Operators Manual

DR560 Serial Number 10346

4-11-2011

Sandvik Mining and Construction

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

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2
III
IV
TABLE OF CONTENTS
Section 1 Introduction ........................................................... 7
1.1 Drill Description 7
1.2 Manual Objectives 7
1.3 Drill Orientation 8
Section 2 Description of Equipment........................................... 9
2.1 Major Components and Sub-assemblies 9
2.2 Electrical Controls 33
2.3 Manual Hydraulic Controls 35
2.4 Display Screens 37
Section 3 Start-Up and Tramming ............................................ 65
3.1 Operating Procedures for Start-Up 65
3.2 Start-Up69
3.3 Tramming 71
3.4 Set-up 75
3.5 Shutdown Procedure 81
3.6 Towing 83
Section 4 Drilling ................................................................. 87
4.1 Drilling Procedures 87
4.2 Delivery Systems 101
4.3 Drilling 103
Section 5 Maintenance and Safety.......................................... 109
5.1 Daily Maintenance Procedures 109
5.2 Lubrication 113
5.3 Safety Procedures 125
Section 6 Troubleshooting ................................................... 135
6.1 Troubleshooting the Tram Drive 135
6.2 Troubleshooting the Hydraulic System 137
6.3 Troubleshooting the Water Injection Pump 139
6.4 Troubleshooting the Air Driven Oil Injection Pump 141
6.5 Troubleshooting the Air Driven Grease Injection 143

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 6.6 Troubleshooting the Air Delivery System 145
6.7 Troubleshooting the Hammer 147
6.8 Troubleshooting the Drill Bit 149
6.9 Troubleshooting Depth Laser 151
Terra DGS Operation Manual................................................. 153
Section 1 Introduction ........................................................ 157
1.1 Features 157
Section 2 Software Removal and Installation............................. 158
2.1 Removal / Installation Procedure 158
2.2 Sensor Installation 165
Section 3 Operation ........................................................... 175
3.1 ZERO-OFFSET Calibration Procedure 182
3.2 Local and Absolute Heading Measurements 185

6 Copyright © Sandvik Mining and Construction

Section 1 Introduction

1.1 Drill Description

The DR560 series of drills are designed to deliver maximum drilling efficiency and flexibility using a
Down-The-Hole (DTH) hammer. The DR560 is a track drill with a boom-mounted feed system that
drills with a pneumatic DTH hammer. The DR560 comes with a 1150 cfm (543 l/s) at 500 psi (34.5
bar) compressor, a mast with carousel capable of handling 20 ft. (6 m) drill pipe and a Cummins
engine. The DR560 also offers up to 1350 cfm (637 l/s) at 350 psi (24.1 bar) air capacity.
The DR560 is designed to drill up to 8” (203 mm) diameter holes to a depth of 140 feet (42.7 m)
without adding drill pipe to the carousel.
The DR560 drills at sea level with a 4” to 5” DTH hammer to a depth of 140 ft. (42.7 m) without
reloading the carousel and to greater depth with reloading. The drill is designed to flexibly switch
between Production Drilling, Pre-Split or Pre-Shear drilling and, with options, Reverse Circulation
sample drilling.

1.2 Manual Objectives

This manual covers a description and the operation of the DR560 drill and can be used as a training aid
for the Operator Training Course.
The objective of this manual is to familiarize operators with the following:
 Major components and sub-assemblies of drill
 Layout of controls and what they operate
 Drilling
 Maintenance
 Operator Safety
 Troubleshooting

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1.3 Drill Orientation
The operator's right hand side is the drill's right hand side with the operator standing at the tram step
facing the mast (Fig 1.1).

Front

Operator’s Mast
Cab

Operator Compressor

Engine

Left Side Right Side

Rear

Fig 1.1 Orientation

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Section 2 Description of Equipment

2.1 Major Components and Sub-assemblies

NOTE: All items shown in Section 2.1 are grouped together by location. The components DO NOT necessarily
work together. Refer to item descriptions for operational functions.

For this section, your drill has been grouped into the following areas.
Refer to Fig 2.1.1

1. Mast and Feed 3. Rear

2. Frame 4. Operator’s Cab

4 2
3

Fig 2.1.1 Drill Areas - top view

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 6

8
4

3 9

10
11

Fig 2.1.2 Mast

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 2.1.1 Mast and Feed
Refer to Fig 2.1.2 to Fig 2.1.8

1. Boom Swing Cylinder

The swing cylinder moves the boom from 30° to the left and 35° to the right. See also Fig 2.1.4.

2. Grease Injector Banks

Banks of grease injectors to centralize grease points. This makes the grease points more
accessible, resulting in improved greasing of components. There are four separate banks of
injectors located on the drill (on the mast, the mast boom, the cab boom, and the frame). See
Fig 2.1.7.a, Fig 2.1.7.b, and Section 5.2.3 for details.

3. Mast Dump Cylinder

This cylinder moves the mast from a horizontal position to 45° past the vertical axis (135° total
from horizontal). See also Fig 2.1.4.

4. Boom

The 9 foot boom allows great flexibility in mast positioning.

5. Digital Guidance System

6. Cable Chain

Air and hydraulic hoses are protected on the mast by the cable chain.

7. Mast Assembly

The mast overall length is 32 ft 7 inches (9931 mm) with 24 ft (7315 mm) of head travel. An
option of 19 ft (5791 mm) of head travel is available.
A chain feed system that uses a powerful hydraulic cylinder provides hoisting and pull down
power. Hoisting force is 10,600 lbs (47 k-N) and pull down force is 10,600 lbs (47 k-N). Also
included is a hydraulic centralizer with a maximum size of 8-3/8 inches (219 mm) along with a
hydraulically actuated slip plate (size varies on drill pipe used).

