D75KS HP LP Maint

D75KS
(LOW & HIGH PRESSURE with CATERPILLAR 3412E or C27)
MAINTENANCE MANUAL
May 2002
(Rev. 9-09)
Serial Numbers 732177 & UP
D75KS
SANDVIK MINING and CONSTRUCTION
BLASTHOLE
732177
34050 kg / 75,000 lb
19658 kg / 43,400 lb
2948 kg / 6,500 lb
Sandvik Mining and Construction

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

! DANGER if not avoided, will result in death or serious injury.
Indicates a hazardous situation which,

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

NOTICE may result damage to machinery or components.
Indicates a situation which, if not avoided,

CAUTION may result in damage to machinery or components.
California Proposition 65
WARNING:
This Product Contains And, When Used, Produces Chemicals Known
To The State Of California To Cause Cancer, And Birth Defects Or
Other Reproductive Harm.
TABLE OF CONTENTS
SAFE OPERATING PRACTICES FOR DRILLERS . iii SECTION 2 PREVENTIVE MAINTENANCE . . . . . . 2-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii SERVICE AND OIL CHANGE INTERVALS . . . . . . . . . . . 2-1

Management's Responsibilities . . . . . . . . . . . . . . . . . . . . . . iii
The Operator’s Responsibilities . . . . . . . . . . . . . . . . . . . . . . iii MAINTENANCE RECOMMENDATIONS . . . . . . . . . . . . . 2-1
Operator's Safety Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
Planning the Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi USE OF CORRECT TOOLS AND PROCEDURES . . . . . 2-2
Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
General Maintenance Safety Practices . . . . . . . . . . . . . . . .viii OIL SAMPLE ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Fire Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
WIGGINS SERVICE STATION . . . . . . . . . . . . . . . . . . . . . 2-2
INCLEMENT WEATHER and SAFE DRILLING PRAC- THE DRILL MONITOR SYSTEM (DMS) . . . . . . . . . . . . . . 2-2
TICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
COMPRESSOR AND HYDRAULIC SYSTEMS . . . . . . . . 2-2
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Oil Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
MANAGEMENT’S RESPOSIBILITIES . . . . . . . . . . . . . . . . xi Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Mixing Hydraulic Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
RAINFALL AND FLOODING . . . . . . . . . . . . . . . . . . . . . . . . xi Initial Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
THUNDERSTORMS AND LIGHTNING . . . . . . . . . . . . . . . .xii
Exceptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xiii HEATING, CUTTING AND WELDING EQUIPMENT
MACHINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . xiii USAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

SECTION 1 COOLANT, FUEL and LUBRICANT SPECI- ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
FICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
COOLANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 1-1
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
FILL WATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 RECOMMENDED TORQUE VALUES FOR STANDARD
Coolant Conditioner Elements . . . . . . . . . . . . . . . . . . . . . . 1-1 HARDWARE - UNC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
FUEL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 RECOMMENDED TORQUE VALUES FOR STANDARD

Cetane Requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 HARDWARE - UNF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Fuel Cloud Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Fuel Sulphur Content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
WHEN REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . .2A-1
CRANKCASE OIL CHANGE INTERVALS . . . . . . . . . . . . 1-2
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1
LUBRICANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . 1-2
Replace Ether Starting Aid Cylinder . . . . . . . . . . . . . . . . 2A-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Engine Oils (CH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1
Lubricating Grease (MPGM) . . . . . . . . . . . . . . . . . . . . . . . 1-2
Check Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1
Compressor Oils (COMP) . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Check the Cooler Core . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-2
Hydraulic Oils (HYDO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Multipurpose - Type Gear Lubricant (MPL) . . . . . . . . . . . . 1-3
AIR CLEANERS - ENGINE & COMPRESSOR . . . . . . . 2A-2
Refrigeration Oil (REF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Changing Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-2
REFILL CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Primary Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-2
Safety Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-3
MINIMUM PERFORMANCE STANDARDS FOR HYDRAULIC
OILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
OPERATOR’S CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-4
Change Air Conditioner/Heater Filter Element . . . . . . . . 2A-4
AIR COMPRESSOR LUBRICANT RECOMMENDATIONS 1-8
Table of Contents 1
DUST COLLECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-4 Change Crankcase Oil and Filters . . . . . . . . . . . . . . . . . . 2D-1
Change the Filter Elements . . . . . . . . . . . . . . . . . . . . . . . 2A-4 Engine Valve Lash (Initial) . . . . . . . . . . . . . . . . . . . . . . . . 2D-2
ALTERNATOR and AIR CONDITIONER COMPRESSOR V-

EVERY 8 SERVICE HOURS OR DAILY . . . . . . . . 2B-1 BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-2
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-2
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1 Check Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-2
Measure Crankcase Oil Level . . . . . . . . . . . . . . . . . . . . . 2B-1 Adjusting the Alternator Belt . . . . . . . . . . . . . . . . . . . . . . 2D-3
Drain Fuel Water Separator Bowl . . . . . . . . . . . . . . . . . . . 2B-1 Adjusting the Air Conditioner Belts . . . . . . . . . . . . . . . . . 2D-3
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2 BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-3

Check Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2 Check Battery Electrolyte Level and Clean Batteries . . . 2D-3
Adding Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-4
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-3 Change Secondary Fuel Filters . . . . . . . . . . . . . . . . . . . . 2D-4
Check Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-3 Priming the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . 2D-5
Drain Condensate From Air/Oil Receiver Tank . . . . . . . . 2B-3
Check Oil Return Line Sightglass . . . . . . . . . . . . . . . . . . . 2B-4 COOLING SYSTEM (3412E Only) . . . . . . . . . . . . . . . . . 2D-5
Check Air/Oil Separator Element Indicator . . . . . . . . . . . . 2B-4 Change Coolant Conditioner Cartridges . . . . . . . . . . . . . 2D-5
Check Fan Motor Overhung Adapter Oil Level . . . . . . . . 2D-6
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-4 Check Cooler Fan Finger Guards and Radiator Blade
Check Oil Level in Reservoir Tank . . . . . . . . . . . . . . . . . . 2B-4 Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-6
Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-5
Drain Water From Reservoir Tank . . . . . . . . . . . . . . . . . . 2B-5 COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-7
Check Hydraulic Tank Air Pressure Regulator Gauge . . . 2B-5 Change Main Oil Filter Elements . . . . . . . . . . . . . . . . . . . 2D-7
Check Servo Replenishing Filters Dirt Alarms . . . . . . . . . 2B-5 Clean Oil Return (Scavenge) Line Strainer . . . . . . . . . . . 2D-8
Sample Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . 2D-8
DRIVESHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-6
Lubricate Pump Driveshafts . . . . . . . . . . . . . . . . . . . . . . . 2B-6 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-9
Change the Servo Replenishing Filter Elements . . . . . . . 2D-9
PUMP DRIVE GEARBOXES . . . . . . . . . . . . . . . . . . . . . . 2B-6 Clean Hydraulic Reservoir In-Line Air Strainer . . . . . . . . 2D-9
Check Oil Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-6 Clean the Water Trap Filter . . . . . . . . . . . . . . . . . . . . . . 2D-10
Replace the Breather/Filter . . . . . . . . . . . . . . . . . . . . . . 2D-10
UNDERCARRIAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-7 Check Hydraulic Tank Mounting Hardware . . . . . . . . . . 2D-10
Check for Debris . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-7
PUMP DRIVE GEARBOXES . . . . . . . . . . . . . . . . . . . . 2D-10
AIR INLET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-7 Clean Breathers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-10
Check Air Cleaner Element Indicators (Machine without DMS)
2B-7 WATER INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . 2D-11
Empty Air Cleaner Dust Cups . . . . . . . . . . . . . . . . . . . . . 2B-7 Check Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-11
Change Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-11
CENTRAL LUBE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . 2B-8
Check Central Lubricator Grease Level . . . . . . . . . . . . . . 2B-8 ROTARY HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-12
Drain Water and Check Pump Oiler Level . . . . . . . . . . . . 2B-8 Check Gearbox Oil Level . . . . . . . . . . . . . . . . . . . . . . . . 2D-12
MISCEALLANEOUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-8 FEED SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-12

Inspect Winch Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . 2B-8 Check Feed Chain Adjustment . . . . . . . . . . . . . . . . . . . 2D-12
Check Air Lubricator Oil . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-8 Lubricate Feed Chain . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-12
Check Feed Chain Adjustments . . . . . . . . . . . . . . . . . . . . 2B-8 Inspect and Lubricate Chain Sprockets . . . . . . . . . . . . . 2D-13
UNDERCARRIAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-13
Check Track Tension and Adjust if Necessary . . . . . . . 2D-13
EVERY 50 HOURS OR WEEKLY . . . . . . . . . . . . . 2C-1
Adjusting Track Tension . . . . . . . . . . . . . . . . . . . . . . . . 2D-13
Check Final Drive Gearbox Oil Level . . . . . . . . . . . . . . 2D-14
AIR SWIVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-1
Grease Air Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-1
CENTRAL LUBRICATION SYSTEM . . . . . . . . . . . . . . 2D-14
Clean Water Trap Filter . . . . . . . . . . . . . . . . . . . . . . . . . 2D-14
INITIAL 50 HOURS OF OPERATION . . . . . . . . . . . . . . . 2C-1
Check System Operation . . . . . . . . . . . . . . . . . . . . . . . . 2D-14
AIR INLET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-15

EVERY 250 HOURS OR MONTHLY . . . . . . . . . . . 2D-1 Check Air Filter Pre-Cleaner Tubes . . . . . . . . . . . . . . . . 2D-15
Replace Engine and Compressor Primary Filter
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-1 Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-15
Check Engine Mount Torque . . . . . . . . . . . . . . . . . . . . . . 2D-1
Table of Contents 2
MISCELLANEOUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-16 MAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2F-5
Check Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . 2D-16 Check the Torque of the Pivot Block Bolts . . . . . . . . . . . 2F-5
Check Intake and Exhaust Systems . . . . . . . . . . . . . . . . 2D-16
Check Dust Collector Hoses . . . . . . . . . . . . . . . . . . . . . 2D-16
Check Decals and Nameplates . . . . . . . . . . . . . . . . . . . 2D-16 EVERY 2000 HOURS OR 1 YEAR . . . . . . . . . . . .2G-1
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2G-1

EVERY 500 HOURS OR 3 MONTHS . . . . . . . . . . 2E-1 Change Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2G-1
Re-Torque Cooler Mounts . . . . . . . . . . . . . . . . . . . . . . . . 2G-2
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-1
Clean Engine Crankcase Breather (3412E Engine) . . . . . 2E-1 UNDERCARRIAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2G-2
Clean Engine Crankcase Breather (C27 Engine) . . . . . . . 2E-1 Change Crawler Final Drive Oil . . . . . . . . . . . . . . . . . . . . 2G-2
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-2 MAST and PEDESTAL . . . . . . . . . . . . . . . . . . . . . . . . . . 2G-3

Replace Primary Fuel Filter/Water Separator . . . . . . . . . 2E-2 Change the Pivot Block Bolts and Hardware . . . . . . . . . . 2G-3
Priming the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . 2E-2 Test the Pedestal Welds . . . . . . . . . . . . . . . . . . . . . . . . . 2G-3
PUMP DRIVE GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . 2E-3

Change Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-3 SECTION 3 MACHINE STORAGE . . . . . . . . . . . . . 3-1
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-3 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Change Return Filter Elements . . . . . . . . . . . . . . . . . . . . 2E-3
Replace Fan Circuit Case Drain Filter . . . . . . . . . . . . . . . 2E-4 SHORT TERM STORAGE . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -1
ROTARY HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-4 Preparation for Short Term Storage . . . . . . . . . . . . . . . . . 3-1
Change Gearbox Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-4 Removal from Short Term Storage . . . . . . . . . . . . . . . . . . 3-1
WATER INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-5 LONG TERM STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Clean Suction Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-5 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Preparation for Long Term Storage . . . . . . . . . . . . . . . . . . 3-2
WINCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-5 Removal From Long Term Storage . . . . . . . . . . . . . . . . . . 3-3
Check Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-5
THREAD LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . 2E-6

Check Grease Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-6
AIR INLET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-6

Replace Engine and Compressor Safety Elements . . . . . 2E-6
Safety Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-6
MAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-6
Inspect the Drill Pipe Safety Hoop . . . . . . . . . . . . . . . . . . 2E-6
Inspect the Pedestal Welds . . . . . . . . . . . . . . . . . . . . . . . 2E-7
EVERY 1000 HOURS OR 6 MONTHS . . . . . . . . . 2F-1
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 2F-1

Change Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2F-1
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2F-2
Re-Torque Compressor Mounts . . . . . . . . . . . . . . . . . . . . 2F-2
Changing the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2F-2
Change Air/Oil Separator Element . . . . . . . . . . . . . . . . . . 2F-2
WINCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2F-4
Change Oil and Clean Breather . . . . . . . . . . . . . . . . . . . . 2F-4
ROTARY HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2F-4

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

Change Fan Motor Overhung Adapter Oil . . . . . . . . . . . . 2F-4
Table of Contents 3
Table of Contents 4
11-06
SAFE OPERATING PRACTICES FOR DRILLERS
Introduction
SANDVIK MINING and CONSTRUCTION drilling equipment is carefully designed, tested and manufactured. When
operated and serviced by trained and qualified personnel, this machine will give safe and reliable service. There are
SANDVIK MINING and CONSTRUCTION offices world-wide to answer questions concerning the safe operation and
maintenance of this equipment.
To minimize the risk of accidents and injuries, all persons involved in the operation and servicing of this machine MUST
read and understand the following safety precautions and the manuals developed for this machine.
While we believe that we have properly identified several potential hazards that could result in property damage or injury
or death to personnel, there are certain hazards which may be present that we have not contemplated. It therefore is
the responsibility of the drill owner, operator and crew to be certain that the drill is properly equipped and safe to operate
to assure accident free operation.
Management's Responsibilities
It is the responsibility of management to:
• See that all operators of this equipment are thoroughly trained (with special emphasis on safety), competent, physi-
cally fit and if required, licensed.
• Assign specific crew members specific safety responsibilities and instruct them how to report any unsafe conditions.
• Enforce the use of protective clothing, eye and hearing equipment.
• See that the operation and maintenance of this drill is in compliance with all Federal, State and local codes, regula-
tions and standards.
• Ensure that the work area is appropriately illuminated when drilling is performed at night.
• Maintain a complete first aid kit at the drill site. At least two members of the drilling crew or personnel in the area
where the drill is operated should be familiar with first aid and Cardiac Pulmonary Resuscitation.
• Contact the utility companies for the exact location of underground transmission lines in the drilling area.
The Operator’s Responsibilities

