fluid and remove return filter cartridges.
2. Remove tank cover and clean tank. Flush as required.
3. Reinstall tank cover and new filter cartridges.
4. Fill with hydraulic fluid (Esso NUTO 46 or equal).

5.8.2 Return Filters

1. Insert a straight tool through the eye of the eye bolts on top of the return filter.
Use the tool to loosen and remove the bolts. Remove filter element and wipe
inside of filter housing. Check that bypass valve and cap seal are not damaged.
2. Lubricate seal on new filter element. Install filter and tighten end cap.
3. Start system, check for leaks and proper operation of filter bypass indicator.

Eye Bolt

Fig 5.8.2 Return Filter

5.8 HYDRAULIC FILTRATION (08/03/25) 5-08-003

5.8.3 Pressure Filter Element

Replacing the pressure filter element and servicing the filter indicator are performed at
different intervals.
1. Remove drain plug from filter bowl to drain fluid.
2. Remove bowl and element, then clean inside of filter head and bowl.
3. Install new element with new O-ring which has been lubricated. Reinstall
remaining filter parts.
4. Check fluid level then start system to check for leaks. If filter indicator is not
performing properly, replace bypass valve inside filter head and service indicator.
When replacing bypass valve, remove filter bowl and filter indicator. Remove
outlet hose connection and unscrew bypass valve by inserting suitable tool into
holes provided.

Fig 5.8.4 Pressure Filter Assembly

5.8 HYDRAULIC FILTRATION (08/03/25) 5-08-004
5.9 PROPORTIONAL VALVES (08/03/25) 5-09-001

5.9 Proportional Valves

Proportional load-sensing type valves are used where variable flow is required. Refer to the
Troubleshooting Section and Electrical Section when determining operating problems.

PM Tasks
Periodic maintenance is limited to external inspections. Overhauling the control valves
includes replacing O-rings, seals and setting the pressure and flow. See Section 5.9.1
Proportional Valve Settings for these specifications. If additional parts need servicing, it
may be more economical to replace the individual valve sections.

1000 Hour Intervals:  Visual inspection

2000 Hour Intervals:  Visual inspection
 Operate controls to check for proper operation

WARNING!
After installing hydraulic components and hoses, check that hydraulic
actuators are operating in direction as indicated on controls.

Operating pressure in hydraulic pump must be set correctly before performing

this adjustment.
Improper Makeup & Breakout Speed may damage equipment or drill pipes.

All proportional valves are equipped with white/grey connectors.

These instructions apply to proportional valves only.

Copyright © Sandvik Mining and Construction

5.9 PROPORTIONAL VALVES (08/03/25) 5-09-002

5.9.1 Proportional Valve Settings

Controls Valve Type Flow Rating Pressure Setting Flow Setting

Tram, left Proportional 47.0 gpm (177.9 l) N/A Wide open

Tram, right Proportional 47.0 gpm (177.9 l) N/A Wide open

Rotation Proportional 47.0 gpm (177.9 l) See Note 1 Wide open

Feed Proportional 47.0 gpm (177.9 l) N/A Wide open

Water Pump Proportional 10.6 gpm (40.1 l) N/A Wide open

Feed Extension Proportional 10.6 gpm (40.1 l) See Note 2 Wide open

Mast Swing Control Proportional 10.6 gpm (40.1 l) See Note 2 Note 3

Mast Dump Proportional 10.6 gpm (40.1 l) See Note 2 Note 3

Boom Swing Proportional 6.6 gpm (25 l) See Note 2 Note 3

Boom Lift Proportional 10.6 gpm (40.1 l) See Note 2 Note 3

Notes: 1. Forward pressure: 1600 psi (110 bar), Reverse pressure: 3200 psi (220.6 bar). Reverse pressure is much
higher than forward pressure to allow for breaking of toll joints.
2. Not applicable
3. Adjust to a speed that feels comfortable to the operator.

Copyright © Sandvik Mining and Construction

5.9 PROPORTIONAL VALVES (08/03/25) 5-09-003

5.9.2 Flow Settings

Proportional valves are used in Tram, Rotation, and Feed controls.
Refer to Section 5.9.1 Proportional Valve Settings when adjusting flow in each valve section.

Fig 5.9.1 Flow Adjustment

Copyright © Sandvik Mining and Construction

5.9 PROPORTIONAL VALVES (08/03/25) 5-09-004

5.9.3 Pressure Setting

Proportional valves are used in Tram, Rotation, and Feed controls.
Refer to Section 5.9.1 Proportional Valve Settings when adjusting pressure in pump side
module.

Fig 5.9.2 Adjusting Screw

1. Remove cap.
2. Loosen setting screw.
3. Loosen counter nut by turning it a few times.

Fig 5.9.3

Copyright © Sandvik Mining and Construction

5.9 PROPORTIONAL VALVES (08/03/25) 5-09-005

4. Set pressure according to Section 5.9.1 Proportional Valve Settings.

5. Turn counter nut to end stop against setting screw.

Fig 5.9.4

6. Turn setting screw in reverse direction with specified torque.

7. Mount protective plug and tighten as specified torque.

Fig 5.9.5

Copyright © Sandvik Mining and Construction

5.9 PROPORTIONAL VALVES (08/03/25) 5-09-006

Copyright © Sandvik Mining and Construction

6.0 DRILL AIR CIRCUIT (08/03/25)

6.0 DRILL AIR CIRCUIT

WARNING!
Wipe up spills immediately!

Copyright © Sandvik Mining and Construction

Copyright © Sandvik Mining and Construction
6.1 AIR SCHEMATIC (08/03/25) 6-01-001

6.1 Air Schematic

See the Appendix for a full size schematic.

Fig 6.1.1 Air Schematic

Copyright © Sandvik Mining and Construction

6.1 AIR SCHEMATIC (08/03/25) 6-01-002

Copyright © Sandvik Mining and Construction

6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-001

6.2 Sullair Compressor

Your new DR Drill is equipped with an onboard two stage, high-pressure Sullair rotary screw
compressor, offering superior performance and reliability along with a minimal amount of
maintenance requirements.
Compared to other compressors, the Sullair is unique in mechanical reliability with virtually no
wear or loss of performance. With Sullair compressors, no inspection is required of the
working parts within the compressor unit.
The package includes a compressor unit, cooling and lubricating system, air inlet system,
compressor discharge system, capacity control system and instruments.

Fig 6.2.1 Compressor

6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-002

Housing unit showing air cavities and rotor bearing

Rotors: driving and driven End Housing

Housing with Rotors installed

Fig 6.2.2
6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-003

6.2.1 Compressor Unit Functional Description

Refer to Fig 6.2.2 and Fig 6.2.3
The compressor unit supplied with this drill is a two-stage positive displacement, high pressure,
flood lubricated type rotary screw air compressor.
Each stage of the compressor utilizes two rotors to compress the incoming air. In the first
stage, air is drawn in through the inlet system and introduced to the rotors. A driven male
rotor drives a female rotor and as they turn the air is compressed and forced around to the
discharge side where it is then discharged to a manifold connecting it to the high-pressure
stage. The process is then repeated to obtain an even higher pressure. The quantity of air
can easily be controlled by regulating the amount of incoming air or by varying the speed at
which the unit rotates. The speed of the unit can be varied by engine speed or changing gear
sets.
NOTE: Each Sullair rotary screw compressor uses oil as a lubricant sealant and coolant
medium (mineral or synthetic). Due to the many types of oil used in the marketplace,
this section will refer to oil as “fluid”.
Fluid is injected into the compressor and mixes directly with the air as the rotors turn,
compressing the air. The fluid has three main functions:
 As coolant, it controls the rise of air temperature normally associated with the heat of
compression.
 It seals the leakage paths between the rotors as well as between the rotors and stator.
 It acts as a lubricating film between the rotors allowing the male rotor to directly drive
the female rotor, which is an idler.
After the air has been compressed, it is discharged in the form of an air/fluid mixture. This
mixture is routed through the discharge system where the fluid is separated from the air. At
this time the air flows to the service line and the fluid is directed through the cooling and
lubricating system in preparation for re-injection.

Low Stage
High Stage

Fig 6.2.3 Compressor

6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-004

Air Filter
(within)

Receiver Tank

Oil Fill Plug

Sight Glasses
Correct level is halfway up the
middle sight glass

Fig 6.2.4 Receiver Tank and Components

Fig 6.2.5 Separator Element and Components

6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-005

6.2.2 Compressor Discharge System Functional Description

The Sullair compressor unit discharges a compressed air/fluid mixture into the receiver tank.
The discharge valve is located on the compressor unit at the end opposite the drive shaft.
The discharge check valve prevents discharged air from returning from the compression
chamber or receiver tank on shut down.
From the discharge valve the air/fluid mixture is directed to the receiver tank. The receiver
tank has four basic functions:
 Acts as a primary fluid separator.
 Serves as the compressor fluid sump.
 Houses the final fluid separator.
 Serves as an air tank receiver.
The compressed air/fluid mixture enters the receiver tank and is directed against the end of
the tank. By change of direction and reduction of velocity, larger droplets of fluid fall to the
bottom of the receiver tank. The fractional percentage of fluid remaining in the compressed
air collects on the surface of the final separator element as the compressed air flows
through the separator. As more and more fluid collects in the element surface, the fluid
descends to the bottom of the separator. A return line (or scavenger tube) leads from the
bottom of the separator element to the gear case of the compressor unit. Fluid collecting on
the bottom of the separator unit is returned to the compressor gear case. An orifice
(protected by a strainer) is included in this return line to assure proper flow.
The receiver tank is ASME code rated at 550 psi (37.69 bar) working pressure. A minimum
pressure valve is located downstream from the separator to assure the required minimum
receiver pressure during all conditions. This pressure is necessary for proper fluid circulation
and air/fluid separation.
The system is protected from excessively high receiver tank pressures by a 550 psi (37.69 bar)
pressure relief valve, which is located on the wet side of the separator and is vented to
atmosphere. Also, a High Compressor Discharge Temperature Shut Down (the compressor
will shut down at 300°F) and High Interstage Temperature Shut Down (set at 280°F) will shut
the compressor unit down if the temperature exceeds the normal operating range.
Fluid is added to the receiver tank via a capped fluid filler opening placed low on the tank to
prevent overfilling to the receiver tank. A sight glass enables the operator to visually
monitor the fluid receiver tank level. The proper level is halfway of the sight glass when the
unit is shutdown. DO NOT OVERFILL.
A hydraulically operated 2-inch ball valve is used to open and close the discharge air when
required.
WARNING!
DO NOT open the fluid filler cap when the compressor is pressurized. Shut down
the compressor and bleed the receiver tank to 0 psi before removing the cap.
6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-006

C - From Cooler

B - To Cooler
A - From Tank

D - To Compressor

Port Stamped on Valve Ports Stamped on Valve

Fig 6.2.5 Thermal Valve Entrance/Exit Ports

6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-007

6.2.3 Compressor Cooling and Lubrication System Functional

Description
The compressor cooling and lubricating system is designed to provide adequate lubrication as
well as maintain the proper operating temperature of the booster. In addition to a cooler
and fan, the system consists of a main fluid filter, thermal valve, fluid stop valve, and
pressure bypass valve.
Fluid is used in the system as a coolant and a lubricant. The fluid is housed in a receiver/sump.
Upon start-up, the temperature of the fluid is cool and routing to the fluid cooler is not
necessary. The fluid, taking the path of least resistance, flows through the thermal valve to
the compressor unit.
The thermal valve has two entrance ports and two exit ports. Refer to Fig 6.2.5. These ports
are stamped on the thermal valve body indicating:
A - From tank
B - To cooler
C - From cooler
D - To compressor
As previously stated, upon start-up the fluid temperature is cool and routing to the cooler is
not required. The fluid first enters the thermal valve and then flows on to the compressor
unit, bypassing the cooler. As the compressor continues to operate, the temperature of the
fluid rises and Port A of the thermal valve begins to close. The closing of Port A forces a
portion of the fluid through the fluid cooler.
The cooler is a radiator type cooler that works in conjunction with the fan. The fan forces air
through the cooler removing the heat of compression from the fluid. From the cooler, the
fluid is routed back to the thermal valve, entering at Port C. Before the temperature of the
fluid becomes high enough that Port A is completely closed, cooled fluid at Port B is mixed
with warmer fluid entering Port A. When the temperature of the fluid reaches 210°F (99°C)
Port A is completely closed causing all fluid to flow to the cooler.
The pressure bypass valve insures a supply of fluid to the compressor during periods of
excessive pressure drops across the cooler, which may occur in extremely cold weather.
After the fluid passes through the thermal valve, it is then directed through the main fluid
filter. There the fluid is filtered in preparation for injection into the compression chamber
and bearings of the compressor unit.
The filter has a replaceable element and a built-in bypass valve, which allows the fluid to flow
even when the element becomes plugged and requires changing, or when the viscosity of the
fluid is too high for adequate flow. After the fluid is properly filtered, it lubricates, seals,
and cools the compression chamber as well as lubricates the bearings and gears. The fluid
stop valve is held open by a pressure signal from the compressor unit.
6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-008

At shutdown, the pressure signal is lost and the fluid stop valve closes, isolating the compressor
unit from the cooling system.
A Low Oil Pressure Shut Off (set at 90 psi) will shut the compressor unit down in the event of
low or no oil pressure.

Fig 6.2.6 Fluid Stop Valve

Fig 6.2.7 Main Compressor Fluid Filter

6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-009

6.2.4 Air Inlet System Functional Description

The compressor inlet system consists of an air filter, restriction indicator, and interconnecting
piping to the compressor.
The air filter is a two-stage dry element type filter. This filter, which incorporates a dust
removal system that utilizes the exhaust to aid in keeping the filter clean, is capable of
cleaning extremely dirty air. In these conditions, it is recommended to clean the air filters
on a regular basis and to check the air filter restriction indicators daily.
The air filter restriction indicator (see DR operators manual for location) will show a red signal
when the restriction of the air passing through the filter becomes too high.
At this time, change the air filter element and manually reset the restriction indicator. The
indicator should be checked daily, after start-up under normal conditions.

Compressor Air
Filter
Engine Air
Filters

6.2.8 Air Inlet System

6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-010

6.2.5 Lubrication Guide

The reliability of the unit is dependant upon the selection and maintenance of the lubricant.
The ambient temperature, relative humidity, discharge pressure, and contamination levels
must be considered in the lubrication selection. All lubrication oil(s) mentioned will be
referred to as “fluid”.

Ambient Temperature Lubricant Change Interval – Hours

-40C to -10C Esso Mobil Rarus SHC1024 1000 hrs

-40F to +14F

-10C to +40C Esso Mobil Rarus SHC1024 1000 hrs

+14F to +104F

Over +40C Esso Mobil Rarus SHC1026 1000 hrs

Over +104F

6.2.6 Application Guide

Water must be drained from the receiver periodically. In high ambient temperature and high
humidity conditions, condensed moisture may emulsify with the oil forming a “milky” color.
ATF is especially prone to this condition. The fluid should be changed if this condition
develops.
DO NOT mix different types of fluids. Combinations of different fluids may lead to operational
problems such as foaming, filter plugging, orifice or line plugging.
When ambient conditions exceed those noted or if conditions warrant the use of other
extended life lubricants, contact your dealer for recommendations.
We encourage the user to participate in a fluid analysis program. This could result in a fluid
change interval differing from that stated in the manual.

Copyright © Sandvik Mining and Construction

6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-011

6.2.7 Control System

6.2.7.1 Purpose of Controls

Fig 6.2.9 Purpose of Controls

Copyright © Sandvik Mining and Construction

6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-012

Control or Indicator Key # Purpose

Compressor 75 Two-Stage Screw Compressor

Receiver Tank Assembly 49 Acts as a fluid separator, sump, and air filter

Safety Relief Valve 46 Opens receiver/sump pressure to the atmosphere should

pressure inside the receiver/sump tank exceed 550
psi (37.5 bar). Located on the wet side of the tank

Minimum Pressure Valve 47 Maintains required minimum pressure in the

receiver/sump tank. This valve restricts the air
discharge from the receiver/sump when the pressure
falls below the minimum operating pressure.
However, full flow is allowed at normal operating
pressures.

Separator Restriction Indicator 51 Indicates required servicing of fluid filter. The indicator
will read in the red zone when a pressure drop
through the filter is excessive.

Oil Return Line Strainer 65 A wire mesh strainer for filtering coarse contaminates in
the return line from the separator.

Sight Glass 71 Used to indicate flow of fluid going back to the

compressor unit from the fluid pickup in the
receiver/sump tank. When the compressor is running
at full load, fluid flow should be visible in this sight
glass. There may be little or no flow when the
compressor is running unloaded. A sluggish flow at
full flow indicates a need to clean the fluid return
line strainer and/or orifice.

Orifice 72 Maintains the correct oil flow from the scavenger line.

Thermal Bypass Valve 63 Controls direction of fluid through the oil cooler
depending on the temperature of the fluid.

Main Fluid Filter 64 Filters fluid prior to injection into compressor.

Oil Stop Valve 68 Cuts off fluid flow to the compressor unit upon
shutdown. On start-up, it allows fluid to flow to the
compressor.

Oil Cooler 56 Removes heat of compression from the fluid.

Manual Drain Valve 48 Manual valve for draining receiver tank.

Copyright © Sandvik Mining and Construction

6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-013

Control Line Moisture Separator 50 Removes vaporized moisture, fluid, contaminates in a

filter medium where they are merged as droplets
which collect in a drain area. The drain area is
cleared by hand through the petcock at the bottom.
It is recommended that this be done daily or more
frequently under severe conditions.

Control Line Pressure Gauge 52 0-600 psi pressure gauge

500 psi Pressure Regulator 13 Operates the running blowdown valve while opening a
pressure line between system pressure and the inlet
control cylinder when in High mode. This allows the
inlet control cylinder to regulate air delivery
according to air demand. It is set at 500 psi.

350 psi Pressure Regulator 13 Operates the running blowdown valve while opening a
pressure line between system pressure and the inlet
control cylinder when in High mode. This allows the
inlet control cylinder to regulate air delivery
according to air demand. It is set at 350 psi.

350 psi Mode Selector Valve 53 Used to select High or Low air mode.

Check Valve 59 Prevents the flow of air in the wrong direction.

180 psi Mode Selector Valve 41 Used to select High or Low air mode.

Low Pressure Regulator Valve 66 Operates the running blowdown valve while opening a
pressure line between system pressure and the inlet
control cylinder when in Low mode. This allows the
inlet control cylinder to regulate air delivery
according to air demand. It is set at 180 psi.

Inlet Cylinder Pressure Regulator 82 Opens a pressure line between the receiver/sump tank
and inlet control cylinder on the rod side of the
cylinder. This allows the inlet control cylinder to
regulate air delivery according to air demand. It is
set at 80 psi.