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

11-06
condition exists. It is the responsibility of the drill operator to ensure that the drill is properly equipped, safe to operate
and that the site conditions make it possible for safe operation:
• The operator must see that all emergency stops, "operational aids" and "warning signals" are functional before oper-
ating.
• The operator must be alert, physically fit, and free from the
influences of drugs, alcohol and medications that might
impair eyesight, hearing or reactions
• The operator should not attempt to start, operate or service the drill unless he has been properly trained and read this
manual.
• The operator should not operate this equipment if any

of it's controls display a "lockout" tag.
• If an unsafe condition exists, the operator must place a

tag, identifying this condition, on the starting controls
and alert other potential users of the drill.
iv
11-06
• The operator should not operate the drill without first

checking that all personnel protection devices and
machinery guards are in place.
Operator's Safety Check

The operator must make a safety check before starting to work to ensure that the machine is in proper order for accident
free operation. Somethings to check are:
• Check that there are no "lockouts" or "tagouts" attached to the

controls.
• Check the machine log book to see that periodic maintenance

and inspections have been performed, and that all necessary
repairs have been made.
• After starting the engine, check all indicators, emergency stop,

trip devices and gauges for serviceability.
• Check the fire extinguisher(s) for charge and accessibility.
• Clean the cab interior windows if necessary.
• Test all controls for proper operation.
• Check access ladders and decking for damage and slipping hazards such as mud, oil or ice.
• At the end of the shift, the operator must properly secure the drill to prevent the machine from being operated by
unauthorized individuals.
• The operator must never permit personnel to ride on the machine except in the passenger compartment.
• The operator should treat all power lines as live.
Safe Operating Practices for Drillers v

11-06
Planning the Job
The person in charge must have a clear understanding of the work to be done and consider all the hazards at the site.
He must develop a plan to do the job safely and explain the plan to the crew members involved. Factors such as these
should be considered:
• Will the drilling take place in wet formations?
• Are there utility lines or structures that must be moved or avoided?
• Are there unusual or extreme weather conditions expected?
• Will drilling be done in night hours?
• Will the machine be propelled on inclines?
• Will drilling be done into difficult formations?
• Has a drilling pattern been developed?
• What is the required depth of the drilling pattern?
• Will special drilling tools be required to complete the job?
• Will vertical or angle drilling be required?
vi
11-06
Operating Precautions
• Operating near or contacting a power line with any part of the

machine can result in electrocution.
Do not raise the drilling mast or operate the machine in the
vicinity of electrical power lines without checking the mini-
mum safe operating perimeter set by local, state or federal
regulations.
• Raising or lowering the mast, and drilling with an unsupported or unleveled machine can result in excessive structural
stress to the machine frames or can cause the machine to overturn.
Do not raise or lower the mast or attempt to drill until the machine is fully supported and leveled by the lev-
eling jacks.
• Drilling with an unlocked mast can result in excessive pressure at the mast raising cylinders causing the mast to fall.
Do not attempt to drill until the mast locking pins are fully engaged.
.
• Before leaving the operator's station, all controls must be in the

neutral position with all locking and safety devices engaged.
Do not allow the drill to operate unattended.
• Do not park or position the machine on grades that exceed the tilt
ratings.
Park or position the machine on level ground or across (hori-
zontal) grade
• Park or position the machine to allow the wind to carry engine exhaust fumes away from the operator.
Exhaust fumes from diesel engines are lethal.
Safe Operating Practices for Drillers vii

11-06
• Drill pipe that is free to slide through the opening in the top plate
could be released from the loader while traveling.
Before lowering the mast, index the loader to a position
such that the top plate of the loader prevents all drill pipe
from moving past the top plate
General Maintenance Safety Practices
While operating and servicing this machine be aware of the following:
• The sudden release of a pressurized lid or hose can spray hot

oil.
Do not open hydraulic tanks, air reservoirs or hydraulic
connections while the machine is running or the sys-
tems are under pressure.
• Before entering any enclosure, be sure that the door is secured open. Avoid entrapment, be sure that no one is
inside any enclosure before closing and latching the doors.
Enclosures can cause suffocation.
• Before starting any service or maintenance work, always perform a safety/risk analysis of the task.
Performing maintenance work without the proper tools and personal protection equipment can cause seri-
ous injury or death.
• Climbing the mast is a crushing and falling hazard.

Climbing the mast may cause serious injury or death. Stay off the mast at all times.
• Hydraulic oil under extreme pressure from a small opening

can penetrate the skin and inject oil into the body.
Do not attempt to locate a hydraulic leak by using your
hand.
• Pressure in hydraulic systems can be retained for long peri-

ods of time. If not properly released before maintenance
people attempt to work on the hydraulic system, this pres-
sure can let components move or cause hot oil to spray
and hose ends to shoot out at high speed.
Release system pressure before attempting to make
adjustments or repairs.
viii
11-06
• Carelessness in getting on and off equipment can result in seri-

ous injuries.
Always wait until the machine has completely stopped. Do
not jump on or off. Always use both hands and feet and
use the 3-point contact rule.
• Riding the rotary head up and down the mast is a crushing hazard.
Never ride the rotary head for any reason!!! It was not designed to be an elevator.
When there is a need for an operator or helper to work on the rig in the working area or danger zone and this work
involves activation of one or several machine functions, this work shall only be done under the following conditions:
a. There must be two safety trained people present, one should supervise the safety of the other doing the servicing.
Supervision should be done from the operator’s station to ensure immediate access to an emergency stop at all
times.
b. The area where the service work is to be done should be properly illuminated.
c. A reliable mode of communication should be establish between the servicing person and the supervisor.
d. The rig must be completely shut down and all methods of starting disabled before servicing work begins.
Fire Prevention
• Keep the machine clean of vegetation, coal dust and oily rags.
• Clean-up any oil and fuel spills particularly around hot surfaces
and heat producing components.
• Check the Fire Suppression System (FSS), if fitted, for damaged hoses or cylinders.
• Check all electrical lines and connections including battery terminals for a tight fit, wear, abrasion, and corrosion.
• Do not use the drilling machine in oil, gas or waterwell operations unless the well head is properly equipped with blow-
out preventers and safety equipment required by law or as recommended in the American Petroleum Institute's doc-
ument API 54.
Safe Operating Practices for Drillers ix

11-06
• Check all machine ignition points (engine block, exhaust manifolds, mufflers, turbo-chargers, etc...) to make sure they
are not in contact with any hoses.
• Keep the batteries secured in their compartment and covered.
• Never inject ether or other starting aids into the engine and compressor intake filter(s). Ether or other aids drawn into
the compressor can cause an explosion.
• Do not store flammable fluids on or in the immediate vicinity of the machine.
• Engine oil, hydraulic fluid and compressor oil are flammable. Do not operate a machine with leaking or worn hoses or
lines.
• Do not clean washable filter elements with flammable solvents, diesel fuel, kerosene, or gasoline.
• Do not attempt to perform welding repairs until all flammable materials including oil and fuel spills oily rags, and rock
and coal dust, have been isolated or removed from the machine.
• Disconnect the battery cables before welding on the machine.
• Keep tools away from exposed live electrical parts such as terminals, to avoid arching.
• If charging the batteries, always turn the charger off before making or breaking connections to the battery.
• The compound (ethyl ether) used in the engine starting aid system is extremely flammable. Changing the cylinders
and servicing this system should be done in a well ventilated area. Do not store or install the cylinders in tempera-
tures above 160° F (71° C).
• The anti-freeze compound (methanol) used in the air line anti-ice systems is flammable. Refill the system with com-
pound only in well ventilated areas, away from heat, open flames and sparks. Do not store or expose this system or
the compound to temperatures above 150° F (65° C), or in direct sunlight.
x
11-06
INCLEMENT WEATHER and SAFE DRILLING PRACTICES
GENERAL
The following safety precautions were developed to minimize the risk of injury during inclement weather when using
Sandvik Mining and Construction drilling equipment.
All persons involved in the planning, operation and servicing of Sandvik Mining and Construction equipment MUST read
and understand the following safety precautions, the manuals developed for this machine and the Safe Operating Prac-
tices outlined in the front of this manual.
While we believe that we have properly identified several potential hazards that could result in property damage or per-
sonnel injury, there are certain hazards which may be present that we have not contemplated.
Bad weather conditions as they relate to this topic include lightning, thunderstorms and severe rainfall.
MANAGEMENT’S RESPOSIBILITIES
High winds, rainfall and cloud cover are often precursors to actual cloud to ground strikes notifying individuals to take
action. Many reported lightning accidents occur with sun, clear skies and no rain present at the beginning as the storm
approaches because; people ignore these precursors. Generally the lightning threat diminishes with time after the last
sound of thunder, but may persist for more than 30 minutes.
It is the responsibility of management to:
• Be aware of daily weather conditions within a 100 mile (161 Km) radius of the mine property.
• Determine a plan of action relating to expected bad or unexpected weather conditions.
• Notify equipment operators of impending storms. Communication to equipment operators may be given via two way
radio and/or in person.
• Consider that drill operators need ample time:
a. to retrieve drill pipe from blastholes and well bottom.
b. lower masts to a horizontal position or position feed rails into feed supports.
c. give the drill engine an adequate cool down period prior to shutting machine down.
d. leave machine cabin or operator platform and transport to central meeting location.
• Give equipment operators an all clear signal after the storm has cleared the area.
Note To Supervisors!
Recognize that equipment operators should be given adequate time to prepare the machine to move to specific loca-
tions for safe keeping. Crawler mounted drill machines have a maximum travel speed not exceeding 2.2 mph (3.5 kph).
RAINFALL AND FLOODING
When notified of an impending storm, machine operators should:
Safe Operating Practices for Drillers xi

11-06
•Move the drill machine to higher ground conditions.

Never leave a drill machine at the lowest floor position of
a mine or quarry or in a low lying ditch that could trap
water runoff.
•Move the drill machine to stable ground and away from

unstable crests or the face.
Never leave a drill machine on the front face of the drill
pattern while rain and severe weather pose a threat of
loose ground falls or washouts.
•When operating machines in a construction application, equipment operators shall move the drill machine to higher
stable ground.
Never leave a drill machine in any construction zone roadway, river bed or drainage ditch.
•Move the drill machine to stable ground away from high walls and any threat where rock or water erosion may
allow unstable ground to fall or slide.
THUNDERSTORMS AND LIGHTNING
A publication written in MSHA Holmes Safety Association Bulletin April 2001 gives a simple flash bang formula to calcu-
late lightning proximity.
The FLASH BANG method is determined by counting the seconds between the visible lightning and the sound of thun-
der. This delay in seconds when divided by 5 will give an approximate value in miles as to how close the active lightning
is to your worksite.
Example: when you see lightning and it takes (10) ten seconds to hear the thunder divide by (5) five. The approximate
distance of lightning proximity is 2 miles (3.2 km).
If the flash bang measurement is 30 seconds or less seek shelter immediately and remain indoors, away from electrical
devices, water and metal components.
Supervisors shall notify equipment operators in a timely manner. This is to allow the drill operator adequate time to per-
form the required operation principals needed and secure the machine in a safe manner.
• Equipment operators shall retrieve drill pipe from blastholes, secure drilling tools and lower mast to a horizontal
position into the mast rest supports.
Understand that the mast in a vertical position with drill pipe in the ground is capable of attracting high volt-
age lightning.
NOTE !
If the operator and machine are inside or near a blast area follow procedures written in USA Federal Metal and Non-
metal Mine safety Standards 30CFR 56/57/58 manual.
• Equipment operators shall move the machine to secure ground as noted in the rainfall and flooding description.
• Equipment operators shall give adequate engine cool down period prior to shutting machine down. Adequate
engine cool down periods range between 3 to 5 minutes.
Follow engine manufacture specifications as a standard.
xii
11-06
• Equipment operators shall secure the machine, close doors and windows, leave the machine cabin and dismount
the machine in a proper 3 point contact with the boarding ladder.
• Equipment operators shall drive or be transported to a central meeting location away from bad weather and storm
conditions.
There are exceptions to the rules when bad weather develops and time does not permit adequate machine preparation
- shutdown principals.
Exceptions
If you do get caught in an electircal storm and have little or no time to prepare, remember that, no place is absolutely
safe from the lightning threat, however, some places are safer than others.
When operators are inside a enclosed stable structure such as a machine cabin or the truck cab it is recommended that:
• all windows are closed
• all doors closed
• do not touch metal parts
• do not use two way radio communication
NOTE!
Wait inside the enclosed cab as long as it takes for the storm or lightning to subside. Do not attempt to dismount the
machine when lightning is in your immediate work area.
If lightning is present within a 20 mile (32 km) radius of your location be aware of your surroundings when outdoors.
Seek adequate shelter immediately.
If lightning is present within the 20 mile (32 km) radius, and a decision is made to dismount the machine, use a standard
3 point contact down the boarding ladder to dismount the machine.
Move away from the machine quickly and into a enclosed vehicle or adequate shelter. Maintain a distance greater than
100 yards (92 m) to prevent electrical draw in the event lightning did strike the mining equipment.
Static interference on AM radio channels is another indicator as to lightning proximity.
Lightning detectors are available aftermarket as a measuring instrument to determine lightning proximity. Blasting crews
are aware of lightning hazards and may have a lightning detector on site.
If you are caught in the open with lightning nearby and shelter is not available the safest position to be in is to be
crouched down on the balls of your feet. Keep your feet as close to one another as possible.
Do not allow your hands (or other body parts) to touch the ground. Use your hands to cover your ears and brace for a
loud thunderous bang.
Lightning struck victims carry no electrical charge and should be given first aid treatment immediately!
MACHINE MAINTENANCE
If lightning does strike a drill machine parked in any position (mast up or down) expect major component failures. A total
machine inspection is in order.
Safe Operating Practices for Drillers xiii

11-06
Electrical charge should dissipate immediately after impact.
Prior to climbing on board a machine known to have been struck by lightning use the back side of either hand (knuckle
side) to lightly touch the boarding ladder.
Reference material
MSHA Holmes Safety Association Bulletin April 2001
Federal Metal and Nonmetallic Mine Safety and Health Standards 30CRF 56/57/58 Ninth Edition (1999).
National weather service (www.noaa.gov)
xiv
SECTION 1 Antifreeze
COOLANT, FUEL and Always use ethylene glycol-type antifreeze and

the correct amount to provide protection to the
LUBRICANT lowest expected operating environment.
SPECIFICATIONS
Coolant Conditioner Elements
COOLANT SPECIFICATIONS Coolant conditioner elements should be used to

maintain a 3 to 6% concentration of conditioner
Always use a mixture of approved fill water, in the coolant. Use a precharge element when
antifreeze and Cooling System Conditioner. filling the system or changing coolant. Install a
new maintenance element after every 250
Refer to the engine manufacturer for detailed hours of service.
specifications, or Caterpillar® form SEBD0518.
FUEL SPECIFICATIONS
FILL WATER
Caterpillar® manufactured diesel engines have
Always add conditioner to coolant water. Never the ability to burn a variety of fuels. These fuels
use plain water only in the cooling system. are divided into two categories: Preferred or
Permissible.
Acceptable water for use in the preparation of
ethylene glycol type antifreeze and water mix- Preferred fuels provide maximum engine ser-
ture is shown in the follow chart. vice life and performance. These fuels are distil-
late fuels and are commonly called; fuel oil,
ACCEPTABLE WATER furnace oil, diesel fuel, gas oil or kerosene.
Permissible fuels are crude oils or blended

Water Content 50% Antifreeze/ Without fuels. Use of these fuels can result in higher
50% Water Antifreeze maintenance costs and reduced engine service
Chlorides 100 ppm 50 ppm life.
or less or less
Refer to form SEHS7067 from Caterpillar® for a
Sulphates 100 ppm 50 ppm
or less or less detailed summary of preferred fuels and their
specifications.
Hardness as 200 ppm 100 ppm
CaCO3 or less or less
Dissolved 500 ppm 250 ppm Cetane Requirement

Solids or less or less
pH 6.5 or higher 6.5 or higher The minimum fuel cetane number recom-
mended for this engine is 40.
ppm = parts per million
1-1
Fuel Cloud Point machine are found on the Lubricant Chart.
Fuel waxing can plug the fuel filters in cold

weather. The fuel cloud point must be below the Engine Oils (CH)
temperature of the surrounding air to prevent fil-
ter waxing and power loss. Fuel heating attach- Only use oils that meet Engine Service Classifi-
ments can minimize fuel filter waxing and are cation CH (MIL-L-2104D).
available from your Driltech or Caterpillar®
dealer. At the factory, this machine was filled with BP
15W - 40. Consult the Caterpillar form
SEBU5939 for a listing of CH oil brands.
Fuel Sulphur Content
NOTE!
The percentage of fuel sulphur content will The engine oil and filter should be changed
affect the engine oil and filter change intervals after the first 50 hours of service on new and
(refer to the following chart). reconditioned engines.
CRANKCASE OIL CHANGE INTERVALS Lubricating Grease (MPGM)
Use only multi-purpose grease (MPGM) which

Fuel Sulphur Oil Change Interval
contains 3 to 5% molybdenum disulphide. NLGI
No, 2 Grade is suitable for most temperatures.
0.0% to 0.4% 250 Hours Use NLGI No. 1 or No. 0 Grade for extremely
0.4% to 1.0% 125 Hours low temperatures.
1.0% to 1.5% 62 Hours
Compressor Oils (COMP)
NOTE!
If the fuel has over 0.5% sulphur content, the As with any oil Do not mix different types of oils.
CG engine oil must have a Total Base Number Contamination of synthetic oils with traces of
(TBN) of 20 times the percentage of fuel sulphur AFT may lead to foaming or plugging of orifices.
(TBN as measured by the ASTM D-2896
method). If the sulphur content is greater than When operating between 80 and 100°F (27 and
1.5% by weight, use an oil with a TBN of 30 and 38°C) and with relative humidity above 80%, a
reduce the oil change interval by one half. Con- synthetic hydrocarbon type fluid is recom-
sult your Caterpillar® dealer for correct engine mended. This machine was filled with Shell
oil recommendations. Corena unless the decal on the receiver tank
specifies otherwise.
LUBRICANT SPECIFICATIONS NOTE!

Compressor oil change intervals will change
depending on the type of oil used. The oil manu-
General facturers recommendations supersede the rec-
ommended interval suggested in this manual.
The classifications listed below follow S.A.E.
J183 classifications. The MIL specifications are
USA Military Specifications. The following defi- Hydraulic Oils (HYDO)
nitions will be of assistance in purchasing lubri-
cants. The specific classifications for this Use industrial-type hydraulic oils that are certi-
1-2
fied by the oil supplier to have anti-wear,-foam, - Refrigeration Oil (REF)
rust, and -oxidation additive properties for
heavy duty usage. Use an ISO 100 refrigeration oil.
At the time of shipment this machine was filled

with Citgo 32 AW hydraulic oil. REFILL CAPACITIES
Multipurpose - Type Gear Lubricant (MPL)

COMPONENT GALLON LITRE
Use Gear Lubricant Classification GL-5 (MIL-L- RECEIVER TANK 70 265

2105B) EP140. Use SHC 75 x 90 in cold ambi- FUEL TANK 600 2274
ent conditions and SHC 5 x 90 in arctic condi-
tions. HYDRAULIC TANK 230 872
PUMP DRIVE GEARBOX 5.5 qt 5.5

(3-hole)
PUMP DRIVE GEARBOX 7.75 qt. 7.3
(4-hole)
ROTARY DRIVE GEARBOX 5 18.9
CENTRALIZED LUBRICA- 30 lb 13.5 kg

TIONS SYSTEM
ENGINE CRANKCASE (3412E) 18 68
ENGINE CRANKCASE (C27) 19 72
COOLANT SYSTEM 25 95
approximately
COOLANT ENGINE 14.5 55
WINCH 2 qt 2
FAN MOTOR OVERHUNG 3.7 oz 110 ml

ADAPTER
CRAWLER FINAL DRIVE (ea) 3.4 13
WATER INJECTION 400 1514

TANK(WO/DUST COLLECTOR or
550 2082
WATER INJECTION TANK(W/ 200 757

DUST COLLECTOR
WATER INJECTION PUMP 1 qt 1
1-3
RECOMMENDED LUBRICANT VISCOSITIES
OUTSIDE °F -22 -4 +14 +32 +50 +68 +86 +104 +122
TEMPERATURE °C -30 -20 -10 0 +10 +20 +30 +40 +50
SAE 5W -20(SPC)
SAE 5W-20
ENGINE CRANKCASE SAE 10W
CH-4 SAE 10W-30
SAE 15W-40
SAE 30
SAE 40
-40°F ISO 32
COMPRESSOR
ISO 46
COMP
Note oil change intervals ISO68
CD SAE 10W
UNDERCARRIAGE, CD SAE 30
FINAL DRIVE GEARBOX CD SAE 40W
MPL
CD SAE 50W
32AW
HYDRAULIC SYSTEM 46AW
HYDO 68AW
100AW
WATER INJ. PUMP - CH SAE 30

SAE 10W-30
ROTARY HEAD, WINCH and

GL-5 EP 90
PUMP DRIVE GEARBOX
SHC 75W-90
MPL
SHC 5W-90
HAMMER OIL ISO 46-100

RDO ISO 100-220
220-460
1-4
996
EQUIVALENT HYDRAULIC OILS
LUBRICANT ISO ISO ISO ISO

MANUFACTURER
BRAND NAME 22 32-46-68 100 150
ACCITE HIDRAULICO MH PETROLEOS MEXICANOS X X
AMOCO AW OIL AMOCO OIL CO. X
AMOCO RYDON OIL MV AMOCO OIL CO. X X
ANTECH EXXON/ESSO X
ASHLAND VG ASHLAND OIL CO. 32
BARTRAN HV BP OIL CO. 46 & 68
BRESLUBE VG BRESLUBE LTD.-CANADA X X
CANADIAN OIL MOXY T OIL CANADA X X X
CANVIS AW BP OIL CO. X X
CHAMPION SUPER GRADE LOWE OIL X
CHEVRON AW CHEVRON X
CITGO AW CITGO X X X
D-A WEAR GUARD II VG D-A LUBRICANT CO.-USA X
DECOL ANTI-WEAR SHELL CANADA X X X
DTE 24-25-26 MOBIL OIL CORP. X
DURO AW ARCO X X
EAL SYNDRAULIC MOBIL OIL CO. X
ELF OLNA DS ELF/ANTAR X
ENERGOL HLP-HD SERIES BP OIL CO. X X
EPPCO UNIVIVERSAL GP EPPERT OIL CO. X
GULF HARMONY AW GULF R&D X
GULF SYNFLUID SL H__AW GULF USA X
HIDRALUB EP MARAVAN S.A. X X
HARMONY AW GULF CANADA LTD. X X
HYDRAFLOW PETRO CANADA X X X
HYDRALUBE AW LUSCON IND. X X
HYDRELF DS ELF 46 & 68
HYSPIN AWS-AD CASTROL INC. X
HYTAC DISTAC LUBRICANTS X X
KENOIL R&O AW KENDALL REFINING CO. X X
LUSCON HD LUSCON IND. X X
MARATHON MULTI. VG MARATHON PETROLEUM X X
MOBIL HYD. OIL NZ MOBIL OIL CO. X
MOBIL HYD. OIL ZF MOBIL OIL CO. X
MYSTIK AW/AL CATO OIL & GREASE CO. X X
NERVOL FLUID SH2 NERVOL X X X
(Page 1 of 2)
1-5
996
LUBRICANT ISO ISO ISO ISO
MANUFACTURER
BRAND NAME 22 32-46-68 100 150
NUTO-H EXXON/ESSO X X X
NUTO-HP EXXON/ESSO 32 & 46
NUTO-H PLUS EXXON/ESSO X
NYCO HYD. OIL NYCO LUBRICANT CORP. X X
ORLY AGENA ORLY INTERNATIONAL X
ORLY GALA ORLY INTERNATIONAL X
ORLY HYDRO ORLY INTERNATIONAL X
PACER POWER V PACER LUBRICANT INC. X X X
PARADENE ANTI-WEAR AW DRYDEN OIL CO. - USA X X X
PEAK HYDRA AW SERIES PEAK OIL CO. 46 & 68 X
PEN PREMIUM EP PENTAGON CORP. 32 & 68 X
PENNZBELL AW PENNZOIL PROD. CO. X X
PENNZOIL AW PENNZOIL PROD. CO. X X X
PENNZOIL AWX PENNZOIL PROD. CO. X X
RANDO OIL HD TEXACO INC. - USA X X
ROL ANTELITTERAM HVI ROL RAFFINERIA X
ROYAL AW EPPERT OIL CO. X
ROYAL PREMIUM VG EPPERT OIL CO. X
RYKON OIL AMOCO OIL CO. X
SELCO SF 330 SELCO X X X
SHARLU HYDROFLUIDS AW SHARJAH NATIONAL LUBE OIL X

CO. LTD.
SHOSEKI W-R SHOWA OIL LTD.-JAPAN X 32, 46 & 56
STAR PREMIUM VG EPPERT OIL CO. X
SUNVIS 8__ WR SUNCOR or SUNTECK X X X
SUPER BLUE HYD. OIL AUTOLINE OIL CO. X X X
SUPER HYD. OIL VG CONOCO X X
TELLUS SHELL CANADA LTD. X X X
TELLUS SHELL CO. - USA X X
TERRAPIN IND. OIL AUTOLINE OIL CO. X X X
TOTAL AZOLI A ZS J.W.LANE 46 & 68 X
TRC HYD. OILS VG TEXACO REFINERY X
UNION UNAX AW VG UNION OIL - USA 32 & 46 X X
UNIVIS N EXXON/ESSO X X
UNIVIS N PLUS EXXON/ESSO X X
UNIVIS SHP EXXON/ESSO 32 & 46
YUKONG SUPERVIS YUKONG LTD. X
(Page 2 of 2)
1-6
MINIMUM PERFORMANCE STANDARDS FOR HYDRAULIC OILS
The following are typical properties of hydraulic oils for use in severe duty applications of axial pis-
ton and vane pumps. Any oil which meets these or similar properties or which is listed in the
approved list of Equivalent Hydraulic Oils may be used.
32 46 68 100
ISO VISCOSITY GRADE
(32AW) (46AW) (68AW) (100AW)
ASTM Viscosity Grade No.

(Saybolt) 150 215 315 465
Gravity: API 31.1 30.3 29.5 28.9
Viscosity, Kinematic: cSt

104°F (40.0°C) 30.04 42.70 62.9 96
212°F (100.0°C) 5.26 6.57 8.43 11.03
Viscosity, SSU
100°F (37.8°C) 155 220 325 500
210°F (98.9°C) 43.9 48.2 54.6 64
Viscosity Index,
ASTM D 2270 106 105 104 99
Interfacial Tension,
D 971
77°F:dyn/cm 31 31 31 32
Flash, P-M: °F (°C) 400 (205) 405 (208) 450 (233) 465 (241)
Flash, OC: °F (°C) 425 (219) 430 (222) 470 (244) 490 (255)
Fire, OC: °F (°C) 455 (235) 470 (244) 500 (260) 545 (285)
Pour: °F (°C) -25 (-32) -25 (-32) -20 (-29) +5 (+15)
Color, ASTM D 1500 L0.5 L0.5 L1.0 L1.5
Carbon Residue,
Ramsbottom:% 0.30 0.30 0.36 0.37
Rust Preventive Test,

ASTM D 665
Procedure A, 24 hr Passes Passes Passes Passes
Procedure B, 24 hr. Passes Passes Passes Passes
Neutralization No.
ASTM D 974
Total Acid No. 0.68 0.68 0.68 0.68
Oxidation Test, ASTM D 943

Time Oxidized
Hr. to 2.0 Acid No. 2000+ 2000+ 2000+ 1500+
Emulsion, FTMS 791 3201,

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

D 611: °F (°C) 217 (103) 220 (105) 228 (109) 234 (113)
1-7
AIR COMPRESSOR LUBRICANT RECOMMENDATIONS
Sandvik Mining and Construction encourages the user to participate in an oil analysis program with
the oil supplier. This could result in an oil change interval differing from what is stated in these
tables.
NOTE!
Mixing synthetic oils with an ATF may lead to operational problems, foaming, or plugging of orifices.
Do not mix different types of fluids.
AMBIENT CHANGE LUBRICANT