Air Inlet Control Cylinder 69 Regulates the amount of air allowed to enter the air
inlet valve. This regulation is determined by the
amount of air being used at the service line.

Muffler 57 Silences the discharge air from the running and

shutdown blowdown valves.

Copyright © Sandvik Mining and Construction

6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-014

Running Blowdown Valve 62 Vents excess receiver/sump pressure to the atmosphere

when receiver/sump exceeds the desired unload
pressure during operation.

System Blowdown Valve 58 Vents receiver/sump pressure to the atmosphere at

compressor shutdown

Discharge Check Valve 78 Cuts off reverse flow of air/fluid mixture through the
compressor discharge system at compressor
shutdown.

High Temp Shut-off Switch 79 Shuts down the compressor when the discharge
temperature exceeds normal operating range.

Temperature Gauge 77 Discharge temperature gauge located in the set-up and

tramming control panel.

Low Oil Pressure Switch 73 Shuts down compressor if the fluid pressure going to the
compressor unit bearings is insufficient.

Inter-stage High Temp Shutdown 80 Shuts down compressor when the inter-stage
temperature exceeds normal operating range.

Manual Unload Valve 67 Valve to manually unload compressor.

Air Filter 76 A multi-staged dry-type filter assembly for filtering the

intake air.

Copyright © Sandvik Mining and Construction

6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-015

6.2.7.2 Butterfly Inlet Valve Functional Description

The purpose of the control system is to regulate the amount of air intake in accordance with
the amount of air being used. The 2-stage compressor is designed to operate in one of the
three modes of operation: the low-pressure mode up to (180 psi {12.4 bar}) and two high
pressure modes (350 psi {24.1 bar}) and (500 psi {34.5 bar}). The control system consists of
an inlet control cylinder, running blowdown valve, and the necessary linkage to connect the
inlet control cylinder to the inlet valve.
The position of the pressure selector determines the pressure that the control system will
respond to. The functional description of the control system is described in four distinct
phases of operation which (except for the start phase) apply to both high and low pressure
modes.

Butterfly
Inlet Valve

Inlet Control
Cylinder

Fig 6.2.11 Butterfly Inlet Valve

Copyright © Sandvik Mining and Construction

6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-016

6.2.7.3 Closed Inlet Start Program

The inlet system incorporates an inlet cylinder and a bypass solenoid valve, which allows the
compressor to start with the butterfly valve completely closed.
The solenoid valve is normally open and it controls the flow over the ¾” line that is bypassing
the butterfly valve.
The inlet cylinder is connected with linkage to the butterfly valve. The cylinder is completely
retracted when the compressor is not running, keeping the butterfly valve closed. System
pressure from the low/high regulators is applied to the rod end of cylinder and, together
with the spring inside the cylinder, tries to keep the cylinder closed. The piston side of the
inlet cylinder is supplied with system pressure, which is regulated down to 80 psi by the inlet
cylinder pressure reducing valve. Air flow from this pressure reducing valve to the inlet
cylinder is controlled with a 3-way solenoid directional valve.
This valve allows flow from the pressure reducing valve to the inlet cylinder when it is not
energized, and dumps the air pressure from the cylinder to the atmosphere and closes the
line to the pressure reducing valve when energized. Energizing this solenoid valve causes air
pressure from the piston side of the inlet cylinder to be dumped to the atmosphere and the
spring on the rod side of the inlet cylinder to retract the inlet cylinder, closing the butterfly
valve.
During start up, the bypass solenoid valve and the 3-way solenoid valves are energized, keeping
the bypass line and the butterfly valve fully closed. Closing the inlet line to the compressor
will disable the compressor to build up pressure and allow the engine to start with minimum
load. After 15 seconds, the bypass solenoid valve de-energizes and the compressor starts to
build pressure very slowly. After the oil pressure reaches 90 psi, the 3-way solenoid valve
de-energizes. This closes the vent line from the inlet cylinder to the atmosphere and opens
the line between the pressure reducing valve and the inlet cylinder, allowing pressure to rise
on the piston side of the inlet cylinder, until there is sufficient pressure to overcome the
spring on the rod side and stroke the cylinder. This opens the butterfly valve and the
compressor will build pressure very rapidly.

System
pressure from
high/low
regulators

From inlet cylinder

pressure regulator
(80 psi)
Muffler

Fig 6.2.12 Closed Inlet

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6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-017

During start up, the bypass solenoid valve and the 3-way solenoid valves are energized, keeping
the bypass line and the butterfly valve fully closed. Closing the inlet line to the compressor
will disable the compressor to build up pressure and allow the engine to start with minimum
load. After 15 seconds, the bypass solenoid valve de-energizes and the compressor starts to
build pressure very slowly. After the oil pressure reaches 90 psi, the 3-way solenoid valve
de-energizes. This closes the vent line from the inlet cylinder to the atmosphere and opens
the line between the pressure reducing valve and the inlet cylinder, allowing pressure to rise
on the piston side of the inlet cylinder, until there is sufficient pressure to overcome the
spring on the rod side and stroke the cylinder. This opens the butterfly valve and the
compressor will build pressure very rapidly.
When the system pressure rises over 180 psi, the low pressure regulator valve opens and air
pressure is supplied to the rod side of the inlet cylinder, helping the spring to overcome the
80 psi air pressure on the piston side of the same cylinder. This causes the cylinder to start
retracting, which partially closes the butterfly valve. Closing the butterfly valve reduces the
amount of air sucked into the compressor and slowing down the system pressure rise. At the
same time, air is also supplied to the pilot line of the running blowdown valve, opening the
running blowdown valve which bleeds air from receiver tank. Bleeding air from the receiver
tank and closing the butterfly valve stops system pressure rise and starts system pressure
decrease.
When the system pressure falls below 180 psi, the pressure regulator closes and air is not
supplied to the rod side of the inlet cylinder anymore. The small orifice with muffler bleeds
air from the rod side of the inlet cylinder, reducing the air pressure on this side of the
cylinder. Constant air pressure on the piston side overcomes the spring on the rod side,
causing the cylinder to start extending, which causes the butterfly valve to open. This
increases the amount of air sucked into the compressor and causes a system pressure rise in
the receiver tank.
This process repeats, trying to keep a constant system pressure.

6.2.7.4 Normal Operation

180 to 500 psi (12.4 to 24.13 bar) High Pressure
0 to 180 psi (0 to 12.4 bar) Low Pressure
When the sump pressure rises above the required minimum pressure, the minimum pressure
valve opens and delivers compressed air to the service line. The control pressure regulator
of either mode (Low or High) remains closed, keeping the inlet control cylinder inactive.
During this phase, the compressor is operating at the full capacity for the selected mode.

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6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-018

6.2.7.5 Modulation
180 to 500 psi (12.4 to 24.13 bar) High Pressure
180 to 200 psi (12.4 to 13.8 bar) Low Pressure
Should less than the rated capacity of air be used, the sump pressure will quickly rise to the
upper limit of the modulating range. At this point, the control pressure regulator will
gradually begin to open, applying pressure to the inlet control cylinder. This pressure causes
the cylinder rod to move, partially closing the compressor inlet butterfly valve.
The closing of the inlet butterfly valve reduces the amount of air entering the compressor until
it matches the amount of air being used. The modulating pressure reaching the running
blowdown valve is not sufficient to cause the valve to open.
The control system will continue to operate in this manner (between the limits of the
modulating range in response to varying demands for compressed air). The control cylinder
has an orifice, which vents a small amount of air to atmosphere when the regulator opens.
This increases the sensitivity of the control system as well as bleeds accumulated moisture
from the cylinder.

6.2.7.6 Unload
In Excess of 500 psi (24.13 bar) High Pressure
In Excess of 180 psi (12.4 bar) Low Pressure
When air requirements are reduced, the receiver tank pressure will rise above the modulating
valve range. The control pressure regulator is open and applying sufficient pressure to the
control cylinder to totally close the inlet valve. At the same time, the running blowdown
valve opens venting receiver tank pressure. This will prevent additional pressure build-up
due to the inlet valve leakage. The running blowdown system will continue to cycle as long
as no air is being used.
As requirements for air increase, receiver tank pressure will drop into or below the modulating
range and the control system will function in accordance with that particular phase. When
operating unattended for a period with no air, it is advantageous to switch the pressure
selector to low-pressure mode. This will reduce the receiver tank pressure and provide a
more economical operation.
When the compressor is shut down, the system shutdown blowdown valve will open and relieve
the receiver pressure.

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6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-019

6.2.7.7 Compressor Start Up Mode and Running Mode Low Air Pressure
Refer to Fig 6.2.13
The inlet system incorporates a Butterfly Inlet Valve to control the amount of air being
consumed by the compressor. The position of this valve is controlled by the Inlet Cylinder
and is regulated by a pilot signal from various valves in the system.
This unit uses a closed inlet start system that operates as follows:

During start up, the bypass solenoid valve and the 3-way solenoid valves are
energized, keeping the bypass line and the butterfly valve fully closed. Closing
the inlet line to the compressor will disable the compressor to build up pressure
and allow the engine to start with minimum load. After 15 seconds, the bypass
solenoid valve de-energizes and the compressor starts to build pressure very
slowly. After the oil pressure reaches 90 psi, the 3-way solenoid valve de-
energizes. This closes the vent line from the inlet cylinder to the atmosphere and
opens the line between the pressure reducing valve and the inlet cylinder,
allowing pressure to rise on the piston side of the inlet cylinder, until there is
sufficient pressure to overcome the spring on the rod side and stroke the
cylinder. This opens the butterfly valve and the compressor will build pressure
very rapidly.
When the system pressure rises over 180 psi, the low pressure regulator valve opens
and air pressure is supplied to the rod side of the inlet cylinder, helping the
spring to overcome the 80 psi air pressure on the piston side of the same cylinder.
This causes the cylinder to start retracting, which partially closes the butterfly
valve. Closing the butterfly valve reduces the amount of air sucked into the
compressor and slowing down the system pressure rise. At the same time, air is
also supplied to the pilot line of the running blowdown valve, opening the running
blowdown valve which bleeds air from receiver tank. Bleeding air from the
receiver tank and closing the butterfly valve stops system pressure rise and starts
system pressure decrease.
When the system pressure falls below 180 psi, the pressure regulator closes and air
is not supplied to the rod side of the inlet cylinder anymore. The small orifice
with muffler bleeds air from the rod side of the inlet cylinder, reducing the air
pressure on this side of the cylinder. Constant air pressure on the piston side
overcomes the spring on the rod side, causing the cylinder to start extending,
which causes the butterfly valve to open. This increases the amount of air sucked
into the compressor and causes a system pressure rise in the receiver tank.
This process repeats, trying to keep a constant system pressure.

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6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-020

Low pressure regulator

set at 180 psi Inlet cylinder
pressure regulator
set at 80 psi
3-way solenoid valve
180 psi selector closed (opens when oil
valve open pressure reaches 90 psi)

Butterfly valve
closed

Manual Unloader
closed

Running blowdown valve

opens (normally closed) By-pass
solenoid valve
closed (opens
after 15 sec.)
System blowdown valve
closes (normally open)
Oil stop valve opens
(normally closed)

Fig 6.2.13 Compressor Start-up Mode

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6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-021

6.2.7.8 Manual Unload Mode

The system can be manually unloaded to run in the low air pressure mode. When the manual
unload ball valve is turned, a signal is sent to the running blowdown valve and to the inlet
control cylinder, closing them.

350 psi and 500 psi

selectors are closed
Low pressure
regulator opens

Manual Unloader
open
Inlet cylinder pressure
regulator set at 80 psi

Running blowdown valve

opens (normally closed)
Oil stop valve opens
(normally closed)
System blowdown valve
closes (normally open)

Fig 6.2.14 Manual Unload Mode

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6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-022

6.2.7.9 Running Mode 350 psi Air Pressure

When 350 psi air pressure is selected, the 180 psi solenoid is now de-energized, closing the
valve. This cuts off the signal to the low pressure regulator. When air pressure reaches 350
psi, the high pressure regulator now functions and opens, sending a signal opening the
running blowdown and the inlet control cylinder, closing it to maintain 350 psi.

350 psi
selector open
180 psi selector closed

Manual Unloader
closed

Inlet pressure regulator

set at 80 psi

Running blowdown valve

opens (normally closed)

Oil stop valve opens

(normally closed)
System blowdown valve
closes (normally open)

Fig 6.2.15 Running Mode 350 psi

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6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-023

6.2.7.10 Running Mode 500 psi Air Pressure

When 500 psi air pressure is selected, both the 180 and 350 psi selectors are closed. The 500 psi
regulator will now function as the air pressure rises. As the air pressure rises to 500 psi, the
regulator opens, sending a signal to the running blowdown valve and the inlet control
cylinder.

500 psi selector opens

350 psi selector
closed

180 psi selector closed

Manual Unloader
closed
Inlet pressure regulator
set at 80 psi

Running blowdown valve

opens (normally closed)
Oil stop valve opens
(normally closed)

System blowdown valve

closes (normally open)

Fig 6.2.16 Running Mode 500 psi

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6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-024

6.2.7.11 Instrumentation and Protection

There is a comprehensive instrumentation and protection group on this unit to protect both the
operator and unit. This package includes visual aids, shutdown protection devices and visual
alarms.
The instrumentation group is provided to allow for visual verification of the operating pressures
and temperatures of various systems incorporated into the compressor unit. These would
include the following:
1. Air filter restriction indicator (located remote from the air filter on receiver tank).
2. Compressor discharge temperature gauge (located in the setup and tramming
control panel).
3. Receiver tank pressure gauge (located in the setup and tramming control panel).
4. Separator restriction indicator (located on the receiver tank).
5. Scavenger line sight glass (located on the receiver tank).
6. Inlet cylinder regulator pressure gauge (located on the inlet pressure regulator).
There are shutdowns and warning indicators incorporated in order to protect the unit and
personnel from damage and or injury. The shutdowns will shut the engine down in the event
that they are activated. Warning indicators warn the operator whenever the system is not
operating within its parameters. Included in this package are the following:
1. Low Oil Pressure Shutdown - located on the oil distribution block; shuts the engine
down immediately if the pressure is below 90 psi. There is a 30 second time delay
on start up, during which time the computer monitors that oil pressure continually
rises.
2. High Interstage Temperature Switch – Normally open (N.O.) switch located in the
manifold connecting the low stage and high stage screws; shuts down the engine
immediately in the event that the discharge temperature of the first stage exceeds
280°F (138°C).
3. High Discharge Temperature Switch - N.O. switch located in the discharge check
valve of the screw compressor; shuts the engine down immediately when the
temperature reaches 300°F (149°C).
Whenever a shutdown or warning has been activated, it will be necessary to acknowledge it by
touching the PanelView on the Acknowledge symbol. The problem must then be diagnosed
and repaired before continued use of the compressor. In the event of a shutdown, it is
necessary to allow the receiver tank to bleed down before restarting the unit.
Also included on the receiver tank is a safety valve that will exhaust receiver tank pressure to
atmosphere in the event that the receiver tank pressure builds past a pre-set level of 550 psi
(37.9 bar).
NOTE: Start up should never be attempted until the receiver tank has fully bled down. If
start up is attempted with high receiver pressure, damage may result.

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6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-025

Compressor Discharge
Pressure gauge

Compressor Discharge
Temperature gauge

Fig 6.2.17 Tram/Set-up Panel

Touchscreen

Throttle Control

Fig 6.2.18 Touchscreen

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6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-026

6.2.7.12 Start Up Procedure

The following procedures should be followed whenever starting the unit up. Refer to the
Operator’s Manual.
1. Use the daily check list to perform a pre-start check.
2. Level the drill so that the fluid level can be checked and added if necessary.
Always check the fluid level after the unit has been shutdown for a minimum of 10
minutes.
3. Fill the compressor receiver/sump with fluid as recommended in the lubrication
guide if required.
4. Check all connections and the general condition of the unit, including all hoses,
whip checks and any visible leaks.
5. Ensure the discharge service valve is closed.
6. After start up check all the gauges while drilling. If any of them are getting close
to running out of their designed parameters, shut the unit down and have the
problem repaired.

6.2.7.13 Shutdown Procedure

The following procedures should be followed whenever shutting the unit down.
1. Using the touchscreen, switch compressor to low position and allow it to stabilize.
See Fig 6.2.18.
2. Check that the mast is on a secured position to prevent inadvertent movement.
3. Using the touchscreen, switch system control off.
4. Using the throttle control, slow engine speed to idle and allow engine to run for at
least 1 minute.
5. Shut engine down.
6. If machine is to be left idle for an extended period of time, switch the battery
disconnect off (see Operator’s Manual for location).

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6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-027

WARNING!
This compressor unit must only be serviced by qualified personnel.
No attempt should be made to alter this unit in any manner without written
permission. Any alterations may result in serious injury or damage to the unit.

Whenever working on this unit, check that the system has fully bled off before opening any
connections. Compressed air has tremendous contained energy, which is released when
opened to atmosphere. The potential to cause severe injury or damage is great if proper
procedures are not followed.

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6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-028

6.2.7.14 Adjustment Procedures

This unit requires the adjustment of four valves during set-ups. They are the inlet control
cylinder regulator (set at 80 psi), the low air pressure regulator (set at 180 psi), the high
pressure regulator (set at 350 psi), and the high air pressure regulator (set at 500 psi). Start
the unit with the drill air selector in the low position and allow it to stabilize. Check the
inlet regulator setting and adjust to 80 psi. While still in the low position, check the opening
point of the low air pressure regulator. The regulator should open, closing the inlet valve, at
180 psi. Switch the system to 350 psi air pressure and allow the system build until the 350
psi air regulator opens. Adjust to open at 350 psi. Switch the system to 500 psi air pressure
and allow the system build until the 500 psi air regulator opens. Adjust to open at 500 psi.

500 psi regulator

350 psi regulator 180 psi regulator

Fig 6.2.19 Valve Adjustment

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6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-029

6.2.8 Compressor Maintenance

6.2.8.1 Main Fluid Filter Service

The main fluid filter is located schematically in the coolant line between the receiver/sump
and the compressor unit. The full flow filter element is replaceable. For installation of filter
element, follow the procedure explained below.
1. The compressor must be shut off and the compressor unit must be relieved of any
pressure.
2. Rotate the filter bowl counter clockwise and remove.
3. Remove the element and discard it. These elements are not cleanable.
4. Clean the housing and filter head.
5. Apply a small amount of oil or grease to the new head seal and install it into the
filter head, making sure it is seated.
6. Place the new element into the head, making sure it is properly seated.
7. Replace the bowl, turning it clockwise and hand tightening.