ISO
TEMPERATURE INTERVAL DESCRIPTION
-40°F to +95°F (-40°C to +35°C) 1000 Hours 32 Mobil SHC-624, 924 & 1024
-40°F to +100°F (-40°C to +38°C) 1000 Hours* 32 Mobil Rarus 424
-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Chevron HiPerSYN
-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Chevron Tegra Synthetic
-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Shell Corena PAO
-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Royco 432
-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Conoco Syncon R&O
-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Texaco Cetus PAO
-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Valvoline Syn Guard CP
-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Petro-Canada Super SCF32
+30°F to +100°F (-1°C to +38°C) 1000 Hours 46 Chevron HiPerSYN
+30°F to +100°F (-1°C to +38°C) 1000 Hours 46 Citgo CompressorGuard
+30°F to +100°F (-1°C to +38°C) 1000 Hours 46 Conoco Syncon R&O
+30°F to +100°F (-1°C to +38°C) 1000 Hours* 46 Mobil Rarus 425
+30°F to +100°F (-1°C to +38°C) 1000 Hours 46 Petro-Canada Super SCF46
+30°F to +100°F (-1°C to +38°C) 1000 Hours 46 Royco 446
+30°F to +100°F (-1°C to +38°C) 1000 Hours 46 Texaco Cetus PAO
+30°F to +100°F (-1°C to +38°C) 1000 Hours 46 Valvoline Syn Guard CP
+80°F to +120°F (+27°C to +49°C) 1000 Hours 68 Conoco Syncon R&O
+80°F to +120°F (+27°C to +49°C) 1000 Hours 68 Mobil SHC-626, 926 & 1026
Low and High Pressure Compressors
When operating between +80 and 100°F (+27 and 38°C) with a relative humidity above 80%, syn-
thetic hydrocarbon type fluid Mobil SHC or equivalent as recommended above should be used.
All lubricant recommendations are based on 1200 rpm maximum WARM-UP speed.
* 500 Hour Interval with High Pressure Compressors

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

forming even the most routine service proce-
Sandvik Mining and Construction encourages dure. You can reduce the possibility of dirt
the user to participate in an oil analysis program entering a system by:
with an oil supplier or engine manufacturer. • Ensuring that all containers used for dis-
Periodically analyzing the oil monitors the con- pensing oil are clean.
ditions of both the machine components and the • Ensure that the areas around filler caps and
oil itself. Also, using an oil analysis program plugs are clean before removing them.
could result in oil change intervals differing from Never leave plugs or caps off any longer
those stated in this manual. than necessary.
• Keep disconnected hoses plugged to pre-
Following the instructions of your program coor- vent entry of dirt.
dinator, we recommend taking samples when • Repair leaking cylinder rod wiper seals
the oil is hot and mixed from the following loca- immediately.
tions: • Change filters and breathers regularly in
• Engine crankcase accordance with maintenance recommenda-
• Hydraulic tank tions.
• Main pump drive gearbox • Ensure that all gaskets, seals and protective
• Final drive gearbox covers are tight and properly fitted.
• Compressor air/oil receiver tank
Oil Contamination
WIGGINS SERVICE STATION
Water or air in a hydraulic system can cause
If your machine is equipped with a Wiggins ser- pump failure. If hydraulic oil appears cloudy,
vice station it should be used whenever replen- water or air is entering the system and the oil
ishing fluids to reduce the risk of contamination should be drained, the system flushed and
and the chance of mixing fluids. cleaned, and refilled with new oil. Points of
entry for air or water such as suction hoses or
loose clamps, faulty seals or gaskets, and areas
2-2
where water may pool and be drawn into the • Component bearing failure
system should be checked and remedied. • Acid formation
• Overheating
Leaks
Initial Start-Up
If a leak has developed in a system, it is
because there is a fault which may not be On the initial start-up of the machine, the
noticeable or immediately evident. A leak is hydraulic actuators may move without notice or
generally a symptom of a fault such as: without any control input signal due to air
• Overheating. entrapment in the circuits. Ensure that all per-
• Overpressure sonnel are clear prior to starting. Normally,
• Excessive vibration through a mechanical cycling the component several times will cause
component fault. the air to bleed off. However, if the condition
• Incorrect operating procedure. continues it will require technical assistance.
• Poor maintenance procedure.
When fixing a leak, try to identify the real cause. Hose Replacement
If a hose is frayed or damaged, it must be

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

more of the preceding properties) is to be
Welding on a pressure vessel or near batter-
avoided at all costs. Never top off or fill a res-
ies could cause an explosion resulting in
ervoir with an incompatible fluid. Use only
injury or death.
the oils specified in the “COOLANT, FUEL and
LUBRICANT SPECIFICATION” table in this
All welding should be in accordance with Ameri-
manual.
can Welding Society D1.1 ‘Structural Welding
Code’ in conjunction with AWS D14.3-82R spe-
Problems caused by incompatible fluids are:
cific for welding earth moving and construction
• Sludging
equipment.
• Oxidation
• Reduced lubrication effectiveness
Never use oxy heating or cutting equipment on
• Seal damage
or around hydraulic components. Apart from
• Metallic erosion
fire hazard the heat can damage components.
• Corrosion
Heating or welding on hydraulic pipes or fittings
• Foaming/aeration
will cause a scale to develop on the inside. This
• Solidification/emulsification
scale may enter the system and cause severe and replace these cartridges with maintenance
component damage. cartridges at 250 hour intervals.
Always disconnect the ground terminals from Use only the water and coolants specified in the
the batteries before welding on the machine to “COOLANT, FUEL and LUBRICANT SPECIFI-
prevent damage to electronic controls. CATION” topic in this manual and refer to Cater-
pillar® bulletin SEBD 0518-06.
The ground cable of the welding machine must
be connected to the work piece, as close as If the engine is to be operated or stored in an
possible to the area being welded. The ground area with temperatures below 32°F (0°C), the
cable should not be connected in such a way to cooling system must be protected to the lowest
allow current to flow through a bearing, joint expected ambient temperature.
coupling, sealing surface, lever or control cable.
Clean the cooling system if scale is present or
If welding is performed near pins or in places there is evidence of oil contamination. In either
where flexing may cause shanges in the align- case, overheating may result.
ment of bushings, remove the pins and check
the alignment after welding. When refilling the cooling system, add coolant
no faster than 20 qts (20 l) per minute to prevent
air pockets from developing.
AIR INTAKE SYSTEM
After refilling the system, run the engine with the
The engine and compressor air intake filters radiator cap(s) removed until the coolant level
should be serviced when the service indicates stabilizes. Top off the radiator if necessary.
to do so or the Drill Monitoring System (DMS)
indicator illuminates.
FUEL SYSTEM
Observe the limits on the number of times the
filter elements can be cleaned and when the Use only the fuels specified in the “COOLANT,
safety element should be replaced. FUEL and LUBRICANT SPECIFICATION” topic
in this manual.
ELECTRICAL SYSTEM Have your fuel supplier drain water and sedi-
ment from his fuel storage tanks at weekly inter-
When jump-starting the machine, follow the vals to prevent contamination from being
instructions in the Operators Manual to avoid pumped into the machine’s tank.
equipment damage or injury to personnel.
Always fill the tank at the end of the shift to drive
Always disconnect the batteries before welding out moisture laden air from the tank but do not
on the machine or alternator damage will result. fill the tank to the brim as fuel will expand as it
warms and may overflow
Keep all electrical compartments closed and
properly sealed during machine operation. Allow fuel to settle for a few minutes after filling
before draining water and sediment..
COOLING SYSTEM After changing fuel filters, bleed the fuel circuit
to remove air.
All water is corrosive at engine operating tem-
perature. Always use coolant conditioner pre-
charge cartridges when changing the coolant,
2-4
RECOMMENDED TORQUE VALUES FOR STANDARD HARDWARE - UNC
This table applies to part numbers:

001554-___ CAPSCREW, Hex hd
001559-___ CAPSCREW, Socket hd
001570-___ SCREW, Flat hd socket
001577-___ NUT, Hex - regular
001575-___ NUT, Hex - heavy
001562-___ NUT, Hex - self-locking
Coarse Thread (UNC) Torque Torque

Size Grade 5 Grade 8
(Diameter in Inches) Ft.Lb. (Kg/M) Ft.Lb. (Kg/M)
1/4 6 (.8) 9 (1.2)
5/16 12-14 (1.5) 17-19 (2)
3/8 22-24 (3) 31-34 (4.5)
7/16 36-39 (5) 50-55 (7)
1/2 54-59 (8) 76-84 (11)
9/16 77-85 (11) 110-120 (15-16.5)
5/8 107-118 (15-16) 153-166 (21-23)
3/4 190-210 (26-29) 270-292 (37-40)
7/8 280-310 (38-43) 437-475 (60-66)
1 425-460 (59-63) 650-710 (90-98)
1-1/8 570-620 (79-86) 930-1000 (128-138)
1-1/4 810-870 (112-120) 1310-1410 (181-195)
1-3/8 1060-1140 (146-157) 1730-1850 (239-256)
1-1/2 1410-1510 (195-209) 2290-2460 (316-340)
NOTE: These torque values are to be used for general assembly procedures. Special torque requirements may be
specified on assembly and installation procedures.
NOTE: All fasteners are to be free of dirt and rust at time of assembly. Lubrication is not to be applied to threads unless
so specified.

RECOMMENDED TORQUE VALUES FOR STANDARD HARDWARE - UNF
This table applies to part numbers:

001560-___ CAPSCREW, Socket hd
001571-___ SCREW, Flat hd socket
001578-___ NUT, Hex - regular
001576-___ NUT, Hex - heavy
001563-___ NUT, Hex - self-locking
Fine Thread (UNF) Torque Torque

Size Grade 5 Grade 8
(Diameter in Inches) Ft.Lb. (Kg/M) Ft.Lb. (Kg/M)
1/4 7 (1) 10-11 (1.5)
5/16 14-16 (2) 20-22 (3)
3/8 25-28 (3.5) 35-39 (5)
7/16 39-43 (6) 55-61 (8)
1/2 63-69 (9) 86-94 (12)
9/16 87-95 (12-13) 123-134 (17-18.5)
5/8 126-138 (17-19) 171-187 (24-26)
3/4 213-233 (30-32) 300-328 (42-45)
7/8 312-338 (43-46) 480-520 (66-72)
1 466-504 (64-70) 715-770 (99-106)
1-1/8 640-695 (89-96) 1040-1120 (144-155)
1-1/4 900-960 (124-133) 1460-1560 (202-216)
1-3/8 1210-1300 (167-180) 1970-2100 (272-290)
1-1/2 1585-1700 (167-180) 2570-2750 (272-290)
NOTE: These torque values are to be used for general assembly procedures. Special torque requirements may be
specified on assembly and installation procedures.
NOTE: All fasteners are to be free of dirt and rust at time of assembly. Lubrication is not to be applied to threads unless
so specified.
2-6
WHEN REQUIRED MAINTENANCE CHECKS
Rig Model ..........................................................
Rig Serial Number.............................................
Maintenance Person ...............................................................
Date...................................
Maintenance Point Serviced By
Replace Starting Aid Cylinder
Coolant Condition
Check Cooler Cores for Obstructions
Change Air Cleaner Elements
Change Cab Air Conditioner/Heater Air Cleaner Element
Change Dust Collector Elements
Page 2A
8 HOUR or SHIFT CHANGE MAINTENANCE CHECKS
Rig Model ..........................................................
Date...................................
Perform “Operator’s Safety Check”
Check Engine Oil Level
Drain Primary Fuel Filter Water
Check Engine Coolant Level
Check Air Compressor Oil Level
Drain Condensation from Air/Oil Receiver Tank
Check Compressor Oil Return Line Sightglass
Check Air/Oil Separator Element Indicator
Check Hydraulic Tank Oil Level
Drain Water from Hydraulic Reservoir Tank
Check Hydraulic Tank Air Pressure Regulator Gauge
Check Hydraulic Servo Filter Service Alarm Indicators
Lubricate Pump Driveshafts
Check Oil Level in Pump Drive Gearboxes
Check Undercarriage for Debris
Check Air Cleaner Element Indicators
Empty Air Cleaner Dust Cups
Check Central Lubricator System Grease Level
Drain Central Lubricator Water
Check Central Lubricator Pump Oiler Level
Visually Inspect Winch Wire Rope
Check Air Lubricator Oil Level
Check Feed Chain Adjustment