Fig 6.2.21 Main Fluid Filter Fig 6.2.22

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6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-030

6.2.8.2 Thermal/Bypass Valve

When repairing the thermal/bypass valve, use a repair kit and follow the repair procedure
explained below:
1. With the valve removed from the fluid system, remove the four cap screws, holding
the lower body to the valve body.
2. Remove the o-ring sitting in the lower body and discard.
3. Remove the element and the quad ring inside the housing and discard.
NOTE: there will be slight resistance from the quad/seal ring centered in the
lower housing.
4. Turn the valve over and remove the hex plug. Remove this plug slowly as it is under
spring pressure.
5. Remove the spring, sleeve and bypass piston.
6. Clean the valve parts thoroughly before reassembly.
7. Install the bypass piston, new spring and sleeve into the valve.
8. Install and tighten the new o-ring plug.
9. Coat the new quad ring with quality silicone grease. Install the new quad ring.
10. Install the new element into the housing.
11. Coat the new o-ring with quality silicone grease and install in the lower body.
12. Install the adaptor housing and tighten the four cap screws.
13. Install the four new o-rings on the hose flanges.
14. Install the valve and check for leaks.

Fig 6.2.23 Thermal/Bypass Valve Fig 6.2.24

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6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-031

6.2.8.3 Separator Element Replacement

Refer to Fig 6.2.25 - Fig 6.2.29
When the need for a separator element replacement is indicated by the maintenance indicator
(located on the air receiver/separator tank), use the following procedure.
1. Remove the air/receiver tank lid by removing the twelve hex head capscrews.
NOTE: To assist with the removal of the tank lid, a 1”x 8 nut has been welded to the
lid so an eye bolt can be inserted.
2. Remove the ¾” x 10 jam nut and sealing hex nut from the separator hold down rod.
3. Remove the round separator cover plate from the top of the separator element.
4. Remove the upper grounding spring. A new one is supplied with the new filter
element kit.
5. Remove the old separator element and discard.
6. Replace the lower grounding spring at the lower end of the retaining rod. A new one
is supplied with the new filter element kit.
7. Remove the old gasket from the receiver tank lid and clean all sealing surfaces,
taking care not to allow scrapings to fall into the tank.
8. Before installing the new separator element, make sure to lubricate both sides of the
sealing O-ring on the element.
9. Install the new separator element and upper spring.
10. Install the cover plate, the new ¾” x 10 sealing hex nut and the ¾” x 10 jam nut.
Torque the sealing nut to 85 – 90 ft-lbs (115 – 122 N-m). DO NOT over-tighten as
damage to the separator can result.
11. Install the new tank flange gasket that is provided in the element kit.
NOTE: Be sure not to remove the staples from the gasket as they provide a ground
between the cap and the top of the tank.
Before installing, lubricate both sides of the gasket. Re-install the tank lid. Install the
capscrews finger tight, and then gradually tighten in a crisscross pattern in 4 – 5
steps. Always tighten the capscrews alternately at opposite sides of the cover.
Torque capscrews to 500 ft-lbs (678 N-m).
12. Clean or replace the fluid return line strainer.
13. Clean the fluid line orifice installed in the side of the compressor unit air end.
14. After 24 hours of operation, re-torque the receiver tank cover bolts to 500 ft-lbs
(678 N-m).

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6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-032

Receiver Lid

Fig 6.2.25 Separator Element

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6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-033

Separator Lower spring

retaining bolt ensures a constant
connected to contact/ground
receiver tank, between the
creating a element and the
direct ground. tank.

Retaining Plate Nut

Grounding of separator
is through center stud. Scavenger line to
remove excess
buildup between
the separator and
receiver tank.
Fig 6.2.26
Fig 6.2.27
Separator Retaining Plate
Upper spring
ensures a constant
contact/ground
between the
retaining plate and
the strap.

The strap provides a direct connection to

the separator element to carry the ground
through the spring and retaining plate.

Fig 6.2.28 Fig 6.2.29

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6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-034

6.2.8.4 Running Blowdown Valve Maintenance

When it is necessary to make repairs on the running blowdown valve follow the instructions
provided below.
1. Remove the hex nut from the bottom of the valve. The poppet guide, which is
secured by the hex nut, is under slight spring tension.
2. Remove the poppet guide, poppet assembly and spring from the valve body.
3. Remove and discard the old o-ring and replace it with the new o-ring provided in
the kit. Be sure to lubricate the o-ring with a silicone-based lubricant.
4. Place the new spring and poppet assembly in the valve body as shown. Then place
the poppet guide (with the o-ring in position) over the poppet assembly.
5. Push the hex nut down over the poppet guide and compress the spring while
turning the hex nut until tight. Tighten securely with a wrench.
6. Remove the pilot cap from the top of the valve body and pull the piston out of the
cap.
7. Remove the U-cup from the piston and replace it with a new one. The U-cup should
be lubricated with a silicone-based lubricant.
8. Remove the gland nut from the valve body and pull the poppet pin out to allow
access to the small o-ring in the top of the body.
9. Remove the small o-ring and replace it with a new one. Lubricate with a silicone-
based grease.
10. Replace the poppet pin and gland nut.
11. Place the piston with the new U-cup in position back in the pilot cap with the
recessed centre showing at the valve body end of the cap.
12. Replace the pilot cap and tighten securely with a wrench. At this time the running
blowdown valve is ready for operation.

Fig 6.2.30 Running Blowdown Valve Fig 6.2.31

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6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-035

6.2.8.5 Shutdown Blowdown Valve Maintenance

When it is necessary to make repairs on the running blowdown valve follow the instructions
provided below.
1. Remove the pilot cap and push the piston out of the pilot cap.
2. Remove the U cup from the piston and replace it with the new one provided in the
repair kit. Lubricate the u cup with a silicone-based grease.
3. Thoroughly clean the cap. Place the piston (with the u cup in position) in the cap
so the recessed centre is showing at the valve body end of the cap.
4. Pull the retainer, poppet and spring and separate the poppet from the retainer.
5. Remove the o-rings from the inside and outside diameters of the retainer.
6. Unscrew the stem portion of the poppet to allow removal of the disc. DO NOT mar
the machined finish of the poppet when unscrewing the stem.
7. Remove the disc and replace it with the new one provided.
8. Replace the stem portion and tighten securely.
9. Clean the poppet and retainer thoroughly.
10. Replace the o-rings in the retainer and lubricate thoroughly with a silicone-based
lubricant.
11. Place the poppet in the retainer as it was prior to separating it.
12. Clean the valve body and place the new spring in the valve body.
13. Place the poppet and retainer back in the valve body and replace the pilot cap.
14. Tighten the pilot cap securely with a wrench and the shutdown blowdown valve is
ready for operation.

Fig 6.2.32 Shutdown Blowdown Valve

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6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-036

6.2.8.6 Minimum Pressure/Check Valve Maintenance

The minimum pressure/check valve should be periodically disassembled, inspected for
excessive wear, and cleaned or reassembled.
1. Remove the six cap screws in the cover.
2. Remove the cover, taking care not to damage the gasket.
3. Remove the piston assembly.
4. Clean and inspect parts. Any excessively worn parts should be replaced.
5. Grease the piston and pack the grooves with quality silicone grease.
6. Replace the piston assembly.
7. Replace the cover and gasket.
8. Apply locking compound to the cap screws. Replace and torque to 80 ft-lbs (108 N-
m).

Fig 6.2.33 Min Pressure/Check Valve Fig 6.2.34

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6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-037

6.2.8.7 Discharge Check Valve Maintenance

When servicing of the valve is required follow this procedure:

1. Remove the six cap screws from the valve body cover and remove the cover/shaft
assembly.
2. Remove the gasket and spring from the valve body.
3. Remove disc/bearing assembly from the valve body.
4. Clean cover and valve body gasket surfaces.
5. Install new disc/bearing assembly into the valve housing.
6. Place the spring into the disc/bearing assembly.
7. Place the gasket on the valve body.
8. Install the cover/shaft assembly centering the shaft into the spring.
9. Install the six cover cap screws and torque to 80 ft-lbs (108 N-m).

Fig 6.2.35 Discharge Check Valve Fig 6.2.36

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6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-038

6.2.8.8 Safety Valve

The safety valve is a non-serviceable item and must be replaced if it fails. If replacement is
necessary, follow these instructions.
1. Remove the failed unit and replace with new.
2. Apply a small amount of pipe dope to the male threads only of new safety valve.
3. Tighten by hand, then tighten not more than one extra turn using a wrench on the
inlet hex nut.
During services, it is recommended that the safety valve be cracked open to ensure that it is
still functional. If the witness wire has been broken, the safety valve must be replaced.
Check the pressure ratings on the safety valve as 400 psi, 450 psi, and 550 psi valves are
available.

Fig 6.2.37 Safety Valve

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6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-039

Pressure Regulators

Fig 6.2.38 Pressure Regulators

Fig 6.2.39 Interior of Pressure Regulator

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6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-040

6.2.8.9 Pressure Regulator (Low / High Air Pressure Regulator)

Pressure regulator valve maintenance normally requires the replacement of the internal
diaphragm. Follow the procedures below for proper installation.
Refer to Fig 6.2.38 and Fig 6.2.39 next page
1. Loosen the lock-nut and turn the adjusting screw counterclockwise until the inner
spring tension is relieved. The adjusting screw should turn freely when the spring
tension is relieved.
2. Remove the spring chamber from the body to allow access to internal parts.
3. Next, remove the spring button, spring and the damper located inside the spring.
The damper will stay inside the spring as it is removed. Leave the damper inside
the spring as there is no need to remove it.
4. After removing the spring, remove the diaphragm stop.
5. At this time, remove the pressure plate nut and disassemble the pressure plate,
diaphragm, diaphragm gasket, seat disk and seat gasket.
6. Remove and discard the seat ring.
7. Reassemble the regulator using the new parts provided in the repair kit.
8. Reassemble the diaphragm, pressure plate, diaphragm gasket, seat disc, seat disc
gasket, and tighten the nut. All of these parts with the exception of the pressure
plate are provided in the repair kit.
9. Replace the seat ring with the new seat ring provided.
10. Replace the existing seat ring stop.
11. Next, place these parts in their proper place on the body and replace the spring
as it was prior to removal.
12. Place the spring button over the spring as shown.
13. With all parts in order, replace the spring chamber and tighten.
14. Tighten the adjusting screw until tension is realized.
15. At this time, refer to control system adjustment procedure to readjust the
pressure regulator.

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6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-041

6.2.8.10 Fluid Stop Valve

When servicing the fluid stop valve use the appropriate repair kit and follow the steps below.
The valve may be serviced without removing from its associated piping.
1. Remove the retaining ring.
2. Remove the cap and discard o-ring.
3. Remove the cap screw and flat washer from the outlet connection of the valve.
4. Remove the plate, o-ring, Teflon o-ring and washer from the valve.
5. Separate the washer and plate and discard the o-ring and spring.
6. Remove the piston, o-ring, rod and spring from the valve body. Discard the o-ring
and spring.
7. Clean all parts thoroughly.
8. Install a new o-ring on the piston and coat the piston and o-ring with a silicone
based grease.
9. Install the spring on the rod and install the piston, rod and spring into the valve
body.
10. Assemble the cap screw, flat washer and plate. Install the o-ring onto the caps
crew as shown below.
11. Install Teflon o-ring into the plate.

Fig 6.2.40 Fluid Stop Valve Fig 6.2.41

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6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-042

Copyright © Sandvik Mining and Construction

6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-043

6.2.9 Screw Compressor

6.2.9.1 Screw Compressor Arrangement

ENGINE

COMPRESSOR

Fig 6.2.42 Screw Compressor Arrangement

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6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-044

6.2.9.2 Drive Coupling Assembly

Follow this procedure for assembly of the drive coupling.
Refer to Fig 6.2.42, Fig 6.2.43, and Fig 6.2.44
1. Attach the compressor mounting adapter to the compressor unit using ½” X 1 ¾”
ferry head capscrews (12 total). Torque to 105 ft-lbs (143 N-m).
2. Place the shaft spacer on the shaft and put the ⅝” key in place on the shaft.
3. Insert the taperlock bushing into the rubber drive element (the bushing will fit only
one way). Snug the setscrews for the bushing with a 5/16” Allen head wrench
(setscrews must be in holes threaded in rubber drive element). Place the element
with bushing on the compressor shaft, making sure the key is properly aligned. Tap
around the bushing to assure that the bushing is tight against the shaft, then
tighten the setscrews to 67 ft-lbs (91 N-m).
4. Attach the drive ring to the engine using ½” X 2 ½” ferry head capscrews (8 total)
coated with Loctite 242 or equivalent, and torque to 105 ft-lbs (143 N-m). The
recessed side of the drive ring should face the compressor.
5. Grease the rubber element and align the compressor with the engine.
6. Insert the 7/16” X 2 ¾” ferry head capscrews (24 total) and torque to 67 ft-lbs (91
N-m).

Fig 6.2.43 Fig 6.2.44

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6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-045

6.2.9.3 Coupling Alignment

Align the pump drive coupling as follows:
1. To correct for angular misalignment, use calipers to check the gap between hubs.
Adjust or shim equipment until the gap is the same at all points around the hubs.
See Fig 6.2.45.
2. To correct parallel offset, place a straight edge across the hub flanges in two
places at 90° to each other (see Fig 6.2.46). Adjust or shim equipment until the
straight edge lays flat on both sides.
3. Tighten down connected equipment and re-check alignment.
4. Install the elastomer element, tightening all capscrews to the values shown in the
table below.
5. If practical, re-check and tighten capscrews after several hours of operation.
WARNING!
Failure to secure capscrews properly could cause coupling components to become
dislodged during operation, resulting in personal injury.
Capscrews have self-locking patches which should NOT be used more than twice.

Fig 6.2.45 Angular Misalignment Fig 6.2.46 Parallel Offset

Capscrew Torque (Dry)

In-lbs Ft-lbs N-m

900 75 100

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6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-046

Copyright © Sandvik Mining and Construction

6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-047

6.2.9.4 Compressor Operator Daily Checklist

Compressor Operator Daily Checklist

Serial Number: Date:

Operator Name: Hour meter reading start of shift:

Foreman: Hour meter reading end of shift:

Set Up location:

NOTE: If any of the following checks are “No”, DO NOT RUN UNIT.
Pre-start Inspection YES NO
Is oil visible in receiver/sump tank glass?

Is the compressor free from oil leaks?

Are the oil cooler and fan clean?

Are hose whip checks in place?

Are hoses in good condition?

Has the signal filter been drained?

Are the fire extinguishers in place and accessible?

Has the general condition of the compressor been checked?

Operating Inspection YES NO

Do all the following checks and readings under full load and air flow.
Has the unit been checked for oil leaks?

Has the unit been checked for air leaks?

Air discharge pressure psi

Comments:

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6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-048

Copyright © Sandvik Mining and Construction

6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-049

6.2.9.5 Maintenance Schedules

250 Hour Maintenance Schedule
1. Complete Compressor Operator Daily Checklist.
2. Check inlet air filter restriction indicator. Replace filters if necessary.
3. Replace oil filter element.
4. Check separator differential pressure. If differential pressure is 10 psi or higher,
replace separator element.
5. Check and clean control line moisture separator element.
6. Check oil level. Top up if necessary and record amount added. See Lubrication
Crossover table for details on lubricant.

1000 Hour Maintenance Schedule

1. Complete Compressor Operator Daily Checklist.
2. Check all solenoid valves for operation.
3. Check safety shutdown system, sensors, and switches.
4. Check electrical panel.
5. Inspect air inlet valve cylinder and linkages. Repair or replace any worn parts.
6. Check inlet air filter restriction indicator. Replace filters if necessary.
7. Replace oil filter element.
8. Replace separator element.
9. Inspect and clean pressure regulator valves.
10. Replace control line moisture separator element.
11. Drain and clean receiver/sump tank.
12. Replace oil. Oil capacity of the receiver/sump tank is 35 US gallons (132 litres).
See Lubrication Crossover table for details on lubricant.

Copyright © Sandvik Mining and Construction

6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-050

6.2.9.6 Compressor Lubrication Crossover

Refer to this Cross-Over list for alternate suppliers. If these brands are unavailable, your local
supplier will be able to recommend alternatives using these specifications.

Lubrication Chart for Screw Compressor

Fluid Type Esso/Mobil Shell Chevron/Texaco Sullair

Darina XLEP2 LONA XEP2H MOBILUX Extreme
Pressure
Grease
Grease

Synthetic Synthetic Synthetic Synthetic

SHC1024 Corena AS68 Tegra 68 AWF
Change every Change every Change every 1000 Change every
1000 hrs 1000 hrs hrs 1000 hrs
Compressor Oil

Synthetic compressor fluids do not have to be changed as often as mineral based oils, which
may balance out fluid costs.

CAUTION!
Do not mix different types of fluids.
Do not use automatic transmission fluids.

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6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-051

6.2.9.7 Compressor Troubleshooting

Symptom Probable Cause(s) Remedies

Compressor shuts down Compressor discharge Cooling air flow is insufficient. Clean
with air demand temperature switch is cooler and check for proper ventilation.
present open.
Low fluid receiver tank level. Add fluid.
Dirty compressor fluid. Change fluid.
Clogged compressor fluid filter. Change
element.
Temperature regulating valve is not
functioning properly. Change
thermostatic element.
Defective discharge temperature switch.
Check for a short or open circuit.
Should this check out normal, the
temperature switch itself may be
defective.

Compressor will not build Air demand is too high. Check service lines for leaks or open
up full discharge valves.
Dirty air filter.
pressure
Check the filter indicator and change or
Pressure regulator out of
clean element if required.
adjustment.
Adjust regulator according to control
Defective pressure regulator.
adjustment instructions.
Defective minimum pressure
Check diaphragm and replace if necessary.
valve.
Check that piston is moving freely.
Selector switch is in Low
position.
Signal lines are crossed
between shutdown
blowdown valve and
running blowdown valve.

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6.2 SULLAIR COMPRESSOR (08/03/25) 6-02-052

Improper unloading with Pressure regulating valve is Re-adjust.

an excessive pressure set too high.
Check the control lines.
build-up causing the
Leak in the control system
pressure relief valve Defective pressure regulating valve. Repair
causing a loss of pressure
to open valve.
signal.
Free or replace valve.
Inlet valve jammed.
Check all control lines and components.
Restriction in the control
Ice and other contaminants may cause
system.
restrictions.
Jammed control linkage.
Free jammed portion of linkage and adjust
Defective pressure relief if necessary.
valve.
Replace pressure relief valve.

Insufficient air delivery Plugged air filter. Clean or replace.

Plugged air/fluid separator. Replace separator element and also
change compressor fluid and fluid filter
Defective pressure regulator.
at this time.
Power source speed too low.
Adjust or repair.
Inlet valve not opening
Re-adjust engine speed.
completely.
Re-adjust control linkage.