Page 2B
50 HOUR or WEEKLY MAINTENANCE CHECKS
Rig Model ..........................................................
Date...................................
Perform the 8 Hour Maintenance Checks
Lubricate Air Swivel
* Replace Compressor Main Oil Filter Elements
* Replace Hydraulic Return Filter Elements
* Replace Servo Replenshing Filter Elements
* Change Winch Oil
* Initial 50 Hours or Operation Only
Page 2C
250 HOUR or MONTHLY MAINTENANCE CHECKS
Rig Model ..........................................................
Date...................................
Check Engine Mounts for Tightness
Change Engine Oil and Replace Filters
Inspect Alternator and Air Conditioner Compressor V-Belts
Check Battery Condition and Electrolyte Level
Replace Secondary Fuel Filter
Replace Coolant Conditioner Cartridges (3412E Only)
Check Fan Mountings, Blade, Guards and Hose Condition
Check Fan Motor Overhung Adapter Oil Level
Replace Compressor Main Oil Filter Elements
Clean Compressor Oil Scavenge Line Strainer
Sample Compressor Oil
Replace Hydraulic Servo Replenishing Filter Elements
Clean Hydraulic Tank In-Line Air Strainer
Clean Hydraulic Tank Water Trap Filter
Replace Hydraulic Tank Breather
Check Hydraulic Tank Mounting Bolts
Clean Pump Drive Breathers
Check Water Injection Pump V-Belt Tension
Change Water Injection Pump Oil
Check Rotary Head Oil Level
Check Feed Chain Tension
Lubricate Feed Chains
Page 2D (1 of2)
250 HOUR or MONTHLY MAINTENANCE CHECKS
(Continued)
Rig Model ..........................................................
Rig Serial Number .............................................
Date...................................
Inspect and Lubricate Chain Sprockets
Check Crawler Track Tension Adjustment
Check Oil Level - Crawler Final Drives
Clean Central Lubrication Water Trap Filter
Check Central Lubrication Operation
Check Electrical Wiring Condition
Check Air Intake and Exhaust System
Check Dust Collector Hoses and Components
Check Decals and Nameplates
Replace Engine and Compressor Primary Air Filter Elements
Clean Air Cleaner Inlet Tubes
* Adjust Engine Valve Lash
* Change Oil - Crawler Final Drives
* Initial 250 Hours or Operation Only
Page 2D (2 of 2)
500 HOUR or 3 MONTH MAINTENANCE CHECKS
Rig Model ..........................................................
Date...................................
Clean Engine Crankcase Breather
Change Primary Fuel Filter Element
Change Pump Drive Gearbox Oil
Replace Hydraulic Return Filter Elements
Clean Water Injection Suction Strainer
Check Winch Oil Level
Check Thread Lubricator Grease Level
Replace Fan Motor Case Drain Filter
Replace Engine and Compressor Filter Safety Elements
Inspect Drill Pipe Safety Hoop
Inspect Mast Pedestal Welds
Page 2E
1000 HOUR or 6 MONTH MAINTENANCE CHECKS
Rig Model ..........................................................
Date...................................
Change Hydraulic Oil
Check Compressor Mounting Hardware Torque
Sample or Change Compressor Oil
Change Air/Oil Separator Filter Element
Change Winch Oil and Clean Breather
Replace Rotary Head Gearbox Breather
Replace Pump Drive Gearbox Breathers
Change Fan Motor Overhung Adapter Oil
Check the Torque of the Mast Pivot Block Bolts
Page 2F
2000 HOUR or 1 YEAR MAINTENANCE CHECKS
Rig Model ..........................................................
Date...................................
Change Engine Coolant
Check Cooler Mounting Hardware Torque
Change Crawler Final Drive Oil
Test Mast Pedestal Welds
Replace the Mast Pivot Block Dowels and Hardware (4000 Hours or
One Year)
Page 2G
WHEN REQUIRED
STRAP
FUEL SYSTEM
Replace Ether Starting Aid Cylinder C75-42
! DANGER
ETHER IS POISONOUS !!
Avoid breathing vapors and repeated skin
contact, keep out of the reach of children,
use only in well-ventilated areas, and do not
store cylinders in living areas or operator’s
compartment.
! DANGER C27 ENGINE
ETHER IS FLAMMABLE !!
Observe the following precautions while
handling ether cylinders:
• Do not smoke while changing cylinders.
• Do not store cylinders at temperatures
above 49°C (120°F).
• Do not store cylinders in direct sunlight
• Do not puncture or burn cylinders.
• Discard cylinders in a safe place.
Replace an ether cylinder as follows:
1. If the cylinder bottle is attached with a

clamp, loosen the clamp and unscrew the
empty ether cylinder.
2. Remove the used gasket and install the new

gasket supplied with each cylinder.
COOLING SYSTEM
3. Install the new cylinder. Tighten the cylinder
hand tight. Fasten the clamp securely.
Check Cooling System
! WARNING
Steam can burn. Allow the coolant to cool.
Open the radiator filler cap slowly.
If the cooling system is contaminated, the

engine overheats or if foaming is observed in
2A-1
the radiator, follow the “Change Engine Cool- Primary Element
ant” procedure in the “2000 Hour or 1 Year” 1. Loosen the wing nut and gently slide the pri-
maintenance check. mary element out of the air cleaner assembly.
2. Inspect the service indicator for the safety

Check the Cooler Core element. Remove and replace the element if
the indicator is in the red zone.
Dusty working conditions may require you to
clean the cooler fins more often than a normal 3. Inspect the inside of the filter housing and if
operating maintenance schedule. cleaning is required remove the safety element.
Be careful not to allow dust to enter the intake
duct.
AIR CLEANERS - ENGINE & COMPRESSOR
4. If the filter is dented or bunched it must be
replaced. Never rap or hit the element to
Changing Elements remove dirt. The primary element can be
cleaned with compressed air, pressurized water
General or washed with detergent. If cleaning the pri-
Proper air cleaner servicing will result in maxi- mary element with proceed as follows:
mum protection against dust. Proper servicing
can also save time and money by increasing fil- COMPRESSED AIR
ter life and dust cleaning efficiency. Two of the
most common servicing problems are: Over
Servicing and Improper Servicing. Replace or ! WARNING
clean elements only when the restriction indica- Always use a face shield and protective
tor on the filter or the warning light on the instru- clothing when using compressed air.
ment panel indicate to do so. Don’t be fooled by Failure to do so can cause eye damage or
filter appearance, the filter should look dirty. blindness.
Careless servicing procedures can cause con-
tamination. Use the following procedures as a NOTICE
guide to air cleaner maintenance.
Using compressed air above 30 psi (205
kPa) can damage the filter element.
SAFETY SERVICE
ELEMENT INDICATOR/NUT A. Blow air ALONG (not across) the pleats
inside and outside of the element as shown.
TUBES
PRIMARY COMPRESSED AIR

ELEMENT
DUST B. After cleaning, inspect the element with a

CUP
light bulb as shown. Replace the element if
necessary.
2A-2
PRESSURIZED WATER INSPECTION
NOTICE
Using compressed water above 40 psi (with-
out nozzle) (280 kPa) can damage the filter
element.
A. Direct water ALONG (not across) the pleats

inside and outside the element.
B. Air dry the element Do Not dry with a light
bulb.
C. After drying, inspect the element with a light 5. Before installing the cleaned or new ele-
bulb as shown. Replace the element if neces- ment press the element gasket to ensure that it
sary. has not gotten brittle.
6. Slide the primary element over the safety

element and tighten the wingnut.
7. Inspect all air cleaner and air duct connec-

tions for leakage before starting the engine.
Safety Element
PRESSURIZED WATER
The safety element should be replaced every

third time the primary element is cleaned or
WASHING WITH DETERGENT
replaced or as indicated by the service indicator
A. Remove excess dust with compressed air
in the safety filter hold down nut as shown.
or water as described earlier.
B. Wash the element in warm water with a
1. Remove the primary element as described
non-sudsing household detergent or Donaldson
earlier.
D-1400 Washing Compound.
C. Rise the element with clean water from both
2. Remove the split pin and nut that hold the
sides if necessary.
safety element in place.
D. Let dry in warm circulating air of less than
160°F (71°C).
3. Remove and discard the safety element.
E. After drying, inspect the element with a light
The safety element should not be cleaned.
bulb as shown. Replace the element if neces-
sary.
4. Clean the inside of the filter housing espe-
cially around the areas of the element sealing
surfaces.
5. Install a new safety element.
6. Install the primary element.
2A-3
OPERATOR’S CAB
Change Air Conditioner/Heater Filter Ele- FILTER ELEMENT
ment
Unscrew the nut on top of the pre-cleaner and

empty when dirt reaches the line on the side of
the bowl.
Remove and replace the filter element as

needed.
AIR CONDITIONER/
HEATER AIR CLEANER
PRE-CLEANER
ELEMENT
WING NUT
c245-2
Inspect the filter elements through the access

doors provided. Remove the elements by
unthreading the wingnuts. Be sure to tighten
the wingnuts after the elements have been
replaced or cleaned.
DUST COLLECTOR
Compressed air must be clean and filtered to
ensure that there is no contamination of the
Change the Filter Elements valve seats.
Routine inspection of door gaskets, suction Filters can be ruined by operating under wet
hose, dump hoses, dusthood seals and other conditions. Occasionally the filters can be
wear items is necessary to ensure that there are removed, blown out and inspected for tears.
no leaks to the system.
NOTICE
Do not run the dust collector fan if drill dust
is venting from the fan exhaust. Severe
damage to the fan, the fan shaft and it’s
bearings will occur.
2A-4
EVERY 8 SERVICE HOURS
OR DAILY FILLER
ENGINE
Measure Crankcase Oil Level
1. Measure engine oil level. Maintain oil level

to FULL mark on the ENGINE STOPPED side
of dipstick.
2. Add oil of the typed specified in Section 1 if

necessary through fill point.
460-17
DIPSTICK
3412E ENGINE
FILLER
C27 ENGINE
C27 ENGINE
Drain Fuel Water Separator Bowl

DIPSTICK
1. Locate the water separator bowl at the base
of the primary fuel filter.
2. Open the drain valve to allow the accumu-

lated water to drain.
3. Close the drain valve.
8 Hour Maintenance Checks - Page 2B-1

FILLER
PRIMARY CAP AKG COOLER
FUEL
FILTER
COOLANT
75-1 WATER
SIGHT
GAUGE
DRAIN
3412E ENGINE VALVE
C27 ENGINE
WATER
DRAIN COOLANT
VALVE SIGHT
GAUGE
COOLING SYSTEM
MESABI COOLER
Check Coolant Level
Check that the coolant is visible in the sight-

glass. Add coolant if necessary.
Adding Coolant
! WARNING
Steam can burn. At operating temperature,
engine coolant is hot and under pressure.
Remove the filler cap only when the engine
is stopped. Open the filler cap slowly only
when cap is cool to the touch.
Page 2B-2
Check Oil Level
NOTICE Check the oil level at least 10 minutes after
If filling the radiator via the Wiggins station, shutdown, with the unit level and separator
leave the radiator cap off to prevent pres- pressure zero.
sure from building up during filling.
1. Observe the oil level in the air/oil receiver
1. Remove the radiator filler cap slowly. tank sightglasses.
NOTICE
Cooling System Conditioner contains alkali. OIL LEVEL
Avoid contact with skin and eyes to prevent SIGHTGLASS
1
1
personal injury.
22
2. Inspect the condition of the cap gasket.
Replace if necessary.
3. Maintain the coolant level to the bottom of 75-19

the filler tube.
NOTE!
Add coolant slowly at 20 litres (5 U.S. gallons)
or less per minute to avoid air locks. The oil level should be maintained so that it
is visible in the center sightglass.
4. Replace the cap and tighten.
NOTICE
Do not mix compressor oils. Incompatible
NOTE !
fluids may cause compressor damage or
• Inspect for coolant leaks, damaged or deteri-
reduced oil change intervals.
orated hoses and obstructed radiator cores.
• Any of these may cause damage to the
2. Add oil if necessary, through the fill point (1)
engine through overheating.
or Wiggins station. Do not overfill; the oil level
must not rise above the upper sightglass (2).
COMPRESSOR
! WARNING Drain Condensate From Air/Oil Receiver

Tank
• Do not remove caps, plugs, or other com-
ponents while the compressor system is
Remove the plug from the drain and open the
running or pressurized.
valve. Drain off water until oil appears.
• Stop the engine and allow time for the
NOTE!
system to relieve all internal pressure
Water can cause compressor failure. If the oil
before servicing. Check the air pressure
appears cloudy, water is entering the system.
gauge in the cab to ensure pressure is
Determine the point of entry and rectify the
zero.
problem, then drain, flush and refill the system.

.
75-24
ELEMENT
INDICATOR
DRAIN PLUG
RECEIVER TANK
DRAIN VALVE
RECEIVER
TANK
Check Oil Return Line Sightglass
When the engine is running, inspect the sight-

glass (1) to ensure that oil is visibly flowing. If HYDRAULIC SYSTEM
oil is not visible, clean the in line strainer (2) as
described in the 250 hour maintenance proce-
dures. Check Oil Level in Reservoir Tank
1. Fully retract all hydraulic cylinders and shut-

down the engine.
2. Look at the sight gauge. The oil level must

be maintained to the line. Add oil if neces-
sary.
55-45
2
1 75-2
Check Air/Oil Separator Element Indicator
When the engine is running, ensure the indica- HYDRAULIC OIL

tor is not showing its red band. If the red band SIGHT GAUGE
is fully visible, change the separator element.
Some models do not have a dirt alarm indicator
on the filter housing.
Page 2B-4
Adding Oil problem, then drain, flush and refill the system.
NOTICE
• Before filling, shutdown the engine and
relieve all pressure from the tank by
opening the tank vent ball valve.
75-36
• Double check that all hydraulic cylinders
are retracted, or the tank may be over-
filled and rupture.
HYDRAULIC
Add oil only via the Wiggins station or the hand TANK
DRAIN
pump.
NOTICE
• Do not mix hydraulic oils. Check Hydraulic Tank Air Pressure Regula-
tor Gauge
• Incompatible fluids may cause pump
damage and reduce oil change intervals. The tank is pressurized to prevent entry of con-
tamination and to prime the hydraulic pumps.
TANK VENT Inspect the air pressure gauge while the engine
BALL VALVE
is running. It should read between 3 and 5 p.s.i.
REGULATOR
GAUGE
REGULATOR
HAND GAUGE
PUMP
Drain Water From Reservoir Tank

Check Servo Replenishing Filters Dirt
Open the valve and drain off water until oil
Alarms
appears.
The indicators should be checked to ensure that
NOTE !
they are not seized and for oil bypassing the fil-
Water can cause pump failure. If the oil
ter.
appears cloudy, water is entering the system.
Determine the point of entry and rectify the

1. With the engine stopped, turn the indicators
(1) through their range of movement. They
should turn freely.
2. With the engine and pumps running,

observe the position of each indicator. They
should point to the green sector. If an indicator 75-13
points to either the yellow or red sectors, the fil-
ter element should be changed, as it is clogged
and oil is bypassing the element.
ACCESS
DOOR
1
NOTICE
• Do not overlubricate the universal joints.
• Seal rupture can occur and allow ingress
of dirt.Clean the grease fitting in each
universal joint and lubricate with two
strokes from a hand grease gun.
SERVO
FILTERS
75-31
DRIVESHAFTS
Lubricate Pump Driveshafts PUMP DRIVE

ACCESS
DOOR
Ensure the fittings and grease gun are clean
before servicing.
1. As shown, remove the hardware and open PUMP DRIVE GEARBOXES

the access doors.
Check Oil Levels
2. Locate the dipsticks on the pump drive gear-

boxes.
Page 2B-6
AIR INLET
PROPEL
GEARBOX Check Air Cleaner Element Indicators
(Machine without DMS)
FILL Check the indicator located on the air inlet pipes