Excessive compressor Clogged return line. Clear orifice and strainer.

fluid consumption
Separator element damaged Change separator element.
or not functioning
Check all pipes, connections, and
properly.
components.
Leak in lubrication system.

Compressor overheating Dirty fluid cooler core. Clean core thoroughly.

Faulty thermostat in thermal Change thermostat element.
valve.
Clean tubes thoroughly.
Plugged fluid cooler tubes
Fill.
(internal).
Change element.
Low receiver tank fluid level.
Clean orifice and strainer.
Plugged compressor fluid
filter.
Plugged fluid return line.

Copyright © Sandvik Mining and Construction

6.3 CAT WATER PUMP (08/03/25) 6-03-001

6.3 CAT Water Pump

Driven by a hydraulic motor, the water pump is a positive displacement unit. It is equipped
with a strainer/pressure regulator in the suction line and a relief valve mounted in the
discharge line.

PM Tasks
Visual inspections and changing the crankcase oil are routine maintenance procedures. The
hydraulic motor requires lubrication of the drive coupling but no periodic servicing is
required. Service instructions are not included because replacing the motor is more
economical than overhauling.

250 Hour Intervals:  Check pressure regulator/ strainer

1000 Hour Intervals:  Change crankcase fluid
2000 Hour Intervals:  Perform a pressure test

WARNING!
Disconnect electrical power, mine air, water supply, and relieve pressure
in air receiver before servicing.
NOTICE!
Keep parts separate or mark components to allow installation in original
locations.
Drain pump before exposing to freezing conditions.

Technical Specifications: Volume: 4 gpm (15 l/m) @ 225 rpm

Discharge pressure: 425 psi (29.4 bar)
Speed: 225 rpm
Crankcase Capacity: 40 fl. oz. (1.2 L)
Lubricant Type: Esso NUTO 46 Hydraulic Oil
Weight: 32 lbs. (14.5 kg.)

Pump Accessories: Relief Valve: 425 psi (29.4 bar)

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6.3 CAT WATER PUMP (08/03/25) 6-03-002

6.3.1 Pump Speed Adjustment

The pump has a direct drive propelled by a hydraulic motor. Using a tachometer, set the motor
speed to 225 rpm by adjusting the hydraulic flow at the control valve. Follow the procedure
outlined in Section 5.5.4 Valve Flow Adjustment.

Fig 6.3.1 Water Pump

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6.3 CAT WATER PUMP (08/03/25) 6-03-003

6.3.2 Dismantling of Valves

Refer to Fig 6.3.1
WARNING!
Disconnect electrical power, mine air, water supply, and relieve pressure in air
receiver before servicing.
1. Remove fasteners (53, 55) securing discharge manifold (52) to crankcase (2).
2. Tap discharge manifold from backside with soft mallet to separate it from
crankcase. Repeat action until it breaks free from cylinders.
3. Valve assemblies will remain in manifold. With reverse pliers, remove valve seats
(43). Valve (44), spring (45), and retainer (46) will then fall out when manifold is
inverted.

6.3.3 Assembling of Valves

Refer to Fig 6.3.1
1. Replace retainers (46) in manifold chambers.
2. Insert spring (45) into center of retainers (46).
3. Inspect valves (44) and valve seats (43) for wear, ridges, or pitting and replace as
necessary.
4. Insert valve over spring with recessed (dish) towards discharge manifold.
5. Examine O-ring (42) and back-up ring (66); replace if worn. Lubricate O-rings to
avoiding damaging them.
NOTE: First install O-ring in groove on seat (towards seating surface), then on
back-ring.
6. Insert valve seats into manifold chambers.
7. Install manifold on pump and lubricate O-rings on cylinders. Be cautious when
slipping manifold over cylinders to avoid damaging cylinder O-rings.
8. Install fasteners and torque to 217 in.-lbs (24.5 N m).
NOTE: Reinstall all original shims. When new manifold is used, re-shim pump.
NOTICE!
When starting pump, check to see that there is no cylinder motion as this would
cause premature failure of cylinder O-rings. Motion of center cylinder must be
eliminated by adjustment described later.

Copyright © Sandvik Mining and Construction

6.3 CAT WATER PUMP (08/03/25) 6-03-004

6.3.4 Dismantling the Pumping Section

Refer to Fig 6.3.1
1. Remove discharge manifold as previously described.
2. Grasp cylinders (41) by hand and with up and down motion, pull cylinders from
inlet manifold (31). Mark each cylinder to allow installation in original location.
3. Remove cotter pin (39), nut (38) and washer (37) from piston rod (21).
4. Remove retainer (36), spacer (35) and piston/cup assembly (34, 34A). Remove
inlet valve (33).

6.3.5 Pump Assembly

Refer to Fig 6.3.1
1. Examine surface of inlet valve (33) for pitting or scaling. Reverse valve, then sand
inlet side of valve, using 240 grit emery cloth. Surface must be clean. Replace it if
excessive wear is apparent. Slip it onto rod (21).
2. Examine seating surfaces on piston (34) and sand clean on flat surface using 240
grit emery cloth. Replace piston if extreme pitting or sharp edges are present.
3. Examine cup (34A) for wearing, cracking, or separating from piston and replace as
required. Lubricate it before installing on piston.
NOTE: See parts manual for Cup Insert Tool. Lubricate tool before using.
Push cup (34A) over insert tool and square with all surfaces. Faulty cup installation
causes premature cup failure. Lubricate piston (34) and slip on rod (21).
4. Replace piston spacer (35) and retainer (36) on rod (21).
5. Replace washer (37) and cotter pin (39). Install nut (38) and torque to 60 in.-lbs.
(6.8 N m).
6. Examine cylinder walls for scoring or etching which would cause premature wear
of cups. Replace them if worn.
7. Lubricate cylinder and replace O-ring and/or back-up ring if worn or damaged.
Carefully slip cylinder over rod end and push into inlet manifold. Make sure
cylinders are installed in their original positions.
8. Position discharge manifold on pump, install fasteners and torque to 217 in.-lbs.
(24.5 N m).

Copyright © Sandvik Mining and Construction

6.3 CAT WATER PUMP (08/03/25) 6-03-005

NOTICE!
Cylinder motion will cause premature failure of O-ring and cylinder seals.
Check for cylinder motion immediately after the pump is started. If there is any
motion noted in the center cylinder, switch it with one of the end cylinders
and start the pump again. If there is motion noted in one of the end cylinders,
correct it by removing one manifold shim, then install the lock washers and
nuts. Torque to 10 ft.-lbs. (13.6 N m).

6.3.6 Removing Sleeves and Seals

Refer to Fig 6.3.1
1. Remove discharge manifold (52) and piston assemblies as described previously.
2. Remove inlet manifold (31) containing seals.
3. Grasp sleeves (27), with pulling and twisting motion and remove sleeves from
piston rod (21).
NOTE: Remove sleeve with pliers only if replacing worn sleeves, as using pliers
would mark sleeves.
4. Remove seal retainer (29).
5. Remove O-rings (26) and back-up rings (28) on piston rod then check them for
wear. Replace them as required.

6.3.7 Installing Sleeves and Seals

Refer to Fig 6.3.1
1. Lubricate new O-rings and slip them on piston rod. Install first O-ring in groove on
piston rod. Position back-up ring against shoulder in front of first O-ring. Then
install second O-ring. Exercise caution as you slip O-ring over threaded end of
piston rod.
2. Examine sleeves (27) for scoring or etching and replace as required. Immerse
sleeves in oil and carefully twist and push sleeve on rod (machined counter bore
end first).
3. Install seal retainers (29).
4. Place inlet manifold (31) on pair of clearance blocks with crankcase side down and
drive out old seals (30).
5. Invert inlet manifold with crankcase side up and install new seals. Lubricate
circumference of seal and install Perm-A-Lube seal with Garder spring down.

Copyright © Sandvik Mining and Construction

6.3 CAT WATER PUMP (08/03/25) 6-03-006

6. Lubricate seal insert tool and slip it on piston rod end, position inlet manifold on
pump and remove tool.
NOTE: Install original quantity of washers (48) on studs before installing inlet
manifold (31).
7. Reassemble piston and discharge manifold as described earlier.

6.3.8 Servicing the Crankcase

Refer to Fig 6.3.1
1. While inlet manifold, sleeves and seal retainers are removed, examine crankcase
seals for wear.
2. Check oil for water content.
3. Rotate crankshaft by hand. Rotation must be smooth.
4. Examine crankshaft oil seal (14) for cracking or leaking.
5. Consult your supplier if the crankcase requires servicing.
6. Reassemble in reverse order.
7. Add hydraulic fluid Esso NUTO 46 or equivalent to level indicated on sight glass.

6.3.9 Pump Installation

Install pump on drill and attach hoses. Check the crank case oil. Adjust pump speed and suction
pressure regulator as outlined in beginning of this module.

Copyright © Sandvik Mining and Construction

6.4 GREASE INJECTION (08/03/25) 6-04-001

6.4 Grease Injection

The grease pump injects grease into the drilling air stream. It is a pneumatically-operated unit
that develops a fluid pressure of twenty five times higher than its air supply pressure (see
Fig 6.4.1, Fig 6.4.2, and Fig 6.4.3).

PM Tasks
Keep grease tank, pump, injector, and valves clean. The grease tank is the main source where
contamination may enter into the grease system. Drain and lubricate air supply.
Replace damaged components immediately. Investigate all leaks. All maintenance should be
performed in a clean, well-lit work area. Extreme cleanliness is required when servicing
injecting system components.
Fill up grease tank (13) periodically in order to avoid air trapped in the lines. Add grease every
time the grease level drops below middle window sight.

Every shift:  Check grease level in the tank (13), drain air filter (3), and
check oil in air lubricator (4).

250 Hour Intervals:  Inspect system for leaks

The grease injection system settings are:

- air pressure in the grease pump (13) – by regulator (2).
- cycle time (from 20 sec to 24 hr) – controlled by the PLC.
- amount of grease injected in a cycle – by adjusting the injector (6) to suit the drill
hole size (see specifications below).

Rock Grease Pump Specifications Pressure Ratio: 25:1 – fixed setting

Max Output: 2.15 cu.in. (35.2 cc)/cycle
Air consumption @ 100 psi: 0.5 CFM per stroke

Grease Injector Specifications Operating Pressure: Min 1000 psi

Max 3500 psi
Output: Min 0.05 cu.in. (0.82 cc)
Max 0.50 cu.in. (8.2 cc)

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6.4 GREASE INJECTION (08/03/25) 6-04-002

5
3
2
1
4

Fig 6.4.1
8

9
7

10

Fig 6.4.2
1. Air Filter 4. Injector 8. Fill Cap
2. Air Lubricator 5. Volume Adjustment 9. Breather
3. Solenoid Valve 6. Vent Plug 10. Sight Window
7. Grease Tank

Copyright © Sandvik Mining and Construction

6.4 GREASE INJECTION (08/03/25) 6-04-003

WARNING!
Disconnect electrical power, mine air, water supply, and relieve pressure in air
receiver before servicing.

6.4.1 To Fill Reservoir

Remove fill cap (11), fill with grease until level reaches top window sight (12).
NOTE: When filling the reservoir, caution should be used not to contaminate reservoir.

6.4.2 To Prime System

Supply Lines: After grease tank (9) has been filled with recommended lubricant, turn vent plug
(8) counterclockwise one complete turn and operate pump until lubricant flows freely from
opening in vent plug to expel air pockets trapped. Tighten vent plug.
Feeder Lines: Fill each feed line with lubricant before connecting lines to outlets.
Injectors: Check injector (6) for proper operation. Injector stem moves when injector
discharges grease. This may require cycling system several times. After checking, adjust
injector for the volume required.

6.4.3 Operation
The pre-determined lubrication cycle frequency is set by the PLC.
When a lubrication cycle is initiated the air solenoid valve is energized and air is admitted to
the pump. Lubricant is delivered to the injectors and the injectors discharge lubricant to the
drill air line. When air solenoid valve (5) is de-energized, air is admitted to the opposite side
of the pump air cylinder. As pump plunger returns to its retracted position, the lubricant
pressure in the system is relieved, permitting the injectors to recharge.
System is now ready for the next lubrication cycle.

Copyright © Sandvik Mining and Construction

6.4 GREASE INJECTION (08/03/25) 6-04-004

6.4.4 Adjusting Flow Rate

The maximum setting (flow of oil/grease) is achieved with the adjustment screw backed all the
way out (counterclockwise).

6.4.4.1 Setting for a 4” Hammer

To set the flow of grease/oil for a 4” hammer, which is approximately 0.3 quarts of grease per
hour, you must set the adjustment screw to 30 percent of maximum adjustment.
1. Loosen lock-nut (see Fig 6.4.4).
2. Turn adjustment screw in clockwise with a wrench until it stops (approximately
12-1/2 turns if the adjustment screw is backed all the way out).
NOTE: Be careful not to over torque the adjustment screw. It should take
minimal force to turn the screw clockwise. This will be the minimum injection
setting.
3. Turn the adjustment screw counter counter-clockwise 4 turns.
4. Lock in setting on adjustment screw with lock-nut.

6.4.4.2 Setting for a 6” Hammer

To set the flow of grease/oil for a 6” hammer, which is approximately 0.7 quarts of grease per
hour, you must set the adjustment screw to 70 percent of maximum adjustment.
1. Loosen lock-nut (see Fig 6.4.4).
2. Turn adjustment screw in clockwise with a wrench until it stops (approximately
12-1/2 turns if the adjustment screw is backed all the way out).
NOTE: Be careful not to over torque the adjustment screw. It should take
minimal force to turn the screw clockwise. This will be the minimum injection
setting.
3. Turn the adjustment screw counter-clockwise 9 turns.
4. Lock in setting on adjustment screw with lock-nut.
These settings are approximate values and may have to be adjusted slightly
depending on conditions and the manufacturer of the hammer.

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6.4 GREASE INJECTION (08/03/25) 6-04-005

Adjustment Screw

Lock Nut

Injector Body
Bleed

Grease Outlet

Grease Inlet

Fig 6.4.4 Adjusting Flow Rate

Press the
Lube/Grease/
Water button

Fig 6.4.5 Accessing Hammer Lubrication

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6.4 GREASE INJECTION (08/03/25) 6-04-006

6.4.5 PanelView Settings for DR

NOTE: The adjustments in the section are to be done by qualified maintenance
personnel.
For injecting oil, the setting of the injector can be maintained, but the timers for on
and off must be adjusted by maintenance personnel. This screen can be accessed
just as accessing the Auto-Lube settings (see Section 2.3.1.5, Panelview Settings,
steps 1-3). After completing those steps, continue as follows:
1. Several new options will appear on the left side of the screen. For the Hammer
Lubrication settings, press the Lube/Grease/Water button. See Fig 6.4.5.
Once inside the Lube/Grease/Water screen, you can select from two Hammer
Lubrication options; Hammer Lubrication On Time and Hammer Lubrication Off
Time.
2. Press the Hammer Lubrication On Time button to set the maximum on time for the
Hammer Lubrication cycle. The keypad will open; use it to input your settings. See
Fig 6.4.6.
Press the Hammer Lubrication Off Time to set the off time for the Hammer Lubrication
cycle. Again, use the keypad to input your settings. See Fig 6.4.7.
The Hammer Lubrication On Time screen and the Hammer Lubrication Off Time
screen are virtually identical. Ensure you are in the correct screen for the time you
are setting; the active button will be outlined in green (refer to Fig 6.4.6 and Fig
6.4.7).
The timer settings for either grease or oil are as follows:
Oil: 8 seconds on 7 seconds off
Grease: 10 seconds on 20 seconds off

Fig 6.4.6 Hammer Lubrication On Time Fig 6.4.7 Hammer Lubrication Off Time

Copyright © Sandvik Mining and Construction

7.0 ELECTRICAL (08/03/25)

7.0 ELECTRICAL

WARNING!
Servicing the Control Panel is for Qualified
Electrical Technicians ONLY!

Copyright © Sandvik Mining and Construction

Copyright © Sandvik Mining and Construction
7.1 ELECTRICAL CIRCUITS (08/03/25) 7-01-001

7.1 Electrical Circuits

Wiring Diagrams are located in Section 8 of the Parts Manual. The main Electrical General
Arrangement is located in the back of this manual.

PM Tasks
Preventative maintenance includes cleaning and inspecting of the electrical components.
Consult the Parts Manual for complete parts description. Label wires before dismantling any
equipment.
Service Intervals: See the Preventative Maintenance Schedules in Section 2.4

WARNING!
THE MAINTENANCE PROCEDURES ARE FOR QUALIFIED ELECTRICAL
TECHNICIANS ONLY.

Circuit Voltages: Main Circuit: 24V

Valve Control: 24 volts, DC

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7.1 ELECTRICAL CIRCUITS (08/03/25) 7-01-002

Copyright © Sandvik Mining and Construction

7.2 ELECTRICAL COMPONENTS (08/03/25) 7-02-001

7.2 Electrical Components

PM Tasks
Clean and inspect the electrical components at the specified intervals. Replace damaged parts
immediately to avoid down time.

250 Hour Intervals:  Clean and inspect electrical system

 Inspect dust boot on all joysticks
 Inspect seals on all panels

NOTICE!
Isolate ground before arc welding.

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7.2 ELECTRICAL COMPONENTS (08/03/25) 7-02-002

7.2.1 Electrical Panel

WARNING!
The following procedures are to be performed by qualified electrical technicians
only.
1. Push lamp test button at panel to check for defective bulbs. Replace as required.
2. Clean and inspect electrical panel. Check for loose connections.
3. Clean contacts with proper contact cleaner.
4. Replace any slightly damaged parts to avoid downtime. Inspect panel seals.

7.2.2 Control Panels

Visually inspect the switches, gauges, and controls on the drill control panel and the set-up/
tramming panels. Replace worn joystick boots and contact blocks.

7.2.3 Replacement Parts

Check the Parts Manual for complete replacement components; if parts are not listed, contact
the Parts Department.

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7.3 ON/OFF VALVE ACTIVATION (08/03/25) 7-03-001

7.3 On/Off Valve Activation

Fig 7.3.1 On/Off Valve Activation

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7.3 ON/OFF VALVE ACTIVATION (08/03/25) 7-03-002

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7.4 TYPES OF VALVES (08/03/25) 7-04-001

7.4 Types of Valves

The circuit voltage in the setup and drilling panel is approximately 24 volts DC. The On/Off
valves are equipped with black Hirschmann connectors and have a smaller solenoid than the
proportional valves (see Fig 7.6.1).
On/Off valves are used on the following applications:

 Cab Tilt  Lower Breakout Clamp  Breakout

 Oscillation  Carousel Arm  Centralizer
 Carousel Rotation  Jib Boom  Diverter
 Air  Cab Swing  Carousel Clamp
 Upper Breakout Clamp  Winch

Proportional valves with white/grey connectors are installed on the following applications:

 Tram control  Boom Lift

 Rotation control  Boom Swing
 Feed control  Mast Dump
 Feed Extension  Mast Swing
 Water Pump

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7.4 TYPES OF VALVES (08/03/25) 7-04-002

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7.5 TESTING OF VALVE SOLENOIDS (08/03/25) 7-05-001

7.5 Testing of Valve Solenoids

When troubleshooting control valves equipped with remote joysticks, the electrical circuit
needs to be tested. There are no simple procedures to determine if the solenoids are
defective.
Use the elimination process to check related components before replacing the valve solenoids.
Refer to the Troubleshooting Section before performing the following tests.
NOTE: The On/Off valves have different testing method than the proportional valves.

NOTICE!
Eliminate all possible problems before replacing valve solenoids.
WARNING!
Use proper start-up procedures when starting drill.

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7.5 TESTING OF VALVE SOLENOIDS (08/03/25) 7-05-002

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7.6 TESTING ON/OFF VALVES (08/03/25) 7-06-001

7.6 Testing On/Off Valves

When malfunctioning of the solenoid is suspected, perform the following test:
1. Remove Hirschman connector and check voltage between pin 1 and pin GR (Fig
7.6.2). Zero voltage reading indicates faulty circuit or joystick. Refer to
electrical circuits to troubleshoot the problem.
2. If voltage reading is approximately 24 volts, inspect and clean pins in connector
and solenoid. Reinstall connector and operate valve. Replace solenoid if valve is
not operating.
NOTE: Pin 3 is not used on the On/Off valves.

Fig 7.6.1 On/Off Valve

Fig 7.6.2 Hirschman Connector

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7.6 TESTING ON/OFF VALVES (08/03/25) 7-06-002

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7.7 PROPORTIONAL VALVES (08/03/25) 7-07-001

7.7 Proportional Valves

The joystick sends an electrical signal to the PLC and the PLC sends the signal to the solenoid
that responds to joystick’s position. This signal (set-point) is converted into a hydraulic
pressure which moves the main spool.
Inside the transducer (C), the position of the main spool is converted to an electrical signal
(feed-back). This signal is registered by the electronics.
The variation between the set-point and feed-back signals activates the four miniature valves
in the solenoid (see Fig 7.7.1). These miniature valves move the main spool to adjust to the
changes set by the joystick.

Fig 7.7.1 Proportional Valve

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7.7 PROPORTIONAL VALVES (08/03/25) 7-07-002

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7.8 FAULT MONITORING SYSTEM (08/03/25) 7-08-001

7.8 Fault Monitoring System

The proportional valves are equipped with a fault monitoring system, located in the solenoid,
to stop the hydraulic flow in the event of uncontrollable spool movements or positions. It
produces a fast and operator-independent reaction to stop the current to the solenoid,
causing the main spool to return to the neutral position. The indicator light on the solenoid
near the connector changes from green to red when the fault monitoring system is
activated.
The fault monitoring system is activated by the following problems:
1. If the set-point voltage is less than 10% or more than 90% of the supply. A short
circuit in the wiring harness to the joystick would create a lower set-point
voltage.
2. If the feed-back signal from the position transducer corresponds to a main spool
travel beyond the set-point signal of 15%. A stuck main spool would not move to
neutral position when the operator slows the operation.
NOTE: The monitoring system reacts only to faults of more than 500 ms
durations. It continues to interrupt until the problem is repaired, even after
restarting the drill.

7.8.1 Testing Proportional Valves

Remove the Hirschman connector and check the voltage between the pins to pin GR (See Fig
7.6.2).
NOTE: The joystick must be in full up, down or dead center position when
checking voltage at pin 1 & 2.
Supply voltage is 24 volts. Actual voltage may vary slightly.

Joystick in forward position (see Fig 7.8.1): pin 1: 24 volts DC (100% of supply voltage).

pin 2: 6 volts DC (25% of supply voltage).

Joystick in neutral (see Fig 7.8.1): pin 1: 0 volts DC

pin 2: 0 volts DC

Joystick in backward position (see Fig 7.8.1): pin 1: 24 volts DC (100% of supply voltage).

pin 2: 18 volts DC (75% of supply voltage).

Joystick in left position (see Fig 7.8.1): pin 1: 24 volts DC (100% of supply voltage).
pin 2: 18 volts DC (75% of supply voltage).

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7.8 FAULT MONITORING SYSTEM (08/03/25) 7-08-002

Joystick in right position (see Fig 7.8.1): pin 1: 24 volts DC (100% of supply voltage).

pin 2: 6 volts DC (25% of supply voltage).

Conclusion: If readings match above test, replace the solenoid

If readings do not match, check the following:

 Joystick not travelling to full position

 Faulty joystick
 Faulty wiring
 Improper voltage

Fig 7.8.1

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7.9 ACCRA-FEED CONTROL SYSTEM (08/03/25) 7-09-001

7.9 Accra-Feed Control System

The Accra-Feed System (AFS) is controlled by a programmable logic controller (PLC) that
provides significant productivity gains through improved hole accuracy and increased drill bit
life. The Accra-Feed system can consistently deliver hole accuracy of less than one (1)
percent deviation in holes over 30 meters long.

7.9.1 Accra-Feed Operation

During Accra-Feed operation, the forward rotation pressure and holdback relief circuit are
combined together, if the drill bit binds in the hole, the rotation pressure will increase in
turn, so will the holdback pressure. This will relieve weight on bit, as rotation pressure
decreases, so will the holdback and feed will return to the pre-set rate (feed
potentiometer).
Should forward rotation pressure exceed 1200 psi, the pressure switch will close, sending a
signal to the PLC which signals the anti-jam circuit to retract the feed cylinder for two (2)
seconds. How far the feed cylinder travels in two (2) seconds is controlled by the anti-jam
potentiometer. If forward rotation drops below 1200 psi, feed will resume.
If not, the PLC will again signal the anti-jam circuit. This is a continuous cycle of five (5)
attempts. After that, the feed cylinder will retract and stop. Rotation will be maintained
and a beacon or alarm will sound (optional).

7.9.2 Accra-Feed Components

VMM (Vansco Multiplexing Module)
ROTATION PRESSURE SWITCH
 Monitors forward rotation pressure (set at 1200 psi). See hydraulic
schematic.

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7.9 ACCRA-FEED CONTROL SYSTEM (08/03/25) 7-09-002

7.9.3 PLC Operation

When Accra-Feed is on, 24V is fed to PLC382, VMM8, Output 9 that energizes the hydraulic
valve to enable the rotation and holdback circuit. Feed and rotation signals from respective
potentiometers will be sent to the corresponding proportional valves. PLC422, VMM9, Input
11is the rotation pressure switch and will see 24V on a hydraulic pressure of 1200 psi. If this
happens, the signal of the anti-jam potentiometers will be sent to the feed proportional
valve until the pressure drops below 1200 psi for more than two (2) seconds.
Rotation Pressure Switch PLC422, VMM9, Input 11
Accra-Feed Valve PLC382, VMM8, Output 9
Feed Proportional Valve Consists of:

 Feed Power PLC262, VMM5, Output 4

 Feed Signal PLC262, VMM5, Output 5
Rotation Proportional Valve Consists of:

 Rotation Power PLC262, VMM5, Output 9

 Rotation Signal PLC262, VMM5, Output 10
Accra-Feed is set On/Off by pressing Accra-Feed button on the right joystick.
Pulldown is controlled by joystick and holdback is controlled by rotation pressure.

7.9.4 Maintenance of PLC in Accra-Feed System

1. Periodically, inspect the tightness of the terminal’s screws. They become
loose over a period of time.
2. Ensure that components are free of dust and contaminants.
3. Corrosion may take place in some environments (e.g. mining environment).
Check periodically for corrosion of connecting terminals. Printed circuit board
and connector may become corroded internally.

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7.9 ACCRA-FEED CONTROL SYSTEM (08/03/25) 7-09-003

7.9.5 Troubleshooting Guide

Symptoms Causes Corrective Action

No response or - The Feed joystick not all Call Electrician to troubleshoot the
movement from the way up or down following causes:
top drive while
- Loose wiring on terminals of 1) Check the terminal voltage signal of
moving the Feed
control panel Feed joystick-voltage power should be
joystick in manual
24 vdc and feed signal 6-18 vdc. If none
mode - Loose wiring in pins and
of this condition-replace the joystick.
sockets
2) Check for any loose wiring from
- Loose wiring on the
controller to the feed valve.
terminals of PLC
3) Check the voltage on Hirschmann
- Power supply is OFF
connector. For pin 1 =24 vdc, pin 2 = 6-
- PLC on error mode 18 vdc.
- PLC is OFF 4) If the PLC is on error mode, reset the
error or the power.
5) Check for Power LED. If not, consult
schematic for power wires.
If the problem still persists, call Technical
Support.

Slow feed travel up or - The Feed joystick is not all See No. 1
down in manual mode way up or down

No response or - No feed power 6) Check the Feed joystick if it is away

movement from the from the center.
- No feed signal
top drive during
7) Check PLC262, VMM5 Output 5 -if
Accra-Feed ON - Loose wiring
there’s no signal-replace the Anti-Jam
- No PLC power and Speed Adjustment Box.
- PLC on error mode 8) See No.3
9) Check Feed Power – PLC262, VMM5
Output 4.
If the problem still persists, call Technical
Support.

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7.9 ACCRA-FEED CONTROL SYSTEM (08/03/25) 7-09-004

No response or rotation - No rotational power 10) Check the terminal voltage signal of
from the saver sub rotational Joystick -voltage power
- No rotational signal
while moving the should be 24 vdc and rotational signal
Rotation joystick in - Loose wiring 6-18 vdc. If none of this condition -
manual mode - PLC on error mode replace the joystick.

- No power supply 11) Check for any loose wiring from

controller to the rotational valve.
12) See No.3
13) See No.4
If the problem still persists, call Technical
Support.

Slow rotational rpm in - The Feed joystick is not all See No. 10
manual mode way up or down

No response or rotation - No rotational power 14) Check the Rotation joystick - if it is

from the saver sub away from the center.
- No rotational signal
during Accra-Feed ON
15) Check PLC262, VMM5, Output 9 for
- Loose wiring
rotational power; PLC262, VMM5,
- No PLC power Output 10 for rotational signal pot-if
- PLC on error mode there’s no signal local or remote
rotational pot.
16) See No.3
If the problem still persists, call Technical
Support.

Rotational pressure - Loose wiring 17) Check the voltage supply on

switch won’t work Hirschmann connector between pin 1
- Defective pressure switch
and 3.
- Not set at 1,400 psi
18) Check the forward rotation torque
- PLC on error mode adjustment pressure if it is below 1,400
- No power supply psi (normal factory setting is at 1,600
psi).
19) Check the pressure switch, if it is
defective – replace with a new one.
20) Check PLC422, VMM9, Input 11 for
terminal connection.
If the problem still persists, call Technical
Support.

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7.9 ACCRA-FEED CONTROL SYSTEM (08/03/25) 7-09-005

Anti-Jam is not working ----- 21) Check the high pressure switch
when Accra- Feed is PLC382, VMM8, Input 6.
on
If the problem still persists, call Technical
Support.

Beacon alarm is not - Loose wiring 22) Check the voltage signal at PLC422,
working VMM9, Output 4 for beacon alarm.
- Defective light
23) Check the power supply for beacon
- PLC on error mode
alarm.
- No power supply
24) If the beacon is defective - replace
them with the new one.

Accra-Feed System is not See the previous causes 25) Check for the rotational pressure
working properly switch.
26) Check if the PLC is on error mode.
If the problem still persists, call Technical
Support.

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7.9 ACCRA-FEED CONTROL SYSTEM (08/03/25) 7-09-006

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7.10 OPERATOR INTERFACE PANELVIEW 1000 (08/03/25) 7-10-001

7.10 Operator Interface PanelView 1000

7.10.1 Maintenance of PanelView Terminal
1. Use ethyl alcohol (ethanol) on a cotton gauge pad or soft cloth to clean the touch
screen. This is more efficient than isopropyl (which leaves a slight residue upon
first application), and more safe than methyl ethyl ketone (MEK) which may discolor
the screen on repeated applications.
2. Use 50% solution of alcohol (ethanol or isopropyl) in water on a cotton gauge pad or
soft cloth to clean the enclosure.
3. Change intensity of the screen, as needed, from the start screen.

7.10.1 Main screen

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7.10 OPERATOR INTERFACE PANELVIEW 1000 (08/03/25) 7-10-002

7.10.2 Troubleshooting PanelView Terminal

PanelView is a color touch screen and it is mounted inside the cab. This terminal has 24VDC
power supply. The following table lists the most common messages that can occur on a
PanelView terminal.

Message Cause What To Do

Application is corrupted. The application file has become Try downloading the file again.
corrupted (checksum failure)
or invalid data was read from
it.

Application file is not The application file requires a Install the correct version of
compatible. later version of Firmware. Firmware.

Error erasing memory card. The memory card could be Try reformatting the memory
faulty. card using the “format
destination” button in the
memory card transfer
application screen. If this
does not work, replace the
memory card.

Error writing to memory. The memory card could be Try reformatting the memory
faulty. card using the “format
destination” button in the
memory card transfer
application screen. If this
does not work, replace the
memory card.

The transfer failed. File transfer failed. Try downloading the file again.
Application file corrupt.

Invalid file I/O. An error has occurred accessing Try reformatting the memory
the memory card. The card card using the “format
could be faulty. destination” button in the
memory card transfer
application screen. If this
does not work, replace the
memory card.

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7.10 OPERATOR INTERFACE PANELVIEW 1000 (08/03/25) 7-10-003

Memory card containing The current application is on the Replace the card and re-select
application file has PCMCIA card and the card is the application.
been ejected. Current ejected.
application file has
been de-selected.

Memory card format The memory card could be Try reformatting the memory
failed. Please try again. faulty. card using the “format
destination” button in the
memory card transfer
application screen. If this
does not work, replace the
memory card.

Time/Date received from The value of one or more of the Check that the PLC program is
PLC is invalid. Time and Date from PLC tag sending valid values to the
is not valid. terminal.

No memory card in the There is no memory card in the Insert a compatible memory
socket. Please replace socket. card in the sockt and try
card and try again. your action again.

“PLC communication lost” Cable problem. Check the termination and

message in the cable pin assignments.
PanelView display.

Rack assignments in the PLC and Make sure the rack

terminal do not match. assignments in the PLC
match the terminal.

Terminating resistor not Install the terminating resistor

installed properly. at both ends of the link:
 150 Ω ½ watt resistor
for 57.6 or 115.2
kbaud.
 82Ω ½ watt resistor for
230 kbaud.

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7.10 OPERATOR INTERFACE PANELVIEW 1000 (08/03/25) 7-10-004

7.10.3 Alarm Messages on the Terminal

The drill has a number of shutdown conditions in order to protect the drill from any unexpected
damages. The terminal is programmed to display various functions of the drill, as well as
alarm conditions that may shut down the drill if the conditions exceed the preset values.
The alarm screen is shown in Fig 7.10.2.

Example – the
applicable error will
be outlined in red

Reset
button

Error button
outlined in red

Fig 7.10.2 Alarm screen

Refer to the operator's manual for details on the display screens and their functions.

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7.11 DR CANBUS ELECTRICAL SYSTEM (08/03/25) 7-11-001

7.11 DR Canbus Electrical System

Your equipment is manufactured utilizing Canbus J1939 Multiplexing technology to provide the
machine with superior operating characteristics enhancing performance and minimizing
downtime of the unit.
Compared to conventional wiring utilizing relays the Canbus system offers reduced
maintenance, reduced space requirements, fewer connections, more options and fewer
reliability issues.
Multiplexing is used to combine multiple signals into a single complex signal to be transmitted
over a shared single medium. After transmission the complex signal is then restored to its
original constituent signals.
OEM’s are implementing multiplexed electrical systems because it reduces fuses and relays,
minimizes wiring costs and complexity, simplifies troubleshooting and provides unparalleled
reliability. Multiplexing also facilitates software configurable interlocks.

7.11.1 Components

7.11.1.1 Cab Control Panel

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7.11 DR CANBUS ELECTRICAL SYSTEM (08/03/25) 7-11-002

7.11.1.2 Rear Control Panel

7.11.1.3 PanelView

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7.11 DR CANBUS ELECTRICAL SYSTEM (08/03/25) 7-11-003

7.11.1.4 Joysticks

7.11.1.5 Mast Sensor Junction Box

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7.11 DR CANBUS ELECTRICAL SYSTEM (08/03/25) 7-11-004

7.11.1.6 Carousel Junction Box

7.11.1.7 10-Channel Low-Pass Filter Module

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7.11 DR CANBUS ELECTRICAL SYSTEM (08/03/25) 7-11-005

7.11.2 Canbus Components

7.11.2.1 Vansco Multiplexing Module (VMM) 1210 Multiplexing Module

Multiplexing technology allows manufacturers to reduce cost while increasing flexibility in
design and improving diagnostic capability.

Features

Economical and Rugged VMMs were designed and built for the on-highway and off-highway
industry by experienced professionals. This system is compliant to SAE J1455 and J1113
Environmental Standards.
“Plug and Play” Modules allows users to install a new module without having to resort to laptop
computers or other external devices. Very little training is required to diagnose and replace
a module.
Large I/O Count reduces the number of modules per vehicle, reducing system cost. The high
capacity self-limiting outputs eliminate the need for breakers and fuses and can be used in
parallel for higher current requirements.
Single Part Number System reduces inventory costs and simplifies diagnostic and repair work.

User Friendly Software uses a ladder logic format in a Windows™ environment. This allows for
easy initial programming, easy software/vehicle configuration changes, and simple
diagnostics.
Improved Connectivity with other parts of the electrical system on the vehicle. The VMM
System uses industry standard SAE J1939 CAN-based architecture for easy connectivity to
other standard devices.
Simple Diagnostics with indicator lights on each module and intuitive diagnostic software in
your PC, the VMM System reduces the time required to find and repair system faults, thereby
reducing downtime.

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7.11 DR CANBUS ELECTRICAL SYSTEM (08/03/25) 7-11-006

7.11.2.2 Pocket Gateway Module (PGM)

The Vansco Pocket Gateway Module is a general-purpose data protocol converter that can
receive, translate, and transmit information over J1708 and J1939 protocols. The PGM has
two J1939 ports and one J1708 port for connection to the most common automobile
networks. Additionally, the PGM has an RS-232 interface for connection to on-board
computers or laptops for diagnostics/reprogramming.