PLUG 75-28
as shown. Service the elements as needed as
explained in the “When Required” maintenance
checks.
DIPSTICK
ELEMENT INDICATOR
3. The oil level should be between the LOW

and FULL marks on the dipstick. If necessary
add oil of the type specified in the “Coolant,
Fuel and Lubricant Specification” section of this
manual through the fill opening.
DIPSTICK
FILL
PLUG
75-30
Empty Air Cleaner Dust Cups
Dust cups should be inspected very 8 hours of

machine service. Open the latches and allow
dust to empty. Close the latches after emptying.
HYDRAULIC
GEARBOX
UNDERCARRIAGE
Check for Debris
Visually inspect the undercarriage for rocks,

debris and built-up dirt. Clean idlers and
sprockets as necessary.
DUST CUP

CENTRAL LUBE SYSTEM MISCEALLANEOUS
Check Central Lubricator Grease Level Inspect Winch Wire Rope
Slowly turn the cap to release any pressure in Visually inspect the winch wire rope for kinking,
the tank. Remove the cap and refill as needed. twisting and general wear. Replace as neces-
sary and discard in accordance with 3.5 of ISO
4309:1990.
Check Air Lubricator Oil
75-38
Locate the lubricator tank sight gauge and fill as
required through the filler port.
FILLER
CAP
CAP
Drain Water and Check Pump Oiler Level
1. Unscrew tap (1) under the bowl to drain the

water. Close the tap after draining.
LEVEL
2. Check the oil level through sightglass (2). If SIGHTGAUGE
oil is needed, unscrew the bowl and add Engine
Oil (CH) as required.
AIR CLEANER
75-33
Check Feed Chain Adjustments
With the mast lowered and the rotary head at

the top of it’s travel, check the sag of the chains
1 2 as shown.
Page 2B-8
TABLE ROTARY HEAD
3mm (1/8”)
245-41
FEED CHAIN
ADJUSTMENT
HOIST CHAIN
ADJUSTMENT

Page 2B-10
EVERY 50 HOURS OR INITIAL 50 HOURS OF OPERATION
WEEKLY Replace Air Compressor Main Oil Filter Ele-

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

NOTICE Elements
• Do not over-lubricate. Refer to the “250 Hour Maintenance Checks.”
• Do not use a pressure grease gun, as this

can cause damage to the seals. Change Winch Oil
1. Remove the protective cap to expose the
lubrication fitting.
2. Lubricate the air swivel with two strokes of a

hand grease gun.
3. Replace the protective cap.
LUBRICATION
FITTING
245-46 AIR SWIVEL
50 Hour Maintenance Checks - Page 2C-1

Page 2C-2
EVERY 250 HOURS OR Change Crankcase Oil and Filters
MONTHLY !! WARNING
Hot oil or components can cause burns if
they contact skin.
ENGINE
1. With the oil warm and the engine stopped,
drain the crankcase by removing the plug from
Check Engine Mount Torque
the oil pan and allowing the oil to drain into a
suitable container.
Inspect the front and rear engine mounts for
cracks or signs of movement and the bolts for
tightness. 3412E ENGINE
460-17
ENGINE PLUG OIL FILTERS DIPSTICK WIGGINS

75-5 MOUNT REFILL
HOSE
(FRONT)
C27 ENGINE
3412E ENGINE
C27 ENGINE
2. Install the plug when draining is completed.

ENGINE
MOUNTS
(REAR) 3. Use a strap wrench to remove the oil filters.
250 Hour Maintenance Checks - Page 2D-1

cations” tables.
FILLER 8. Start the engine and run long enough to

ensure that the lube system cavities and filter
have oil.
460-31
9. Stop the engine and allow the oil to drain
back to the sump for a minimum of five minutes.
The oil level reading should indicate FULL on
the ENGINE STOPPED side of the dipstick.
Engine Valve Lash (Initial)

3412E ENGINE
ADJUST
Adjust valve lash (clearance) at the first oil

change. All subsequent adjustments are to be
performed at the “Every 3000 Service Hour”
interval.
Refer to Engine Valve Lash in the Caterpillar®

Maintenance Manual for the procedure.
ALTERNATOR and AIR CONDITIONER COM-

PRESSOR V-BELTS
FILLER Inspect
Inspect the belts for wear. Replace the belts if

C27 ENGINE
worn, cracked or frayed.
4. Clean the filter base to ensure that all traces

of the old seals are removed. Check Belt Adjustment
5. Coat the seals on the new filter cartridges 1. Open the access door to view the belts.
with clean engine oil.
6. Install the new filters by hand. When the fil-

ter seal contacts the base, tighten the filter 3/4
turn more.
75-12
NOTE !
Do not overtighten the filter.
7. Refill the crankcase. See the “Refill Capaci-

ties” and “Fuel, Coolant and Lubricant Specifi- 3412E ENGINE
Page 2D-2
2. Apply a 12 kg (25 lb.) force perpendicular to 4. If a new belt is installed, check the belt
the belt, midway between the driving and driven adjustment after 30 minutes of engine opera-
pulley. Measure the belt deflection. Proper belt tion.
deflection is 15 to 20 mm (9/16 to 7/8 inch).
Adjust the belt tension as required. 5. Secure the access cover.
Adjusting the Alternator Belt Adjusting the Air Conditioner Belts
1. Loosen the alternator pivot bolt and the lock- 1. Loosen the adjusting screw jam nut.
nut on the belt tensioner rod.
ALTERNATOR
BELT
TENSIONER ADJUSTING
SCREW
LOCKNUT
245-20
75-7
3412E ENGINE
3412E ENGINE
2. Turn the adjustment screw until correct belt

deflection is obtained.
3. Tighten the jamnut.
4. If new belts are installed, check the belt

adjustment after 30 minutes of engine opera-
tion.
5. Secure the access cover.
C27 ENGINE BATTERIES
2. Turn adjustment nut until correct belt deflec- Check Battery Electrolyte Level and Clean
tion is obtained. Batteries
3. Tighten the locknut. Locate the battery box located on the right side
of the machine next to the engine. replace, clean or tighten cable clamps.
!! WARNING 3. Clean the cable clamps and terminals with a

wire brush, then coat them with petroleum jelly.
• Batteries give off explosive hydrogen
gas.
!! WARNING
• Do not smoke or allow any other ignition DO NOT top off batteries with acid.
source near the batteries.
4. Remove the battery fill caps. Maintain the
• Battery electrolyte contains sulfuric acid. electrolyte level to the bottom of the filler tube.
It will cause severe personal injury if it If the level is low, top up with distilled or dem-
contacts skin or eyes. ineralized water.
• Always wear protective glasses when 5. Replace the fill caps and install the cover.
working with batteries.
1. Remove the wingnuts and lift the covers off

of the battery box. FUEL SYSTEM
3412E ENGINE !! WARNING

• Fuel leaked or spilled onto hot surfaces
or electrical components can cause a
75-32 fire.
• Disconnect the battery when changing

fuel filters.
BATTERIES Change Secondary Fuel Filters
1. Stop the engine.
2. Close the fuel supply line valve (if fitted).

C27 ENGINE
3. Use a strap wrench to remove the fuel filters.
4. Clean the filter base. Be sure to remove all

of the old seal.
5. Apply a light coat of clean fuel to the new fil-

ter seal.
6. Install the new filters by hand. When the

seal contacts the base, tighten 3/4 turn more.
2. Clean the tops of the batteries with a clean
cloth. Check for corrosion or looseness of the NOTE !
terminals and cable clamps. If necessary, Do not overtighten a filter.
Page 2D-4
3412E ENGINE
FUEL
PRIMING
75-1
PUMP
PLUNGER
75-1
SECONDARY
FUEL
FILTERS
3412E ENGINE
FUEL
PRIMING
PUMP
PLUNGER
SECONDARY
FUEL
C27 ENGINE FILTER
C27 ENGINE
7. Open the fuel supply valve.
8. Prime the fuel system. See the topic “Prim- 2. Pump the plunger to fill the new filter ele-
ing the Fuel System”. ment. Continue pumping until resistance is felt,
indicating that the filters are full.
9. Start the engine and inspect for leaks.
3. Turn the pump handle knob clockwise to
lock the plunger.
Priming the Fuel System 4. Start the engine and check for fuel leaks.
Priming the fuel system fills the fuel filters and

removes air from the fuel system after the filters
have been changed. Refer to the Caterpillar® COOLING SYSTEM (3412E Only)
engine Operation and Maintenance manual if
the engine fuel supply has run dry.
Change Coolant Conditioner Cartridges
1. Turn the priming pump plunger counter-
clockwise and pull out the plunger. Check the cooling system only after the engine
is stopped and cool to the touch. Refer to the
engine manufacturer’s Operation and Mainte-
nance Manual for coolant testing and additional
specifications.
NOTE ! ity of 162 ml (5.5 oz) and the two vent adapter .8
Ensure that a MAINTENANCE (not a PRE- l (28 oz) Remove the vent and check the oil
CHARGE) conditioner cartridge is used for this level, add clean compressor oil if necessary .
service, unless the coolant is also being
changed.
VENT
1. Close the coolant inlet and outlet valves.
2. Use a strap wrench to remove the car-

tridges.
NOTICE
Engine coolant contains alkali - avoid con-
tact with skin and eyes.
3. Clean the filter base.
4. Install the new cartridges by hand. When VENTS

the seal contacts the base, tighten 3/4 turn
more.
SHUTOFF
VALVES
75-35
Check Cooler Fan Finger Guards and Radia-

COOLANT
CONDITIONER tor Blade Condition
CARTIDGES 3412E ENGINE
Check the tightness of the fan guards and

inspect the fan blades for cracks. Replace if
NOTE ! necessary.
Do not overtighten the cartridges.
5. Open the shutoff valves on the coolant lines
6. Check for leaks with the engine running. FINGER

GUARD
HARDWARE
Check Fan Motor Overhung Adapter Oil

Level
Two types of adapters are used on this model of

machine. The single vent adapter has a capac-
Page 2D-6
COMPRESSOR
Change Main Oil Filter Elements 1
The filters should be changed every 500 hours 6
unless the service light indicates the filters are 2

bypassing oil, in which case they should be
5
changed immediately.
3 GROMMET
COMPRESSOR
MAIN OIL FILTER 7
NOTICE
Ensure the engine is shutdown and the
internal pressure relieved.
1. Unscrew the filter housing cap (1). BASE
2. Remove the cap (1), spring (2) and washer

(3).
SHOWN
WITH MANUAL INDICATOR
3. Quickly remove the two filters from the hous-

ing to prevent dirty oil from the elements from
dripping into the housing.
4. Note the order and orientation of the compo- 5. Replace the O-ring and backup rings on the
nents, especially the connector (1) for assem- cap and base.
bly.
6. Install two new elements, ensuring they are
NOTICE joined with the plastic connector.
Be sure to inspect the inside of the filter
7. Install the washer, spring and cap.
base to ensure that the element grommet
was removed at the time the lower element
8. Check the oil level and replenish if neces-
was removed.
sary.

9. Start the engine and inspect for leaks. Sample Compressor Oil
NOTE ! NOTE !
Only Schroeder elements are authorized for use The oil change interval depends on the type of
in the compressor system. Use of any other oil and whether or not oil analysis is being used.
brand must be authorized by the Sandvik Min- See the ‘Recommended Lubrication Viscosity
ing and Construction Engineering Department. Chart’ in section 1 of this manual for details.
NOTE !
The oil should be warm when changed.
Clean Oil Return (Scavenge) Line Strainer
The oil line strainer should be cleaned every

250 hours or when oil is not visible in the sight-
!! WARNING
glass. Avoid touching hot oil or components -
these can cause burns.
NOTICE NOTICE
Be sure the engine is shutdown and pres-
sure relieved before proceeding. Ensure the engine is shutdown and internal
pressure relieved.
1. Unthread the plug and remove the screen
from the housing. Locate the drain valve and take an oil sample
for analysis. If required, change the oil (refer to
2. Wash the screen clean with a non-flamma- the 1000 Hour Preventive Maintenance section.
ble solvent and dry with compressed air.
3. Reinstall the strainer and plug.
RECEIVER TANK PLUG

DRAIN VALVE
SIGHTGLASS
HOUSING PLUG
PLUG
Page 2D-8
HYDRAULIC SYSTEM
4
Change the Servo Replenishing Filter Ele-
ments
The filter elements should be changed after the

first 50 hours of operation and at each 250
hours thereafter, or as indicated by the dirt
alarm indicator. 5
3
1
2
SERVO
REPLENISHING
FILTERS
4. Thoroughly clean the element housing and
inspect the bypass mechanism (4) on the filter
base and O-ring (5) for damage. Replace if
!! WARNING necessary.
Avoid skin contact with hot oil or compo- 5. Install a new element and replace the ele-
nents - burns will result. ment housing. Tighten the housing firmly but do
not overtighten.
1. Ensure the engine is stopped, and the
hydraulic tank pressure relieved. 6. Start the engine and inspect for leaks.
2. Unthread the filter housing (1).
3. Remove the element (2) together with grom- Clean Hydraulic Reservoir In-Line Air
met (3). Strainer
NOTICE
The air line to the hydraulic tank may be
pressurized. Vent air pressure by opening
the air vent ball valve.
1. Shut down the engine and vent air pressure

by opening ball valve (1).
2. Remove strainer (2) from the air line.
3. Clean the strainer in a non-flammable sol-

vent and dry with compressed air.
4. Replace the strainer.

NOTICE
Do not overtighten the filter/breather assembly.
Breather/Filter
4
2. Screw the new filter assembly onto the
check valve fitting by hand.
Check
Valve
5
Regulator
7 Ball
Valve
Check Hydraulic Tank Mounting Hardware
(Vent)
1 Inspect the mounts at the four corners of the
tank for signs of cracks or movement and re-
Pressure
Relief torque the mounting bolts.
Valve
6
Water Trap PUMP DRIVE GEARBOXES

3
Air Strainer
2 Clean Breathers
1. Remove the breathers.
Clean the Water Trap Filter 2. Clean in a non-flammable solvent and dry
with compressed air.
1. Unscrew the water trap filter housing (3).
3. Install the breathers.
2. Remove the filter element.
3. Clean the element in a non-flammable sol-

vent and dry with compressed air.
4. Replace the element and screw the housing

on hand tight.
Replace the Breather/Filter
1. Unscrew breather/filter assembly and dis-

card.
NOTE !
PUMP
Ensure that the check valve assembly under the DRIVE
breather has been retained in the fitting and not BREATHERS
removed with the breather/filter assembly.
Page 2D-10
WATER INJECTION PUMP
7
Check Belt Tension
!! WARNING
Ensure the keys are removed and the
machine has been tagged-out before
proceeding.
1. Undo the four bolts (1) and remove belt drive

guard (2).
6
2. Inspect the condition of drive belts. Replace 5

BELT ADJUSTMENT
as a pair if cracked or frayed.
3. Measure the belt deflection using thumb

pressure (approximately 12 kg (25 lbs) midway Change Oil
between the pulleys. Deflection should be 13 to
19 mm (1/2 to 3/4 inch).
!! WARNING
Use caution and avoid touching hot oil or
components - these can cause burns.
2 NOTE !
1. Remove fill plug (1) and drain plug (2) and

1 allow the oil to drain into a suitable container.
2. Replace the drain plug.