Features

Network Link provides data connection between the drive train network and chassis networks
while providing isolation between the networks. The PGM will pass through information that
is required by a second network and block all other traffic.
Data Link Adapter (DLA) The PGM provides PC interface to drive train network and other data
networks through the built-in RS-232 port. The PGM will pass real-time data through the
serial port for performing diagnostics.
Upgradeable Flash based application can be reprogrammed through the serial port without
disassembly.
Programmable general purpose platform can be programmed with custom applications for use
as a Master Controller/Gateway/Router/Bridge in any CAN/J1939/J1708 system.
Rugged Enclosed in a rugged plastic housing for protection from drops and chemical spills.
Operates over the industrial temperature range.

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7.11 DR CANBUS ELECTRICAL SYSTEM (08/03/25) 7-11-007

7.11.3 Operation
The VMM1210 is a programmable logic controller (PLC) for applications with steady state
voltages less than 32V. It has 12 inputs and 10 outputs as well as a CAN/J1939
communication port and an RS232 programming port. The VMM1210 performs the following
tasks:

Receives Digital/Analog/Frequency Inputs:

The VMM1210 has 8 digital inputs capable of reading either active high or active low
type inputs. In addition, it has 4 inputs capable of reading analog voltages,
frequency values or digital active low type inputs.

Activates Outputs:

The VMM 1210 has 8 high current (10A max) high side outputs. In addition it has two
low current (3A max) outputs capable of driving either high side or low side loads
and can also be arranged in an H-Bridge configuration. Outputs can drive any type of
load including lights, relays, solenoids, fans, etc.

Monitor Outputs:

The VMM1210 monitors its 10 outputs continuously for fault information. Faults include
short circuits (to ground or power), over currents and open load. The VMM1210
allows systems to reduce the number of fuses by allowing the outputs to protect
themselves electronically. In the event of a fault the VMM1210 will disable the
output(s) that are faulted. The automatic recovery of faulted states can be turned
on or off (for safety reasons). As well, if turned on, the automatic fault retry can be
adjusted to suit a variety of safety related situations. Open load detection allows
for the detection of open (burnt out) loads, this detection can be turned on or off
and can also be modified to check only at power up of the system or continuously.
Over current levels can be adjusted in one amp increments anywhere from 1A to
12A to allow the system to react more like various fuse types.

Communicate Input/Output State Information:

In order to multiplex, the VMM1210 must be able to communicate its information to

other CAN/J1939 messages representing the states of its inputs and outputs and
other ladder logic based equipment. These messages are broadcast type and can be
read by and acted on by any other module connected to the same CAN/J1939
network.

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7.11 DR CANBUS ELECTRICAL SYSTEM (08/03/25) 7-11-008

Processes Ladder Logic

Ladder logic is a graphical representation of standard logic (AND, OR, NOT, etc). The
VNN1210 processes ladder logic written using the Vansco Multiplex Module Software
Package (VMMS). The ladder logic defines which inputs or arrangement of inputs
turns on which outputs on the module. The inputs and outputs in the ladder logic
can be from one or more modules connected together in a system via the
CAN/J1939 network.
The VMM1210 is connected to various types of inputs and loads to allow the transmission of
input and output state information to other areas of the vehicle as shown below. In addition,
the VMM1210 can be liked via a Vansco Pocket Gateway Module (PGM) allowing it to remain
isolated from the drive train network and to communicate with devices on other networks
such as J1708. The following figure shows the arrangement of VMM1210’s and the CAN/J1939
network in a typical vehicle application.

In a typical arrangement, the VMM1210’s are place at various locations in the equipment (front,
rear, top, and bottom) and all are linked via the CAN/J1939 twisted pair shielded cable. This
arrangement allows the modules to act as multiplexors in that they all receive inputs and
drive outputs in their respective zones, but also communicate that input/output state
information to all others in the system. This has the effect of reducing long runs of wiring
from front to rear or top to bottom in equipment since all input/output information is
available on the CAN/J1939 network.

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7.11 DR CANBUS ELECTRICAL SYSTEM (08/03/25) 7-11-009

7.11.4 VMM 1210 Hardware and Software

7.11.4.1 Hardware
The VMM 1210 Hardware consists of the following:
 Infineon C167 microcontroller, 256KB Flash, 64KB SRAM
 8 General purpose digital inputs (programmable as active high or low and as power
control inputs)
 4 Programmable inputs (programmable as analog, digital or frequency)
 5 Dedicated address inputs
 8 General purpose high side drivers (10A per output rating, programmable PWM with
programmable base frequency)
 2 General purpose high side/low side outputs (programmable as high side or low side or
as an H-Bridge)
 2 High current bus bar inputs (supplies power to high side drivers)
 1 Logic power input
 1 CAN/J1939 Network Port
 1 Pseudo – RS232 Programming Port

General Purpose Inputs

Inputs 1 to 8 on the VMM 1210 are general purpose digital inputs. These inputs can be
programmed as active high or active low and as power control inputs using the VMM
Software package.

Programmable Inputs

Inputs 9, 10, 11 and 12 on the VMM1210 are programmable inputs. These inputs can be
programmed as analog, digital or frequency type inputs.

Address Inputs

There are 5 dedicated address inputs. These inputs are used to set the system address on the
module such that it is unique among all other modules in the system.

General Purpose High Side Outputs

Outputs 1 to 8 on the VMM1210 are general purpose, high current high side outputs.

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7.11 DR CANBUS ELECTRICAL SYSTEM (08/03/25) 7-11-010

General Purpose Low Side Outputs

Outputs 9 and 10 on the VMM1210 are general purpose, low current, programmable high or low
side outputs.

Power Connections

There are two main power connections, the high current bus bar battery power inputs and the
low current logic power input. The bus bar inputs are separated into two connectors of two
wires each. Bus bar current flow greater than 20A requires two wires in the connector, less
than 20A only requires one wire in the connector. To maintain product moisture sealing, if
both wires are not populated, the spare location should be populated with a plug.
There is one main low current logic power connection (power and ground wire) which is
required as the main power source for the VMM1210 circuitry. This draws low current
(<500mA) and should be connected to a power location with little voltage drop. This allows
the VMM to take advantage of its full voltage range as well as prevent analog shifts due to
ground level shifts.

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7.11 DR CANBUS ELECTRICAL SYSTEM (08/03/25) 7-11-011

7.11.4.2 VMM 1210 Software

The VMM 1210 has three pieces of software on board during normal operation. These are:
 Boot Code
 Application Code
 Ladder Logic

Boot Code

The boot code acts as a base operating system for the VMM1210. It provides the ability to
download other applications (such as ladder logic or application code) to the VMM1210 via
the CAN/J1939 port. Boot code is downloaded to the product at the factory and is typically
not upgradable by the end customer.

Application Code

The application code acts as the second level operating system for the VMM1210. It provided
the I/O scanning functions, the I/O state transmission functions, the plug and play functions
and the ladder logic processing functions. Application code is upgradable by the customer
and can be downloaded to VMM1210’s via the VMM Software package through the CAN/1939
network.

Ladder Logic

The ladder logic is the main program for the VMM1210 which allows the VMM1210 to perform
tasks based on the user requirements. Ladder logic is written using the VMM Software
package; a powerful, user-friendly, windows-based application. Ladder logic is drawn on the
graphical user interface and compiled, that is, converted into a format readable by the
VMM1210.

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7.11 DR CANBUS ELECTRICAL SYSTEM (08/03/25) 7-11-012

7.11.4.3 Updating the VMM1210 Software

The VMM1210 software can be updated with the use of the VMM Software package. The
software package provides the means to update Application Code as well as Ladder Logic.
This update is done through the CAN/J1939 network using either a Vansco Data Link Adapter
(DLA) or PGM to link the PC to the CAN/1939 network.
To update software, go the TOOLS menu and select DOWNLOAD LOGIC, DOWNLOAD
APPLICATION or DOWNLOAD PCM APPLICATION (see Section 7.11.4.4)
NOTE: the software must be setup with a key that provides permissions to download any or
all of these items. For keys or for more information on keys, please contact your local
reps.

7.11.4.4 PC Software Installation

The VMM software application is all that is required to generate and download ladder logic
applications, diagnose electrical system problems and start using the VMM1210. The
software is available through your local reps.

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7.11 DR CANBUS ELECTRICAL SYSTEM (08/03/25) 7-11-013

7.11.5 Functions

7.11.5.1 DR Input/Output List – Cab Control Panel – VMM1 PLC22

Inputs Outputs
Input # Pin # Function Input # Pin # Function
1 J1-1E Master Power 1 J1-3C Drill Light Cab Boom
2 J1-2A Engine Start 2 J1-3D Drill Light Cab Top
3 J1-2C Emergency Stop Cab 3 J2-1C HID Drill Light Mast Bottom
4 J1-2F Drill Light 4 J2-3C HID Tram Light Forward
5 J1-3B Tram Light 5 J1-3F HID Tram Light Reverse
6 J1-3E Horn 6 J1-1C HID Drill Light Mast Top
7 J2-1E Cab Pressurizer 7 J1-1D Tram Strobe Light
8 J2-1B Spare 8 J1-1F Work Strobe Light
9 J2-2B Spare 9 J2-3D Horn
10 J2-2D Spare 10 J2-1D Spare
11 J2-2C Spare
12 J2-2E Spare

7.11.5.2 DR Input/Output List – Cab Control Panel – VMM2 PLC62

Inputs Outputs
Input # Pin # Function Input # Pin # Function
1 J1-1E Master Power 1 J1-3C Master Power
2 J1-2A Pendant Start 2 J1-3D Wiper Drill Window
3 J1-2C Breakout Wrench In 3 J2-1C Spare
4 J1-2F Breakout Wrench Out 4 J2-3C Wiper Tram Window
5 J1-3B Winch In Slow 5 J1-3F Wiper Top Window
6 J1-3E Winch In Fast 6 J1-1C Spare
7 J2-1E Winch Out Slow 7 J1-1D Chair Heater
8 J2-1B Winch Out Fast 8 J1-1F Floor Heater
9 J2-2B Floor Heater On 9 J2-3D Cab Pressurizer
10 J2-2D Door Safety Bar 10 J2-1D Dome Light
11 J2-2C Throttle Supply
12 J2-2E Throttle Position

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7.11 DR CANBUS ELECTRICAL SYSTEM (08/03/25) 7-11-014

7.11.5.3 DR Input/Output List – Cab Control Panel VMM3 PLC102

Input Output
Input # Pin # Function Input # Pin # Function
1 J1-1E Master Power 1 J1-3C Air Conditioning 1
2 J1-2A Spare 2 J1-3D Air Conditioning 2
3 J1-2C Spare 3 J2-1C Air Conditioning 3
4 J1-2F Spare 4 J2-3C Gauge Power
5 J1-3B Spare 5 J1-3F Gauge On
6 J1-3E Spare 6 J1-1C Computer Power
7 J2-1E Spare 7 J1-1D Computer On
8 J2-1B Spare 8 J1-1F 12V Power Supply
9 J2-2B Spare 9 J2-3D Gauge Lights
10 J2-2D Spare 10 J2-1D Cab Sight Power
11 J2-2C Spare
12 J2-2E Spare

7.11.5.4 DR Input/Output List – Rear Control Panel VMM4 PLC222

Input Output
Input # Pin # Function Input # Pin # Function
1 J1-1E Master Power 1 J1-3C Power Emergency Stop
2 J1-2A Engine Start 2 J1-3D Water Trap Heater
3 J1-2C Compressor Low Oil Pressure 3 J2-1C Engine Start
4 J1-2F Compressor High Interstage Temp 4 J2-3C Low Air (180 psi)
5 J1-3B Compressor High Discharge Temp 5 J1-3F High Air (350 psi)
6 J1-3E Engine Power Unswitched 6 J1-1C Fan Flow Control
7 J2-1E Engine Power Unswitched 2 7 J1-1D Compressor Inlet Open
8 J2-1B Engine Power Switched 8 J1-1F Compressor Inlet Close
9 J2-2B Emergency Mode Enable 9 J2-3D Tram Speed High
10 J2-2D Spare 10 J2-1D Engine Shutdown
11 J2-2C Spare
12 J2-2E Spare

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7.11 DR CANBUS ELECTRICAL SYSTEM (08/03/25) 7-11-015

7.11.5.5 DR Input/Output List – Rear Control Panel VMM5 PLC262

Input Output
Input # Pin # Function Input # Pin # Function
1 J1-1E Master Power 1 J1-3C Feed Power
2 J1-2A Spare 2 J1-3D Feed Signal
3 J1-2C Spare 3 J2-1C Right Tram Power
4 J1-2F Spare 4 J2-3C Left Tram Power
5 J1-3B Spare 5 J1-3F Left Tram Signal
6 J1-3E Spare 6 J1-1C Right Tram Signal
7 J2-1E Spare 7 J1-1D Water Pump Power
8 J2-1B Spare 8 J1-1F Water Pump Signal
9 J2-2B Spare 9 J2-3D Rotation Power
10 J2-2D Spare 10 J2-1D Rotation Signal
11 J2-2C Spare
12 J2-2E Spare

7.11.5.6 DR Input/Output List – Rear Control Panel VMM6 PLC302

Input Output
Input # Pin # Function Input # Pin # Function
1 J1-1E Master Power 1 J1-3C Drill Air On
2 J1-2A Emergency Stop Tram Step 2 J1-3D Drill Air Off
3 J1-2C Emergency Stop Mast Rest 3 J2-1C Mast Swing Power
4 J1-2F Fire Suppression Pressure Switch 4 J2-3C Feed Extension Power
5 J1-3B Safety Relay 5 J1-3F Feed Extension Signal
6 J1-3E Spare 6 J1-1C Mast Swing Signal
7 J2-1E Spare 7 J1-1D Boom Swing Power
8 J2-1B Spare 8 J1-1F Boom Swing Signal
9 J2-2B Spare 9 J2-3D Mast Dump Power
10 J2-2D Spare 10 J2-1D Mast Dump Signal
11 J2-2C Spare
12 J2-2E Spare

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7.11 DR CANBUS ELECTRICAL SYSTEM (08/03/25) 7-11-016

7.11.5.7 DR Input/Output List – Rear Control Panel VMM7 PLC342

Input Output
Input # Pin # Function Input # Pin # Function
1 J1-1E Master Power 1 J1-3C Boom Lift Power
2 J1-2A Oscillation Up 2 J1-3D Boom Lift Signal
3 J1-2C Oscillation Down 3 J2-1C Oscillation Down
4 J1-2F Oscillation Left 4 J2-3C Cab Tilt Down
5 J1-3B Oscillation Right 5 J1-3F Cab Tilt Up
6 J1-3E Oscillation Front 6 J1-1C Oscillation Up
7 J2-1E Horn 7 J1-1D Right Track Power
8 J2-1B Spare 8 J1-1F Right Track Signal
9 J2-2B Spare 9 J2-3D Cab Swing Right
10 J2-2D Spare 10 J2-1D Cab Swing Left
11 J2-2C Spare
12 J2-2E Spare

7.11.5.8 DR Input/Output List – Rear Control Panel VMM8 PLC382

Input Output
Input # Pin # Function Input # Pin # Function
1 J1-1E Master Power 1 J1-3C Pulldown Relief
2 J1-2A Hydraulic Oil Low Level 2 J1-3D Holdback Relief
3 J1-2C Hydraulic Oil High Temp 3 J2-1C Splined Piston
4 J1-2F Engine Air Filter Indicator 4 J2-3C Reverse Drilling
5 J1-3B Compressor Air Filter Indicator 5 J1-3F High Rotation Torque
6 J1-3E Rotation High Pressure 6 J1-1C Thread Greaser
7 J2-1E Spare 7 J1-1D Chassis Greaser
8 J2-1B Spare 8 J1-1F Air Flush
9 J2-2B Feed Flow Channel A 9 J2-3D Accra-Feed
10 J2-2D Feed Flow Channel B 10 J2-1D Hammer Lubrication
11 J2-2C Rotation Flow Channel A
12 J2-2E Rotation Flow Channel B

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7.11 DR CANBUS ELECTRICAL SYSTEM (08/03/25) 7-11-017

7.11.5.9 DR Input/Output List – Rear Control Panel VMM9 PLC422

Input Output
Input # Pin # Function Input # Pin # Function
1 J1-1E Master Power 1 J1-3C HID Tram Light Forward
2 J1-2A VMM Power Mast 2 J1-3D HID Tram Light Reverse
3 J1-2C Unswitched Power Mast 3 J2-1C Back-up Alarm
4 J1-2F Switched Power Mast 4 J2-3C Rear Strobe Light
5 J1-3B Spare 5 J1-3F Level Sensor Power
6 J1-3E Spare 6 J1-1C Flow Transducer Power
7 J2-1E Low Water Level Alarm 7 J1-1D Tram Light Mast Rest
8 J2-1B Low Water Level Shut Off 8 J1-1F Tram Light Left Rear
9 J2-2B Pulldown Pressure 9 J2-3D Pressure Transducer Power
10 J2-2D Holdback Pressure 10 J2-1D Spare
11 J2-2C Rotation Pressure
12 J2-2E Drill Air Pressure

7.11.5.10 DR Input/Output List – Mast Valve Junction Box VMM10 PLC482

Input Output
Input # Pin # Function Input # Pin # Function
1 J1-1E Master Power 1 J1-3C Winch Out
2 J1-2A Spare 2 J1-3D Winch In
3 J1-2C Spare 3 J2-1C Centralizer In
4 J1-2F Spare 4 J2-3C Breakout Wrench Out
5 J1-3B Spare 5 J1-3F Breakout Wrench In
6 J1-3E Spare 6 J1-1C Centralizer Out
7 J2-1E Spare 7 J1-1D Diverter Down
8 J2-1B Spare 8 J1-1F Diverter Up
9 J2-2B Spare 9 J2-3D Slips Out
10 J2-2D Spare 10 J2-1D Slips In
11 J2-2C Spare
12 J2-2E Spare

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7.11 DR CANBUS ELECTRICAL SYSTEM (08/03/25) 7-11-018

7.11.5.11 DR Input/Output List – Mast Valve Junction Box VMM11 PLC522

Input Output
Input # Pin # Function Input # Pin # Function
1 J1-1E Master Power 1 J1-3C Carousel Arm In
2 J1-2A Arm Out 2 J1-3D Carousel Arm Out
3 J1-2C Cable Safety Switch 3 J2-1C Spare
4 J1-2F Spare 4 J2-3C Carousel Clamp Close
5 J1-3B Spare 5 J1-3F Carousel Clamp Open
6 J1-3E Spare 6 J1-1C Spare
7 J2-1E Spare 7 J1-1D Winch High Speed
8 J2-1B Spare 8 J1-1F Sensor Supply
9 J2-2B Spare 9 J2-3D Carousel Rotate In
10 J2-2D Spare 10 J2-1D Carousel Rotate Out
11 J2-2C Spare
12 J2-2E Spare

7.11.5.12 DR Input/Output List – Mast Sensor Junction Box VMM12 PLC582

Input Output
Input # Pin # Function Input # Pin # Function
1 J1-1E Master Power 1 J1-3C Stage Sensor Power
2 J1-2A Stage 1 2 J1-3D Laser Sensor Power
3 J1-2C Stage 2 3 J2-1C Drill Light Makeup & Breakout
4 J1-2F Spare 4 J2-3C Spare
5 J1-3B Spare 5 J1-3F Spare
6 J1-3E Spare 6 J1-1C Spare
7 J2-1E Spare 7 J1-1D Spare
8 J2-1B Spare 8 J1-1F Spare
9 J2-2B Spare 9 J2-3D Spare
10 J2-2D Spare 10 J2-1D Spare
11 J2-2C Spare
12 J2-2E Spare

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7.12 SOFTWARE UPGRADES (08/03/25) 7-12-001

7.12 Software Upgrades

Occasionally, software (program) upgrades will be necessary and you may be required to
upgrade these in the field. This section contains the information required to perform these
upgrades.

7.12.1 Installing Vansco Software onto a Laptop

The following is a step-by-step procedure for installing Vansco Software version
VMMS_V5_0_4_532 and the license key onto a laptop.
NOTE: ONLY THIS VERSION OF THE VANSCO SOFTWARE IS COMPATIBLE WITH YOUR DR DRILL.
The Vansco software and license key must be obtained from your local dealer. Installing a
different version of the Vansco software will result in your machine not functioning.

7.12.1.1 Basic Qualifications

The individual performing installation tasks must have a good familiarization with
computers. A person must be familiar with opening, saving, and copying files on
a computer, as well as exploring the different drives on a computer. They must
understand, and be competent with, loading programs and/or software on a
computer. Most importantly, a person must be able to follow technical
instructions.

7.12.1.2 Procedure
1. Insert the memory stick into a USB port on your laptop.
2. Locate the USB drive (D:, E:, etc) on your laptop and open it.
3. Copy the zip file with the Vansco software onto your laptop in whatever location
is convenient (the Desktop, the My Documents folder, etc).
4. Open the folder where you copied the zip file (see Fig 7.12.1) and double click
on it to open it.

Zip file

Fig 7.12.1

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7.12 SOFTWARE UPGRADES (08/03/25) 7-12-002

5. Fig 7.12.2 shows the screen that will open. Now double click on the
VMMS_V5_0_4_532 folder to open it.

VMMS_V5_0_4_532
folder

Fig 7.12.2

6. Fig 7.12.3 shows the screen that will open. Now double click on SETUP.EXE to
start the installation.

SETUP.EXE

Fig 7.12.3

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7.12 SOFTWARE UPGRADES (08/03/25) 7-12-003

7. A box will appear, showing that the installation files are being extracted (see Fig
7.12.4).

Fig 7.12.4

8. When the Welcome screen appears, click on “Next” (see Fig 7.12.5).

Click here

Fig 7.12.5

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7.12 SOFTWARE UPGRADES (08/03/25) 7-12-004

9. When the Software License Agreement appears, click “Yes” (see Fig 7.12.6).

Click here

Fig 7.12.6

10. When the User Information box appears, you can fill in your name and company
and then click “Next” (see Fig 7.12.7).

Click here

Fig 7.12.7

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7.12 SOFTWARE UPGRADES (08/03/25) 7-12-005

11. When the Choose Destination Location box appears, click “Next” (see Fig
7.12.8). A new folder will be automatically created – there is no need to choose
a different location.

Click here

Fig 7.12.8

12. When the Select Program Folder box appears, click “Next” (see Fig 7.12.9). The
correct program will be automatically selected – there is no need to select the
program manually.

Click here

Fig 7.12.9

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7.12 SOFTWARE UPGRADES (08/03/25) 7-12-006

13. When the Start Copying File box appears, click “Next” (see Fig 7.12.10).

Click here

Fig 7.12.10

14. The next screen that appears shows the status of the software being loaded (see
Fig 7.12.11).

Shows how much (%) of the

program has been loaded

Fig 7.12.11

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7.12 SOFTWARE UPGRADES (08/03/25) 7-12-007

15. When the Setup Complete box appears, click “Finish” (see Fig 7.12.12). The
Vansco software is now loaded on your laptop.

Click here

Fig 7.12.12

16. Now we will load the license key. First, go to your Windows Start button, then
All Programs, then VMM Software V5.0.4.532, then click on “VMMS V5.0.4.532”
(see Fig 7.12.13).

3. Select VMM Software V5.0.4.532

2. Select All Programs 4. Click here

1. Click Start

Fig 7.12.13

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7.12 SOFTWARE UPGRADES (08/03/25) 7-12-008

17. Now you should see the VMM Software banner at the top of your screen (see Fig
7.12.14).

Fig 7.12.14

18. On the VMM Software banner, click on “Help” and then click on “Enter Product
Key” (see Fig 7.12.15).

Click here

Fig 7.12.15

19. Now the VMMS Authentication box will open and you can enter the license key
that has been provided in the space provided. When it has been entered, click
“OK” (see Fig 7.12.16).

Click here

Fig 7.12.16

NOTE: The product key shown here is not necessarily the correct key for your
software. Enter the product license key supplied to you.

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7.12 SOFTWARE UPGRADES (08/03/25) 7-12-009

20. The last box that appears is to verify that the license key has been accepted.
Click “OK” to complete the process.

Click here

Fig 7.12.17

Your VMM Software and License Key have been loaded successfully.

Copyright © Sandvik Mining and Construction

7.12 SOFTWARE UPGRADES (08/03/25) 7-12-010

7.12.2 Installing Software into the DR

The purpose of this document is to describe the step by step procedure for installing
software on the GenV DR’s. We will cover the basic qualifications of the
individual performing the tasks, the two different program systems on a DR that
may require software or program installations, and the tools required for
software installation.

7.12.2.1 Basic Qualifications

The individual performing installation tasks must have good familiarization with
computers. They must be competent with and understand loading programs and
or software on a computer. A person must be familiar with opening, saving, and
copying, files on a computer, as well as exploring the different drives on a
computer. Most importantly, a person must be able to follow technical
instructions.

7.12.2.2 Program Systems on the DR

ERIS
The first system on the DR is the Eris system. This system takes your input from the
touchscreen and sends signals to the Vansco modules.

Vansco
The second system is the Vansco system. This system is the control system of the
drill. The Vansco modules will receive signals from the ERIS program and operate
the drill accordingly.

7.12.2.3 Tool List

Part # Description Qty. Use
N/A PERSONAL LAPTOP 1 For Vansco programming
CX001989 CABLE-USB 1 For ERIS programming
CP000272 USB TRAVEL KEYBOARD 1 For ERIS programming
CP000271 USB FLASH DRIVE 512MB 1 For ERIS and Vansco programming
CP001046 VANSCO DATA LINK ADAPTER 1 For Vansco programming

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7.12 SOFTWARE UPGRADES (08/03/25) 7-12-011

7.12.2.4 Pre-Installation
All procedures in Section 7.12.2 will take place inside the cab of the DR (see Fig 7.12.18).

Cab

Fig 7.12.18

Inside the cab, we have the main control panel called the Cab Control Panel, or CCP for short.
It is inside the CCP that we will make our connections for loading programs (see panel in
Fig 7.12.19).

Cab Control Panel

(CCP)

Fig 7.12.19

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 7.12 SOFTWARE UPGRADES (08/03/25) 7-12-012

7.12.2.5 Accessing the Cab Control Panel

1. In order to access the CCP, there are four locking clips securing the top cover.
You must pull the clips up and then turn them to release the cover (see Fig
7.12.20).

Locking Clips
Locking Clips

Fig 7.12.20

2. Now that the cover is released, you can lift the cover and use the locking bar on
the left side of the cabinet to hold the cover open (see Fig 7.12.21).

Locking Bar

Fig 7.12.21

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3. You can now grab the front cover with your hands and pull up to remove it. Make
sure you grab the cover in the middle at the top when pulling it up. This will give
you more complete access to the inside of the control panel (see Fig 7.12.22).

Front Cover
removed

Fig 7.12.22

All the remaining procedures in Section 7.12.2 will take place in the cab with the
control panel opened as in Fig 7.12.22.

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7.12 SOFTWARE UPGRADES (08/03/25) 7-12-014

NOTE: Section 7.12.2.6, Section 7.12.2.7, Section 7.12.2.8, and Section 7.12.2.9, MUST
BE PERFORMED IN ORDER.

7.12.2.6 Connecting the Keyboard to the CCSystems Computer

In this section, we will be covering the steps required to connect the keyboard to
the computer in the drill in order to load programs.
There are only two tools required for this section:
USB Cable, Part Number CX001989 (See Fig 7.12.23)

Fig 7.12.23
USB Keyboard, Part Number CP000272 (See Fig 7.12.24)

Fig 7.12.24

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7.12 SOFTWARE UPGRADES (08/03/25) 7-12-015

1. We now need to locate the computer to attach our cable for programming. The
computer is inside the control panel and is located on the back left side (see Fig
7.12.25 for identification).

Computer

Fig 7.12.25
2. The computer comes with a plate that identifies what each port is for. For our
programming, we will be using one of the four USB ports. It does not matter
which USB port you use. In this example, USB 1 and 2 are used by the joysticks;
therefore, USB 3 or 4 can be used for programming (see Fig 7.12.26).
NOTE: Two of the USB ports will already be occupied by the joysticks.

Used USB ports

Free USB ports

Fig 7.12.26

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7.12 SOFTWARE UPGRADES (08/03/25) 7-12-016

NOTE: The plug on your cable and the USB port are keyed so that they can only go
together one way. The USB cable has a groove cut into it (see Fig 7.12.27) and
the computer has a notch moulded into it (see Fig 7.12.28). They are made this
way so that you cannot plug in the cable incorrectly.

Groove Notch

Fig 7.12.27 Fig 7.12.28

3. Now take your USB cable (see Fig 7.12.29) and plug it into one of the vacant USB
ports on the computer (see Fig 7.12.30).

Plug into keyboard

Plug in

Fig 7.12.29 Fig 7.12.30

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7.12 SOFTWARE UPGRADES (08/03/25) 7-12-017

4. Now take your USB keyboard (see Fig 7.12.31) and plug it into the other end of
the USB cable that you just connected to the computer (see Fig 7.12.32).

Plug in

Fig 7.12.31 Fig 7.12.32

Your keyboard is now connected to the CCSystems computer.

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7.12 SOFTWARE UPGRADES (08/03/25) 7-12-018

7.12.2.7 Loading ERIS Software into the DR Drill

ERIS software is the program that loads onto the monitor screen to operate the drill.
This section will cover the step by step procedure for loading ERIS software on a
DR drill. It is important to note that THE COMPUTER MUST BE ON TO LOAD
PROGRAMS.
NOTE: Make sure that you have completed the previous section “CONNECTING TO
THE CCSYSTEMS COMPUTER”, before starting into this section. UPON
COMPLETION OF SECTION “CONNECTING TO THE CCSYSTEMS COMPUTER”, STEP 1
BELOW SHOULD BE COMPLETED. IF NOT, REPEAT PREVIOUS SECTION.
Three are only three tools for this section. Two of them are from the previous
section:
USB Cable, Part Number CX001989 (See “Connecting to the CCSytems Computer”
section)
USB Keyboard, Part Number CP000272 (See “Connecting to the CCSytems
Computer” section)
USB Flash Drive 512MB, Part Number CP000271 (See Fig 7.12.33)

Fig 7.12.33

1. First, plug the USB keyboard into any of the USB ports on the CCSystems
computer (computer located inside of Cab Control Panel), and wait a minute for
the computer to recognize the keyboard. See also step 3 in Section 7.12.2.6.

Fig 7.12.34 USB Keyboard Fig 7.12.35 USB ports, CCSystems Computer

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7.12 SOFTWARE UPGRADES (08/03/25) 7-12-019

2. Press the “ESC” button on the keyboard to open Windows on the touchscreen.

ESC Key

Touchscreen

Fig 7.12.36 ESC (escape) key Fig 7.12.37

3. Plug your USB key into one of the USB ports on the keyboard to copy the ERIS
software onto the desktop.

USB port location

USB ports

Fig 7.12.38 Fig 7.12.39

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7.12 SOFTWARE UPGRADES (08/03/25) 7-12-020

4. Once the folder for your USB key opens (see Fig 7.12.40), copy the ERIS program
to the Desktop for present and future installation. Then proceed to step 7.
If the folder for your USB key does not open automatically, go to step 5.
See Section 7.12.2.7.1 for instructions on how to copy the program to the
Desktop.

Copy the ERIS program file

onto the Desktop

Fig 7.12.40

5. If your USB key does not open automatically, then right click over top of the Start
button at the bottom left of the screen and then select “Explore” (see Fig
7.12.41).

Right-click on “Start”, then

select “Explore”

Fig 7.12.41

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7.12 SOFTWARE UPGRADES (08/03/25) 7-12-021

6. Once the Windows Explorer opens, locate the USB drive (D:, E:, etc) and left click
on it once to display the files on it. Then copy the ERIS program file and paste it
onto your Desktop. See Fig 7.12.42.

ERIS program file

USB key

Fig 7.12.42

7. Before we install the new program, we must first un-install the existing program.
Click on the Start tab at the bottom left of the Desktop and go to Programs, then
ERIS, then DR OCC, and click “Uninstall”. See Fig 7.12.43.

3. Select ERIS

2. Select Programs

4. Select DR OCC

1. Click Start

5. Click here

Fig 7.12.43

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7.12 SOFTWARE UPGRADES (08/03/25) 7-12-022

8. Once the program has been uninstalled, you have to install the new program
(should now be located on your Desktop). See Fig 7.12.44. Follow the steps A – B
(following) to install the software.

New program

Fig 7.12.44

A) Double left-click the icon. (100145 - v1.11 - ERIS Software Assembly Install - DR.)
NOTE: The text on your icon will be specific to your drill type (DR, Orion, etc).
B) Then follow the prompts as follows:

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7.12 SOFTWARE UPGRADES (08/03/25) 7-12-023

i) Click “Install”.

Click here

Fig 7.12.45

ii) Click “Next”.

Click here

Fig 7.12.46

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7.12 SOFTWARE UPGRADES (08/03/25) 7-12-024

iii) Click “Install”.

Click here

Fig 7.12.47

iv) Click “Close”.

Click here

Fig 7.12.48

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7.12 SOFTWARE UPGRADES (08/03/25) 7-12-025

v) Click “Next”.

Click here

Fig 7.12.49

vi) Click “Install”.

Click here

Fig 7.12.50

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7.12 SOFTWARE UPGRADES (08/03/25) 7-12-026

vii) Click “Close”.

Click here

Fig 7.12.51

viii) Click “Close”.

Click here

Fig 7.12.52

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7.12 SOFTWARE UPGRADES (08/03/25) 7-12-027

9. Once the new program is installed, re-start the computer to ensure the ERIS
program loads into Windows.

NOTE: If you experience any problems with the installation of the new program,
please contact technical support.

7.12.2.7.1 How to copy the ERIS program to the Desktop

1. Put your arrow over top of the ERIS program icon and right click your mouse. A
menu will open; select “Copy”.

Right-click here

This menu will appear

– click “Copy”

Fig 7.12.53

2. Hold your arrow over a blank spot on your Desktop and right click your mouse. A
menu will open; select “Paste”.

Click “Paste”

Fig 7.12.54

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7.12 SOFTWARE UPGRADES (08/03/25) 7-12-028

3. Your program has now been copied to your Desktop. You will see an icon for your
program on the Desktop (see Fig 7.12.55).

Program icon

Fig 7.12.55

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7.12 SOFTWARE UPGRADES (08/03/25) 7-12-029

7.12.2.8 Connecting a Laptop to the Vansco System

In this section, we will be covering the steps required to connect to the Vansco
system for loading programs.
There are only two tools required for this section:
Laptop, Part Number CP001560 (See Fig 7.12.56)

Fig 7.12.56
Vansco Data Link Adapter, Part Number CP001046 (See Fig 7.12.57)

Fig 7.12.57

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7.12 SOFTWARE UPGRADES (08/03/25) 7-12-030

1. In order to connect to the Vansco system, we must return to the CCP (see Fig
7.12.58).

Fig 7.12.58

2. Locate the three programming ports for the Vansco system (see Fig 7.12.59). Two
of these ports will be connected with a jumper plug.

Programming ports for

Vansco system

Fig 7.12.59

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7.12 SOFTWARE UPGRADES (08/03/25) 7-12-031

3. You must remove one of the plugs from a port to connect your Data Link Adapter
(see Fig 7.12.60).

Remove plug from port

Fig 7.12.60

4. Now take the three pin connector on the Data Link Adapter (see Fig 7.12.61) and
plug it into the empty port (see Fig 7.12.62).

Three pin connector

Connector plugged in

Fig 7.12.61 Fig 7.12.62

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7.12 SOFTWARE UPGRADES (08/03/25) 7-12-032

5. Now take the USB cable from the Data Link Adapter (see Fig 7.12.63) and plug it
into a USB port on your laptop.

USB cable

Fig 7.12.63

Your laptop is now connected to the Vansco system.

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7.12 SOFTWARE UPGRADES (08/03/25) 7-12-033

7.12.2.9 Loading Vansco Programs on your DR Drill

Vansco programs are the programs that control the functions of the drill. This
section will cover the step by step procedure for loading Vansco programs on a
DR drill. It is important to note that THE VANSCO MODULES MUST BE ON TO LOAD
PROGRAMS.
NOTE: Make sure that you have completed Section “CONNECTING A LAPTOP TO THE
VANSCO SYSTEM” before starting into this section. Upon completion of Section
“CONNECTING A LAPTOP TO THE VANSCO SYSTEM”, step 1 below should be
completed. If not, repeat the previous section.
There are only two tools required for this section:
Laptop, Part Number CP001560 (See “Connecting a Laptop to the Vansco System”
section)
Vansco Data Link Adapter, Part Number CP001046 (See “Connecting a Laptop to
the Vansco System” section)

1. Using the Vansco-USB Data Link Adapter (see Fig 7.12.64), connect the USB plug
to the port on the laptop (see Fig 7.12.65) and the three-pin connector (see Fig
7.12.66) to one of the three Canbus ports in the Cab Control Panel (see Fig
7.12.67).