To adjust:
3. Refill the compartment.
1. Loosen 4 bolts (5).
4. Replace fill plug (1).
2. Slide motor (6) away from pump (7) to
tighten the belts and then retighten bolts ().
1
3. Replace belt drive guard (2).

ROTARY HEAD
ROTARY
HEAD
Check Gearbox Oil Level MOTOR
1. With the mast raised, lower the rotary head

to access the fill plug. c40-14
2. Remove the fill plug and inspect the oil level.

The correct oil level should be to the center of
the planetary ring. Filling to the bottom of the
plug wll cause oil to blow out of the breather. FILL/LEVEL
PLUG
3. Add oil of the type specified in Lubrication

Section if necessary.
4. Clean and replace the fill plug when finished.

FEED SYSTEM
Check Feed Chain Adjustment
With the mast lowered and the rotary head at

the top of it’s travel, check the sag of the chain
as shown.
Lubricate Feed Chain
1. Clean the chain with 30 psi compressed air
TABLE ROTARY HEAD
3mm (1/8”)
245-41
FEED CHAIN
ADJUSTMENT
HOIST CHAIN
ADJUSTMENT
Page 2D-12
or with a brush. Do Not Pressure Wash or
Steam Clean the Feed Chains!
2. Brush or spray a light penetrating oil (such

as WD-40) onto the chains to lubricate internal
surfaces of the chain and drive out water.
3. Brush SAE 40, or heavier, on all chain sur-

faces. to provide a barrier against dirt and
moisture, and prevent corrosion. GROUSER
3. Where the track sags the most, measure the

Inspect and Lubricate Chain Sprockets distance between the top of the track grouser
and the bottom of the straight edge. When the
Inspect all sprockets for wear and lubrication track is adjusted correctly, the distance should
even if an auto-lubrication system is used. The be 40 to 55 mm (1-5/8 to 2-1/8 inches).
lower sprockets are particularly susceptible to
wear because of the accumulation of drilling
dirt.
Adjusting Track Tension
C40-22
UPPER SPROCKET
TRACK TIGHTENING
1. Clean the grease fitting (1) on the track

adjuster.
TRACK ADJUSTMENTS 2
UNDERCARRIAGE
Check Track Tension and Adjust if Neces-

sary
2. To tighten the track chain, pump grease into
1. Propel the machine backwards for a dis- the fitting until correct track tension is reached.
tance of 20 meters on level ground. Bring the
machine to a SLOW STOP and shutdown the 3. Propel the machine back and forth to equal-
engine. ize the pressure.
2. Place a straightedge, long enough to reach 4. Check the track tension as described earlier.
from the idler to the upper roller, on top of the
track.

TRACK LOOSENING to the bottom of the fill plug opening.
!! WARNING 4. Add oil, of the type specified in “Recom-

mended Lubricant Viscosity” table, through the
• Grease may vent from the valve at high level/fill opening if necessary.
pressure.
• Never look at the valve to see if grease is 5. Clean and replace the plug.
coming out of it - watch the idler and
track chain for movement. 6. Repeat the procedure for the other final
• Loosen the relief valve one turn only. drive.
• If the track does not loosen, close the
relief valve and contact your Caterpillar®
dealer.
CENTRAL LUBRICATION SYSTEM
1. To slacken the chain, undo the relief valve
(2), NO MORE than one turn. Clean Water Trap Filter
2. Tighten relief valve (2) to 34 Nm (25 ft lbs) 1. Turn the thumbscrew to allow water to drain.
when the desired track tension is reached.
2. Close the valve when all water has drained.
3. Propel the machine back and forth to equal-
ize the pressure. 3. Disassemble the filter and clean the parts in
a non-flammable solvent. Dry with compressed
4. Check the track tension as described earlier. air.
4. Reassemble the filter.

Check Final Drive Gearbox Oil Level
Check the crawler final drive gearbox oil level

as follows:
55-43
1. Position the machine on a level surface.
2. Position one of the final drives so that the

drain plug is at the bottom.
DRAIN PLUG WATER TRAP

c40-20 FILTER
FILL/LEVEL PLUG Check System Operation
Inspect all lubrication points serviced by the

3. Remove the level/fill plug. The oil should be central lubrication system to ensure that ade-
Page 2D-14
quate lubricant is being delivered. Check the
following areas:
• Undercarriage Pivot Points
• Feed Chain Sprockets and Winch
Sheaves
• Loader Pivots
• Mast Lock Pivots
AIR INLET
CLEANING PRE-CLEANER TUBES

Check Air Filter Pre-Cleaner Tubes
1. Loosen the dust cup housing retainer band 3. After cleaning, reassemble the filter making
and remove the dust cap housing. sure that all connections are sealed properly.
RETAINER BAND
SCREW Replace Engine and Compressor Primary
Filter Elements
SAFETY SERVICE
ELEMENT INDICATOR/NUT
c90-66
TUBES
(SHOWN WITH EVACUATOR SYSTEM) PRIMARY

ELEMENT
NOTICE DUST
CUP
Never clean the air cleaner tubes with com-

pressed air or water with the elements 1. Loosen the wing nut and gently slide the pri-
installed in the assembly. Never steam clean mary element out of the air cleaner assembly.
the tubes.
2. Inspect the service indicator for the safety
2. Light dust plugging of the tubes can be element. Remove and replace the element if
removed with a stiff fiber brush. If heavy plug- the indicator is in the red zone.
ging is evident, remove the lower body section
of the air cleaner and clean with compressed air 3. Inspect the inside of the filter housing and if
or hot water not exceeding 160°F (71°C). cleaning is required remove the safety element.
Be careful not to allow dust to enter the intake
duct.

4. If the filter is dented or bunched it must be
replaced. Never rap or hit the element to
remove dirt. The primary element can be
cleaned with compressed air, pressurized water
or washed with detergent.
MISCELLANEOUS
Check Electrical Wiring
Visually inspect the electrical wiring for wear

particularly near areas of high heat.
Check Intake and Exhaust Systems
Visually inspect the intake and exhaust system

pipe connections.
Inspect the engine exhaust muffler for wear.
Check Dust Collector Hoses
Visually inspect the condition of the dust collec-

tor hoses. Replace as necessary.
Check Decals and Nameplates
Walk around the machine and check the condi-

tion of the safety and information decals. Refer
to the parts manual for decal locations and
ordering information.
Page 2D-16
EVERY 500 HOURS OR Clean Engine Crankcase Breather (C27
Engine)
3 MONTHS
The breather is located on the back of the
engine. Clean an engine crankcase breather as
ENGINE
follows:
1. Loosen hose clamp (1).

Clean Engine Crankcase Breather (3412E
Engine)
2. Loosen the remove the four bolts (2) secur-
ing the breather to the engine.
Clean an engine crankcase breather as follows:
3. Remove the breather and detach the hose
from breather.
1. Loosen hose clamp (1).
4. Check the condition of the breather seal and
2. Detach the hose from breather (3).
replace if necessary.
3. Loosen clamp (3) and remove breather (2)
5. Remove the breather element and wash it in
and the seal.
clean, non-flammable solvent. Shake the ele-
ment until dry.
4. Wash the breather in clean, non-flammable
solvent and allow to dry. Inspect the seal for
6. Install the element in the breather and install
cracks or damage.
the breather.
5. Apply clean petroleum jelly to rubber parts
7. Attach the tube and secure with clamp (1).
and install the seal.
Tighten the clamp
6. Install the breather and secure it in place
with clamp (3).
1
7. Attach the hose and secure with clamp (1).
Tighten the clamp to 4.5 Nm (40 in-lbs).
C27 ENGINE
c245-48 2
3412E ENGINE
500 Hour Maintenance Checks - Page 2E-1

FUEL SYSTEM 4. Clean the filter base of any gasket material.
5. Unthread the bowl from the base of the ele-

! WARNING ment.
• Fuel leaked or spilled onto hot surfaces
or electrical components can cause a 6. Clean the bowl in clean fuel before installing
fire. it onto the new element.
• Disconnect the battery when changing 7. Thread the element onto the filter base until
fuel filters. until the element seal contacts the base.
Tighten the element 3/4 of a turn more.
Replace Primary Fuel Filter/Water Separator 8. Open the fuel supply line valve.
1. Stop the engine. 9. Prime the fuel system. See the topic “Prim-
ing the Fuel System”.
2. Close the fuel supply line valve (if equipped).
3. Using a strap wrench, remove the filter

assembly. Priming the Fuel System
Priming the fuel system fills the fuel filters and

BASE
removes air from the fuel system after the filters
3412E ENGINE have been changed. Refer to the Caterpillar®
engine Operation and Maintenance manual if
the engine fuel supply has run dry.
75-1
1. Turn the priming pump plunger counter-
clockwise and pull out the plunger.
FUEL
PRIMING
PUMP
PLUNGER
DRAIN VALVE BOWL ELEMENT

75-1
C27 ENGINE
3412E ENGINE
2. Pump the plunger to fill the new filter ele-

ment. Continue pumping until resistance is felt,
indicating that the filters are full.
Page 2E-2
3. Turn the pump handle knob clockwise to 2. Inspect and clean the drain plugs.
lock the plunger.
3. Replace the drain plugs.
4. Start the engine and check for fuel leaks.
4. Refill the housings through the fill ports,
located on the sides of the housings, and
replace the plugs. See the “Recommended
PUMP DRIVE GEARBOX Lubricant Viscosities” table. Check the oil levels
using the dipsticks provided.
Change Oil NOTICE

The oil should be changed at 500 hour intervals, Overfilling a gearbox can cause overheating
or whenever the oil shows traces of dirt, water, and damage will result.
or the effects of overheating (discoloration or
strong odor). 5. Start the engine and inspect for leaks.
NOTE !
HYDRAULIC SYSTEM
! WARNING
Use caution and avoid touching hot oil or Change Return Filter Elements
components - these can cause burns.
The filter elements should be changed after the
HYDRAULIC
first 50 hours of operation and at each 500
FILL GEARBOX hours thereafter, or as indicated by the DMS.
PLUG DIPSTICK
75-14 ! WARNING
Avoid skin contact with hot oil or compo-
nents - burns will result.
1. Relieve the hydraulic tank pressure by open-

ing the ball valve on the hydraulic tank.
COVER
SCREWS
FILL DIPSTICK
PLUG
Take an oil sample for analysis.
1. While the unit is still warm, remove the drain

plugs located at the bottom of the housings or
dipsticks and allow the oil to drain into a suitable BALL VALVE
container. Examine the oil for contamination or
metal particles. HYDRAULIC TANK

2. Slowly unthread the filter cover screws and Replace Fan Circuit Case Drain Filter
remove the spring loaded filter covers to expose
the elements. 1. Use a strap wrench to remove the oil filter.
3. Quickly remove the elements from the hous- 2. Clean the filter base to ensure that all traces
ings and drain the oil into an appropriate con- of the old seal are removed.
tainer.
3. Coat the seal on the new filter cartridge with
4. Inspect the housings for contaminents. clean hydraulic oil.
Clean the housings.
4. Install the new filter by hand. When the filter
5. Install new elements. seal contacts the base, tighten the filter 3/4 turn
more.
6. Replace the O-rings on the covers and
install the covers. NOTE !
Do not overtighten the filter.
7. Check the oil level and replenish if neces-
sary.
8. Start the engine and inspect for leaks.
COVER
SCREWS
COOLER
FAN CIRCUIT
CASE DRAIN
FILTER
FILTER
ELEMENT
ROTARY HEAD
NOTE!
New ‘Dirt Catcher’ filters are availible. Only Change Gearbox Oil
Schroeder elements are authorized for use in
the hydraulic system. Use of any other brand 1. with the mast raised and the rotary head
must be authorized by the Sandvik Engineering lowered to a working height, remove the two
Department. drain plugs from the gearbox and allow the oil to
drain into a suitable container.
Page 2E-4
DRAIN PLUGS VALVE STRAINER
HANDLE
PLUG
245-50
75-29
2. inspect, clean and replace the plugs.
3. Refill the gearbox through the fill/level port

with the type of oil specified in Section 3.
3. Clean the strainer with compressed air.
4. Replace the strainer and reconnect the

valve.
WINCH
c40-14
FILL/LEVEL
PLUG Check Oil Level
1. With the mast raised, remove the fill/level

plug. The oil level should be visible at the bot-
tom of the plug port.
2. If oil is needed, fill to the port opening with

the type of lubricant specified in Section 3.
4. Replace the fill/level plug. Operate the
rotary head and check for leaks.
1190e-44
WATER INJECTION
Clean Suction Strainer FILL/LEVEL

PLUG
1. Drain the water tank by removing the drain
plug and opening the valve.
2. Unscrew the fitting and remove the strainer

from the tank.

THREAD LUBRICATION SYSTEM The safety element should not be cleaned.
4. Clean the inside of the filter housing espe-

Check Grease Level cially around the areas of the element sealing
Determine the amount of grease in the lubrica- surfaces.
tion bucket and replace as needed.
SAFETY SERVICE
ELEMENT INDICATOR/NUT
1190e-49
TUBES
PRIMARY
ELEMENT
DUST
CUP
5. Install a new safety element.
6. Install the primary element.
AIR INLET MAST
Replace Engine and Compressor Safety Ele- Inspect the Drill Pipe Safety Hoop
ments
After each 500 hours of drilling, lower the mast
into the mast rest and inspect the hoop and sup-
Safety Element porting weldments for fatigue. Check the mount-
ing hardware torque. Replace or re-weld any
The safety element should be replaced every items that appear to be damaged.
third time the primary element is cleaned or
replaced or as indicated by the service indicator
in the safety filter hold down nut as shown.
1. Remove the primary element as described

earlier.
2. Remove the split pin and nut that hold the

safety element in place.
3. Remove and discard the safety element.
Page 2E-6
Inspect the Pedestal Welds
DRILL PIPE SAFETY HOOP
Clean the pedestal areas to be inspected and visu-
ally inspect for cracks or signs of stress.
SUPPORT WELDS
MOUNTING HARDWARE

Page 2E-8
EVERY 1000 HOURS OR
6 MONTHS
HYDRAULIC SYSTEM PLUG
Change Hydraulic Oil

DRAIN
NOTE ! VALVE
! WARNING 4. Remove the hydraulic tank lid and lift the

Avoid touching hot oil or components - handle to allow oil trapped in the high pressure
these can cause burns. tank return reservoir to drain.
! WARNING
Be sure that the engine is stopped, hydraulic
pressure relieved and the hydraulic tank air RELEASE HANDLE
pressure relieved before working on the
hydraulic tank. t40-42
1. Take an oil sample for analysis.
2. Relieve the hydraulic tank pressure by open-

ing the ball valve and venting the tank. HIGH PRESSURE
RETURN TANK
5. Replace the return filter elements as

described in the 500 Hour Maintenance
Checks.
6. Close the drain valve. Install the plug.
7. Refill the tank with the hand pump provided

or the Wiggins quick fill port to the correct level.
BALL VALVE 8. Start the engine and check for leaks.
3. Remove the plug. Open the tank drain valve

to and the oil into a suitable container.
2F-1
COMPRESSOR 4. Start the engine and check for leaks.
Re-Torque Compressor Mounts

Change Air/Oil Separator Element
Using a torque wrench, re-torque the compres-
sor bolts. See the “Recommended Torque Val- Change the air/oil separator element when the
ues” table. service indicator shows red.
MOUNTING
HARDWARE
75-23
55-13
RECEIVER
ELEMENT TANK
INDICATOR
Changing the Oil ! WARNING

Be sure that the engine is stopped and pres-
NOTE ! sure relieved before working on the receiver
The oil should be warm when changed. tank.
LOW PRESSURE COMPRESSOR

! WARNING 1. Ensure the engine is shut down and the
Avoid touching hot oil or components -
these can cause burns. internal pressure relieved.
Ensure the engine is shutdown and internal
pressure relieved. 2. For ease of removal, remove scavenge tube
(1) from cover (3).
Locate the drain valve and take an oil sample
for analysis. 3. Remove hardware (2) and lift off receiver
cover (3).
1. Locate the drain and valve. Remove the plug
and drain the oil into a suitable container. 4. Lift out the filter element (4) and wipe the
cover and base sealing areas clean.
2. Close the drain valve and install the plug.
NOTE!
3. Change the separator element. Refill the Inspect the element for damage. Never install
tank with oil of the type specified in the “Recom- damaged elements back into the compressor
mended Lubricant Viscosities” table. system.
2F-2
1
2 3 245-8
4 ELEMENT
INDICATOR
5
6
LOW PRESSURE
SYSTEM c40-50 1. Ensure the engine is shut down and the
internal pressure relieved.
2. Remove the bolts (1) from cover (2).
3. Lift off the filter cover (2) and gasket (3).

! WARNING Remove the nuts (4) and retaining plate (5).
Installing a filter element without staples in
the upper gasket can cause a static charge 4. Lift out the filter element (7) and wipe the
and result in fire. Do not remove the staples element seal and base areas clean.
from the upper sealing gasket.
NOTE!
5. Install a new element (4) in place making Inspect the element for damage. Never install
sure that gaskets (5) are in place on both sides damaged elements back into the compressor
of the element flange and that the upper gasket system.
has staples (6) 180° apart to disipate static
charge. 1
2
6. Replace cover (3) and torque hardware (2)
to 270-292 ft-lbs (364-394 Nm). Install scav-
enge tube (1) in the cover. 3
HIGH PRESSURE COMPRESSOR 5
Refer to the 250 Hour Maintenance Checks for 6

oil sampling procedures.
7
Change the air/oil separator element when the
service indicator shows red.
HIGH PRESSURE
SYSTEM
! WARNING
Be sure that the engine is stopped and pres-
sure relieved before working on the receiver
tank.
2F-3
5. Install a new element (7) in place. Intall it when dry.
6. Install retaining plate (5) and nuts (4).

Torque to 6.9 kg/m (50 ft. lb.).
ROTARY HEAD
7. Inspect the condition of cover gasket (3).
Replace if damaged.
Replace Gearbox Breather
8. Replace cover (2) and torque bolts (1) to
190 - 210 FtlLbs (256 - 283 Nm). 1. With the mast raised, lower the rotary head
to access the breathers.
WINCH
BREATHERS
Change Oil and Clean Breather

55-20
1. With the mast raised, align the drain plug in

the winch drum with the hole in the side support.
2. Install a short piece of 25 mm (1 inch) pipe

into the threaded drum port to prevent oil from
darining onto the winch base.
VENT 2. Remove the breathers and replace them

with new breathers.
FILL/LEVEL
PLUG
COOLING SYSTEM
DRAIN Change Fan Motor Overhung Adapter Oil

PLUG
1190e-44 Two types of adapters are used on this model of
3. Insert a wrench through the pipe to remove machine. The single vent adapter has a capac-
the drain plug allowing the oil to drain into a suit- ity of 162 ml (5.5 oz) and the two vent adapter
able container. .8 l (28 oz) Remove the vent and drain the oil.
Add clean compressor oil.
4. Remove the drain pipe installed previously
and replace the drain plug.
5. Remove the fill/level plug and refill the winch

with the type of oil specified in Section 1 to the
bottom of the port.
6. Remove the vent and clean it in a solvent.

2F-4
VENT
PIVOT BLOCK
BOLTS (SHOWN
WITH LOCKING
TABS BENT DOWN)
VENTS
MAST
Check the Torque of the Pivot Block Bolts
Bend the bolt locking tabs back and check that

the torque on the bolts is 881 Nm (650 ft-lbs).
Bend the tabs up over the sides and top of the
bolts after tightening.
2F-5
2F-6
EVERY 2000 HOURS OR ant to drain into a suitable container.
1 YEAR 3. Close the radiator drain valve and install the

plug.
COOLING SYSTEM
RADIATOR DRAIN
VALVE
Change Coolant
! WARNING
Steam can burn. Allow coolant to cool
before draining. Remove the radiator filler PLUG
cap slowly to relieve pressure.
1. Loosen the radiator filler cap slowly to

release pressure before removing the cap.
FILLER
4. Replace the coolant conditioner cartridges
CAP with precharge cartridges (refer to “250 Mainte-
AKG nance Checks” for more information on replac-
COOLER ing these cartridges).
3412E ENGINE
75-35
COOLANT
CONDITIONER
CARTRIDGES
NOTICE NOTICE
Add coolant only when the engine is
Cooling System Conditioner contains alkali.
stopped and the radiator filler cap is cool
Avoid contact with skin and eyes to prevent
enough to touch with your bare hand.
personal injury.
5. Fill the system with a solution of approved
2. Remove the drain plug and open the drain
water and antifreeze. See “Refill Capacities” for
valve at the front of the radiator. Allow the cool-
amount of solution needed.
2000 Hour Maintenance Checks - Page 2G-1
NOTE!
Add coolant slowly at 20 litres (5 U.S. gallons)
or less per minute to avoid air locks. FILL/LEVEL
PLUG
6. Start the engine with the radiator filler cap
off. Operate the engine until the thermostat
opens and coolant level stabilizes. Fill the cool-
ing system to the bottom of fill tube. Install the
radiator filler cap.
DRAIN
Re-Torque Cooler Mounts PLUG
Check the torque of the cooler mounting hard- 1. Position the final drive so that oil drain plug
ware. See “Recommended Torque Values”. is positioned at the bottom.
2. Remove fill/level plug and take an oil sample

for analysis.
3. Remove the drain plug. Allow the oil to drain

into a suitable container.
75-21 4. Clean the plugs and inspect the O-rings.

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

fied in the “Recommended Lubricant Viscosi-
ties” chart.
RADIATOR MOUNTING HARDWARE
NOTICE
Allow time for the oil to flow through the
UNDERCARRIAGE gears and ensure that the entire quantity of
oil specified for each compartment is added.
Do not operate the machine with low final
Change Crawler Final Drive Oil drive oil - final drive failure will result.
NOTE ! 6. Replace the fill/level plug.

7. Completely remove oil spilled onto surfaces.
! WARNING 8. Start the machine and allow the machine to
Use caution and avoid touching hot oil or propel in both directions. Position the drives to
components - these can cause burns. recheck the oil levels. Check for leaks after one
hour of operation.
Page 2G-2
MAST and PEDESTAL Kit Part Number 036837-053
Description Part# Qty in Kit
Bolts 001554-200 8
Lock Tabs 018767-001 4
Change the Pivot Block Bolts and Hardware Washers 010550-013 8
Dowel Pins 001584-070 4
Grease Fitting 001539-001 2
1. Lower the mast into the mast support. Set Screw 036796-012 4
2. Lockout and tagout the machine.

LOCKING TABS
3. Bend the bolt locking tabs back. BENT UP
4. Support the block cap, it weighs approxi-

mately 32 kg (70 lbs).
5. Remove the bolts, washers and locking

tabs. Discard this hardware.
6. If need, install jacking bolts into the dowel

pin holes and slowly pry the cap off the block.
7. Remove the existing dowel pins and replace

them.
Test the Pedestal Welds
8. Install the block cap over the dowels. Clean the pedestal areas and inspect for cracks
using a non-destructive inspection (NDT)
9. Apply ‘Anti-Seize’ to the threads of the new method such as a dye penetrate or magnetic
bolts. Install the locking tabs, washers and bolts particle testing.
on the blocks.
10. Diagonally tighten the bolts until a torque of

908 Nm (670 ft-lbs) is achived.
11. Bend the tabs up over the sides and top of

the bolts after tightening.
PIVOT BLOCK
BOLTS (SHOWN
WITH LOCKING
TABS BENT DOWN)
2000 Hour Maintenance Checks - Page 2G-3

Page 2G-4
SECTION 3 MACHINE STORAGE
GENERAL
If this machine is to be removed from service for an extended period of time, the following proce-
dures should be used when removing the machine from service and placing the machine back into
service to ensure proper operation of the machine at all times.
SHORT TERM STORAGE
General
Short term storage for the machine is 30 days or less.
Preparation for Short Term Storage
Perform the following steps to prepare the machine proper for short term storage:
1. Clean the entire machine.
2. Touch up painted surfaces as necessary, after proper preparation and priming.
3. Lubricate all grease points on the machine.
NOTE !
Step 4 is unnecessary if the machine is stored in a building and the air will be dry for the duration of
storage.
4. With all hydraulic cylinders fully retracted, coat the exposed portions of the cylinder piston rods
with multipurpose grease.
5. Contact the engine manufacturer for engine storage procedures.
6. Clean and lubricate the feed chain or cables.
Removal from Short Term Storage
1. Lubricate all points equipped with grease fittings.
2. Remove preservative grease, if applicable, from the cylinder piston rods and other surfaces
where applied.
3. Check the oil levels in each gear housing. Add oil as necessary as specified in Section 1.
3-1
4. Check the oil level in the hydraulic reservoir. Add oil of the proper type, as specified in Section 1.
5. Install the battery if it was removed, fully charged.
6. Contact the engine manufacturer for procedures on removing the engine from storage.
7. Make a thorough visual inspection of the entire machine before operating it for the first time fol-
lowing storage. Check, especially, for damaged or deteriorated hydraulic hoses.
LONG TERM STORAGE
General
Long term storage for the machine proper is for periods longer than 30 days.
Preparation for Long Term Storage
To prepare the machine proper for long term storage, proceed as follows:
1. Clean the entire machine thoroughly.
2. Inspect for loose or missing attaching hardware throughout the machine. Tighten or replace as
necessary.
3. Inspect all painted surfaces for rust, bare metal chipping, or other defects. Prepare, prime, and
repaint as necessary.
4. Liberally lubricate all points equipped with grease fittings.
5. Drain all gear cases and clean the magnetic plugs and breathers. Replace the drain plugs and
refill each housing and case with the oil type specified in Section 1.
6. Contact the engine manufacturer for engine storage procedures.
7. Clean the battery compartment using a soda and water solution, if necessary, to remove corro-
sion. Wrap the cable terminals with waterproof tape, after cleaning.
8. Run the engine until the hydraulic oil is warm. Then drain the hydraulic system completely.
9. Replace the hydraulic filter elements.
10. Refill the hydraulic reservoir to the prescribed level with the proper oil type.
11. Operate all hydraulic functions to distribute the new oil throughout the systems.
12. Apply a suitable preservative grease to exposed portions of hydraulic cylinder piston rods, con-
trol valve spools, and other exposed unpainted surfaces.
3-2
13. When the machine is parked in the spot it is to be stored in, fill the hydraulic reservoir to the top
with hydraulic oil.
Removal From Long Term Storage
1. Clean the entire machine thoroughly. Then inspect the machine thoroughly, paying particular
attention to hydraulic hoses, tubes, and fittings.
2. Lubricate all points equipped with grease fittings.
3. Check the oil levels in the gear housings including the winch and crawler final drive. Add oil as
required of the types specified in Section 3.
4. Drain the hydraulic reservoir down to the proper level.
5. Remove the preservative grease from the cylinder rod pistons and other machined surfaces, if
applicable.
3-3
3-4

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D75KS

(LOW & HIGH PRESSURE with CATERPILLAR 3412E or C27)

Sandvik Mining and Construction

Indicates a hazardous situation which,

Indicates a hazardous situation which,

Indicates a situation which, if not avoided,

Indicates a situation which, if not avoided,

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

MACHINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . xiii USAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

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

FUEL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 RECOMMENDED TORQUE VALUES FOR STANDARD

ALTERNATOR and AIR CONDITIONER COMPRESSOR V-

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2 BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-3

MISCEALLANEOUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-8 FEED SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-12

AIR INLET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-15

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

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-2 MAST and PEDESTAL . . . . . . . . . . . . . . . . . . . . . . . . . . 2G-3

PUMP DRIVE GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . 2E-3

WATER INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-5 LONG TERM STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

THREAD LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . 2E-6

AIR INLET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-6

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

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

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

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

SAFE OPERATING PRACTICES FOR DRILLERS

It is the responsibility of management to:

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

The Operator’s Responsibilities

Safe Operating Practices for Drillers iii

• The operator should not operate this equipment if any

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

• The operator should not operate the drill without first

Operator's Safety Check

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

• Check the machine log book to see that periodic maintenance

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

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

• Clean the cab interior windows if necessary.

• Test all controls for proper operation.

• The operator should treat all power lines as live.

Safe Operating Practices for Drillers v

Planning the Job

• Will the drilling take place in wet formations?

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

• Are there unusual or extreme weather conditions expected?

• Will drilling be done in night hours?

• Will the machine be propelled on inclines?

• Will drilling be done into difficult formations?

• Has a drilling pattern been developed?

• What is the required depth of the drilling pattern?

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

• Will vertical or angle drilling be required?

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

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

Safe Operating Practices for Drillers vii

General Maintenance Safety Practices

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

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