Fig 7.12.64

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7.12 SOFTWARE UPGRADES (08/03/25) 7-12-034

Fig 7.12.65 Fig 7.12.66

Fig 7.12.67

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7.12 SOFTWARE UPGRADES (08/03/25) 7-12-035

2. Now go to the Windows Start menu, select “All Programs”, then select “VMM
Software V7.0.2.717”, then select “VMMS Software V7.0.2.717” (see Fig 7.12.68).

2. Select All Programs

3. Select VMM Software V7.0.2.717

4. Click here
1. Click Start

Fig 7.12.68

3. Now a software license screen will pop up. Just select “Accept” (see Fig 7.12.69).

Click here

Fig 7.12.69

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7.12 SOFTWARE UPGRADES (08/03/25) 7-12-036

4. Now the security screen will pop up. Your UserName is “USERNAME” and the
Password is “password” (both are case-sensitive; enter them exactly as shown).
Once the fields have been entered, click “OK” (see Fig 7.12.70).

Click here

Fig 7.12.70

5. Now you will want to query the CanBus to see which Canbus port you are
connected to (if the ports are labeled, connect to the correct port for your new
program and skip to step 8). There are three options – the Cab, the Mast, or the
RCP (Remote Control Panel). You need to be connected to the correct port for
your new program.
Look at the top left corner of the screen, second row of icons and click on the
button that looks like a magnifying glass (see Fig 7.12.71).

Click here

Fig 7.12.71

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7.12 SOFTWARE UPGRADES (08/03/25) 7-12-037

6. You should now see the Query screen. Click on “Query” at the bottom right hand
of the screen (see Fig 7.12.72).

Click here

Fig 7.12.72

7. The Query screen should now be open. Refer to Fig 7.12.73. In our example (Fig
7.12.73), all 12 VMM’s are showing.

Fig 7.12.73

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7.12 SOFTWARE UPGRADES (08/03/25) 7-12-038

8. Once you are connected to the correct Canbus port, you should always upload
and save the existing program onto your laptop. If there is ever a problem with
the new program, you can reload the previous one.
To upload the existing program, you must click on “Upload Logic” (see Fig 7.12.74).

Click here

Fig 7.12.74

9. You should now see a screen that allows you to begin the program upload. Click
on “Begin” (see Fig 7.12.75).

Click here

Fig 7.12.75

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7.12 SOFTWARE UPGRADES (08/03/25) 7-12-039

10. You should now have a screen come up that is asking you where to save the
uploaded program and what you would like to call it (see Fig 7.12.76).

This screen will open

Fig 7.12.76

11. Using the drop down menu at the top, select Desktop. Your Desktop is an easily
accessible location to find a program if it’s needed (see Fig 7.12.77).

Select “Desktop”

Fig 7.12.77

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7.12 SOFTWARE UPGRADES (08/03/25) 7-12-040

12. You now have to give a name to the program being uploaded. In our example,
we have named it “vmmOLD”. Any name is fine; however, make sure you use a
name you will remember. Then click on “Save” (see Fig 7.12.78).

Click here

New name for program

Fig 7.12.78

13. Once the Upload is complete, you have an option to enter the Editor mode or
the Diagnostic mode. Click on “Cancel” as there is no need to enter either mode
at this time (see Fig 7.12.79).

Click ”Cancel”

Fig 7.12.79

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7.12 SOFTWARE UPGRADES (08/03/25) 7-12-041

14. You must now locate your new VMM program. It should have been emailed to
you previously and saved on your laptop. Once you have located the new
program, double click it to open (see Fig 7.12.80). We have called our new
program “vmmNew” – you can see the new program icon saved on the desktop.

Click here

Fig 7.12.80

15. Once your program has opened, click on the Query button (looks like a
magnifying glass). See Fig 7.12.81.

Click here

Fig 7.12.81

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7.12 SOFTWARE UPGRADES (08/03/25) 7-12-042

16. Now click on “Download Logic” (see Fig 7.12.82).

Click here

Fig 7.12.82

17. You should now see a screen that allows you to begin the program download.
Click on “Begin” (see Fig 7.12.83).

Click here

Fig 7.12.83

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7.12 SOFTWARE UPGRADES (08/03/25) 7-12-043

18. You will now be prompted start the download after the program verifies you are
connected to the VMM’s. Click on “Yes” (see Fig 7.12.84).

Click here

Fig 7.12.84

19. You should now see the following screen showing the progress of the download
(see Fig 7.12.85).

Fig 7.12.85

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7.12 SOFTWARE UPGRADES (08/03/25) 7-12-044

20. You should now see the following screen confirming that the download was
successful (see Fig 7.12.86). If it is unsuccessful, repeat the procedure from step
14; otherwise click on “Close”.

Fig 7.12.86

The download is now complete.

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8.0 TROUBLESHOOTING (08/03/25)

8.0 TROUBLESHOOTING

Clean Tools and Equipment!

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Copyright © Sandvik Mining and Construction
8.1 TROUBLESHOOTING THE TRAM DRIVE (08/03/25) 8-01-001

8.0 Troubleshooting
If the performance is lacking, action must be taken to correct any problems. The
operator is expected to be able to repair minor problems that are within his/her
responsibilities. Any problem beyond that must be repaired by certified
maintenance people.
This section is intended for the use of the operator and a more detailed
Troubleshooting Guide can be found in the Maintenance Manual.
It is the operator's responsibility to report any apparent problems to the
maintenance personnel.

8.1 Troubleshooting the Tram Drive

Crawler Does Not Run but Tramming Motors Are Operating

Check for sheared off bolts at the final drive sprocket.
Check for mud build up at the crawler tracks.
Check if the tracks are off the front idler. Loosen the track and move it back onto
the wheel. Adjust tracks to proper tension.
Check for frozen tracks and thaw the ice as required.

Crawler Does Not Move and Tramming Motor Does Not Run
Check items 1, 2, and 3 as above.
Check for damaged parts in the tram drive and the final drive gearbox.
Check if tram motor is running.

Crawler Does Not Tram Straight

Check if both torque hubs are engaged.
Perform checks as outlined in "Crawler Does Not Move".

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8.1 TROUBLESHOOTING THE TRAM DRIVE (08/03/25) 8-01-002

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8.2 TROUBLESHOOTING THE HYDRAULIC SYSTEM (08/03/25) 8-02-001

8.2 Troubleshooting the Hydraulic System

Pump Does Not Deliver Oil

Check for proper fluid level and appropriate oil viscosity in hydraulic reservoir. In
extreme cold conditions, it may be necessary to heat the oil.
Check for proper pump rotation as marked on coupling guard.
Check for flow restriction by inspecting the suction line, strainer, and reservoir.
Check for air leaks at pump intake. Oil level must be above bottom of sight glass.
Check for sheared off pump drive shaft.
Check pump load sense line for oil flow. Test each function separately.

Pump is Running Hot

Check for any function stuck open.

Cavitation or Pump Noise

Check for air leaks at the pump intake or shaft packing. Pour oil on joints and
around drive shaft then listen for change in operation.
Check for proper oil viscosity.

Insufficient Pressure
Check for proper oil level in reservoir.

Slow Rotation at Top Drive

Check for low pump delivery (see "Pump Does Not Deliver Oil").
Check for malfunctioning of hydraulic motor.

No Rotation at Top Drive Assembly

Check for hydraulic motor malfunctioning.
Check for damaged gears or bearing.
Check for pump flow (see "Pump Does Not Deliver Oil").

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8.2 TROUBLESHOOTING THE HYDRAULIC SYSTEM (08/03/25) 8-02-002

Slow or No Feed
Check for low pump delivery (see "Pump Does Not Deliver Oil").
Check for oil insufficient pressure.
Check pulldown relief valve for high setting. Pulldown pressure must be
approximately 100 psi (6.9 bar) higher than holdback pressure.
Check for high setting of holdback relief valve.
Check for internal leaks in feed cylinder.
Check for binding in top drive mounting plate.

Mast Does Not Rotate

Check for restrictions in set up control valve by removing hoses.
Check for collapsed hydraulic hose to actuator.
Check main pressure in hydraulic pump.

Actuator Allows Mast to Move After Being Set

Check for bypassing of directional control valve. Inspect the valve spool.
Check for damaged counterbalance valve cartridge.

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8.3 TROUBLESHOOTING THE WATER INJECTION PUMP (08/03/25) 8-03-001

8.3 Troubleshooting the Water Injection Pump

Discharge Pressure is Too Low

Check for restrictions in suction line or relief valve.
Check for incorrect valve adjustment or damaged relief valve.
Check for low pump speed. Pump should run at 12 l/min proportionally.

Cavitation Problems
Cavitation occurs in the pump when the cylinders do not fill completely with water
during the suction stroke. This condition creates a pressure pulsation, which may
damage the pump and equipment if not repaired immediately.
Check for proper diameter of water supply line. This line must be the same or
larger than pump suction plumbing.
Check for air leaking into the suction system by tightening fittings and inspecting
hoses.
Check for weak or worn plunger packing. Partially worn plunger packing may draw
air on the suction stroke but these may not leak during the discharge stroke,
creating a similar condition as in cavitation.

No Water Discharge
Check for restrictions in the suction line.
Check if suction line valve is closed.

Excessive Pump Noise

Check for loose suction line connection.
Check for over speeding of pump. Reduce the flow to the hydraulic motor by
adjusting the flow control valve.

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8.3 TROUBLESHOOTING THE WATER INJECTION PUMP (08/03/25) 8-03-002

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8.4 TROUBLESHOOTING THE AIR DRIVEN OIL INJECTION PUMP (08/03/25) 8-04-001

8.4 Troubleshooting the Air Driven Oil Injection Pump

Air Motor Does Not Operate

Check for restrictions in the air supply line.

Air Seepage from Air Exhaust While Pump is Not Working

Check for leaking inlet valve.

Loss of Pressure, Volume, or Continuous Operation of Pump when Not in Normal

Use
Check for foreign particles on the piston seat or on the ball of the foot valve.
Check for damaged piston or foot valve.
Check for scorn pump tube wall and replace if required.

Excessive Amount of Air in Lubricant or Excessive Amount of Lubricant in Air

Check air leakage at gland packing, gland gasket, O-ring and U-cup packing.
NOTE: Some lubricant in the exhaust air is required.

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8.4 TROUBLESHOOTING THE AIR DRIVEN OIL INJECTION PUMP (08/03/25) 8-04-002

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8.5 TROUBLESHOOTING THE AIR DRIVEN GREASE INJECTION (08/03/25) 8-05-001

8.5 Troubleshooting the Air Driven Grease Injection

Air Motor Does Not Operate

Check for restrictions in the air supply line.
Check air pressure on regulator.

Grease Is Not Delivered to the Drilling Air Line

Check if grease level is low.
Check for grease output from vent when open. Prime the line if air is trapped.
Check for grease injection from the injector. Prime and adjust if required.

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8.5 TROUBLESHOOTING THE AIR DRIVEN GREASE INJECTION (08/03/25) 8-05-002

Copyright © Sandvik Mining and Construction

8.6 TROUBLESHOOTING THE AIR DELIVERY SYSTEM (08/03/25) 8-06-001

8.6 Troubleshooting the Air Delivery System

Air Pressure Builds too Slowly

Check for leaks in air line.
Check for restrictions in the air filter or inlet.

Compressor Shuts Down with Air Demand Present

Clean compressor fluid cooler and check for poor ventilation.
Check fluid level, add fluid.
Check compressor fluid, change fluid.
Check temperature-regulating valve.
Check for a short or open circuit in discharge temperature switch. Change if
discharge temperature switch is malfunctioning.

Compressor Does Not Build-Up Full Discharge Pressure

Check for leaks in air line or open valves.
Check for restrictions in the air filter or inlet. Check the filter indicator and change
element if required.
Adjust pressure regulator and replace if necessary.

Compressor Unloading with an Excessive Pressure Build-Up

Readjust pressure-regulating valve.
Check for cracks in unloader line.
Check inlet valve.
Check for worn seals or unloader plunger.

Excessive Compressor Fluid Consumption

Check return line; clean orifice and strainer.
Check and replace separator element if necessary.
Check all pipes, connections, and components in lubrication system.

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8.6 TROUBLESHOOTING THE AIR DELIVERY SYSTEM (08/03/25) 8-06-002

Compressor Overheating
Clean fluid cooler core.
Change thermostat element in thermal valve.
Clean fluid cooler tubes.
Check and fill receiver tank fluid.
Clean orifice and strainer in plugged return line.

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8.7 TROUBLESHOOTING THE HAMMER (08/03/25) 8-07-001

8.7 Troubleshooting the Hammer

Tool Does Not Start

Check for correct assembly of tool.
Check if piston is binding in the piston case or against the valves. Remove all burrs,
gall marks, and scratches.
Check for damaged check valves springs. Clean rust, burrs, and scratches from valve
dart.
Check for broken foot valve assembly.

Tool Stops Operating

Check for "collared" or "bridged" hole. Lift the drill assembly off the bottom of the
hole, then clean the hole with water injection.
Check for damaged parts such as piston case, pistons, driver sub, and drill bit.
Polish galled spots and replace parts as required. Insure that the piston slides
freely inside the piston case.
Check for clogged air passages in the drill bit.
Check for obstructions in the drill pipe, air hoses and top drive.

Operating Pressure is Lower than Specifications

Check if correct type of choke is installed.
Check for wear of choke. Install a smaller choke to bypass less air. If wear is
excessive, replace any worn parts.
Check for restrictions in the air delivery system.

Low Penetration Rate

Check for dull drill bit.
Check for broken or missing carbides in bit. Before using a new bit, clean out the
drilling hole.
Check for excessive back pressure in the drill hole. Remove any collaring around the
hole, then flush the hole with the drill's water injection.

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8.7 TROUBLESHOOTING THE HAMMER (08/03/25) 8-07-002

Galling of Internal Parts

Check for proper lubrication and adjust the oil injection rate.
Check for uneven lubrication. Repair injection pump if required.
Check for foreign material inside of tool.
Check for warpage in the piston case.

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8.8 TROUBLESHOOTING THE DRILL BIT (08/03/25) 8-08-001

8.8 Troubleshooting the Drill Bit

Abrasive Wear
Check for worn carbides in bit. Use the proper rotation speed and drill weight to
suit the drilling conditions.

Loss of Carbides in Bit

Check the bit for loss of carbides. If any are missing and no damage is apparent, it
indicates that the piston was striking the bit while the bit was not in full contact
with the rock formation. This force tends to loosen the inserts. This condition
may occur when the bit encounters broken or loose formation.
To avoid these conditions, control the drill to minimize these heavy blows when the
bit is not in full contact.

Bit Breakage and Carbide Failure

Check for hairline cracks and breakage around the buttons in the bit. Gauge buttons
are most prone to such failures. This condition may be due to excessive weight
on bit, improper rotation speed, or a lack of sharpening the bit.
Inspect the bit face periodically and sharpen the bits when required.

Carbide Breakage
Breakage may occur due to the following:
A piece of carbide may have been left in the socket when a new bit was installed.
The carbide may have been pinched while being pushed into an undersized carbide
hole.
The bit may have been pushed through a bent drill hole casing.
Excessive use between recommended sharpening periods.
NOTE: Drilling in hard formation requires more frequent sharpening.

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8.8 TROUBLESHOOTING THE DRILL BIT (08/03/25) 8-08-002

Uneven Wear Conditions

Uneven wear conditions may be due to the following:
Check for uneven wear spots at the gauge row buttons.
The drill bit may remove the rock chips too slowly. Increase the air volume to avoid
this condition.
Check for a bent drill rod and replace as required, then check the machine set-up.
Check for bit erosion just above the gauge buttons.
This creates spiraling into the rock and poor hole cleaning. Adjusting the rotation
speed and frequent hole cleaning may help but the bit should be replaced at this
time.
Check for excessive button wear or breakage indicating dry drilling conditions. The
buttons may overheat due to extreme weight on the bit or due to improper
rotation speeds.
Increase the water injection and adjust the drilling speed to avoid these problems.
Check for powdery cuttings, which indicate that the bit requires sharpening.
Check for squealing of bit during drilling. The bit steel at gauge may be rubbing.
Grind any projections or deformations on the bit steel. Cutting relief slots in the
bit skirt may also be helpful.
Check for shank failure due to insufficient drill weight, uneven drill feed or
excessive operating pressure.
Operate the drill at the proper air pressure and maintain a steady down pull on the
bit to prevent shock loading.

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8.9 TROUBLESHOOTING THE DEPTH LASER (08/03/25) 8-09-001

8.9 Troubleshooting Depth Laser

Laser appears not working. No red light is coming out of aperture.

Possible causes:
Power supply could be disrupted.
Power supply wiring polarity is not in right order.
Laser unit burnt out. Short condition, Nearby Arc-welding performed, Reverse-
polarity power introduced, water short-condition in junction box …etc.
Solution suggestion:
The unit requires 24VDC power supply.
Red wire must be connected to Positive, and Green wire must be connected to
Negative.
Replace the laser unit.

Laser appears working; red light is pulsing in even intervals, no output signal.
Possible causes:
Short condition cable.
Analog output wiring is reversed.
Laser beam is not reaching/reading the target correctly.
Solution suggestion:
All four connecting wires must be free of insulation damage and in no contact
between them.
White wire is Analog positive output; Black wire is Analog ground output.
Laser beam must be able to reach the target surface throughout the entire
travel. If laser bounces of any surface at any time, the readings would be
incorrect or zero output (Error condition for analog output) appears. Target
surface cannot be reflective or polished surface.

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8.9 TROUBLESHOOTING THE DEPTH LASER (08/03/25) 8-09-002

Laser appears working, red light is pulsing but in un-even intervals

Possible causes:
Laser beam is not reaching/reading the target correctly.
Loose or missing target.
Solution suggestion:
Laser beam must be able to reach the target surface throughout the entire
travel. If laser bounces of any surface at any time, the readings would be
incorrect or zero output (Error condition for analog output) appears. Target
surface cannot be reflective or polished surface.
Target must be “visible” to the laser beam at all the time. Surface of the target
might need re-painting. (Satin/flat finish spray paint in neutral colors are
recommended such as primer gray, primer yellow, primer red).If used in
location where direct sun light is present, olive green (Military) color is
recommended. Loose target plate creates undesirable readings.

General notes:
Check for the condition of the protective lens. The glass must be free of cracks,
dirt, grease and other obstructions. Order and replace lens if required.
To test and inspect the functionality of the TERRA DP-1 laser sensor, you must have
the ANALOG output wires disconnected at the sensor closest mast junction box.
First make sure that laser light is hitting the target and flashing evenly. Use
digital meter instrument to measure the 4-20 mA signal direct from the
disconnected wires. Some digital meters cannot measure this way. If so, connect
the wires back to the PLC input and install the meter leads between the Black
signal wire and the PLC signal input wire.

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