8. Feed Extension Cylinder

Extends the mast into contact with the rock. It has 60 inches (1500 mm) of travel.

9. Mast Valve Bank; Mast Valve Junction Box

Mast mounted valve assembly for mast controls; electrical junction box for mast controls. See Fig
2.1.6 for layout.

1. Lower Breakout Clamp 4. Arm 7. Upper Breakout Clamp

2. Carousel Rotation 5. Divertor 8. Breakout
3. Clamp 6. Centralizer 9. Winch

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 13

14

15

12

2
16

17

Fig 2.1.3 Mast

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 10. Mast Swing Cylinder

The mast swing cylinder has two positions. One allows the mast to be moved ± 30° from vertical
in the perpendicular axis from the drill. The cylinder can be repositioned to allow the mast to
be moved 15° above horizontal. See also Fig 2.1.4.

11. Boom Lift Cylinder

This cylinder raises and lowers the boom from 10° below horizontal to 45° above. See also Fig
2.1.4.

12. Carousel Assembly

The carousel holds up to six rods. These rods can be up to 20 ft (6 m) long and 3½ to 5 inches (89
to 127 mm) diameter.

13. Cable Weight

Maintains constant tension on the winch cable to prevent free/unwanted movement of the cable.

14. Top Drive

Hydraulically driven by two high torque motors, the top drive has a torque capacity of 4225 ft-lbs
(5730 N-m) at 3000 psi (207 bar) standard or an option of 6280 ft-lbs (8517 N-m). The speed is
infinitely variable between 0 to 80 rpm.
Incorporated into the top drive is the splined piston breakout system, which eliminates the need
for wrenches to break out drill pipe.
See Fig 2.1.5 for close view. Refer to Section 4.2 of the Maintenance Manual for more
information.

15. Cushion Sub

The cushion sub was developed primarily to reduce shock and vibration introduced by the rotary
bit or DTH hammer bit. See Fig 2.1.5 for close view. Refer to Section 4.2.10 of the Maintenance
Manual for more information.

16. Triple Jaw Breakout System

A combination of three jaws used to break out drill tool joints. See Fig 2.1.8 for details.

17. Divertor Assembly

Debris and water from hole are diverted from passing to the centralize assembly along the drill
pipe. See Fig 2.1.8 for details.

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 3

10

11

Fig 2.1.4 Boom Cylinders

14

15

Fig 2.1.5 Items 14 and 15

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 Mast Valve Mast Valve
Bank Junction Box

6
Fig 2.1.7.a Item 2 (on mast)
7

Fig 2.1.6 Item 9 Fig 2.1.7.b Item 2 (on mast boom)

Breakout Jaw

Gripping Jaw

17
Centralizer Jaw

Fig 2.1.8 Items 16 and 17

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 8 9
6
7
5

4 10

3 11

12
2

13
14
16 15
17

Fig 2.1.9 Left Side of Frame

21
22
20 23

19

24

25
18

Fig 2.1.10 Right Side of Frame

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 2.1.2 Frame
Refer to Fig 2.1.9 and Fig 2.1.10

1. Undercarriage and Chassis

The tracks use Caterpillar components with 19-5/8 inch (500 mm) wide, triple grouser shoes.
Brakes are spring applied/hydraulic released. Gradability is 36° and ground clearance is 16 inches
(406 mm).

2. Tram Step

3. Remote PLC Panel

Panel contains VMM modules and inputs/outputs. See Fig 2.1.11 for side view details.

1. Lock/Float 4. Engine Start

2. Horn 5. Oscillation up/Down
3. Tram Selector 6. Emergency Stop

4. Panel with Set-up Valve Bank and Gauges

Main valve bank for set-up controls. Tram controls, compressor and tram pressure gauges are also
mounted on the panel. See Fig 2.1.11 for details.

1. Oscillation 6. Mast Swing 11. Compressor Discharge Pressure

2. Cab Swing 7. Mast Dump 12. Compressor Discharge Temperature
3. Cab Tilt 8. Feed Extension 13. Left Tram Pressure
4. Boom Lift 9. Air 14. Right Tram Pressure
5. Boom Swing 10. Water 15. Rotation and Right Tram
16. Feed and Left Tram

5. Water Tank

300 gallon (1135 litre) water tank is available for water dust suppression.

6. Muffler

7. Hydraulic Tank

120 gallon (454 litre) capacity.

8. Compressor Air Intake

9. Engine Air Intake

10. Compressor Air Filter

11. Engine Air Filters

12. Receiver Tank

Receiver tank for compressor. See Fig 2.1.12 for more details.

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 Remote PLC Panel

1
11
2

3
1 2
4
5 12

6
7 13

3 8

9 14

10

5
15
6 16

Fig 2.1.11 Items 3 and 4 (close view)

Compressor/Fan
Control Panel

Hydraulic High
Pressure Filters
Receiver Tank

Manual Hydraulic
Fill Pump Sight Glasses (correct level is
midway up the middle sight glass

Fig 2.1.12 Items 12, 13, 14, and 15 (close view)

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 13. Compressor/Fan Control Panel

14. Manual Hydraulic Fill Pump

15. Hydraulic High Pressure Filters

There is one high-pressure filter for each main hydraulic pump.

16. CAT Water Pump

The water pump is a positive displacement, Tri-Plex piston pump that is hydraulically driven. It
has a maximum flow of 12 gpm (45 l/min). It is used for dust control while drilling.

17. Grease Injector Bank

Banks of grease injectors to centralize grease points. This makes the grease points more
accessible, resulting in improved greasing of components. See Fig 2.1.16 and Section 5.2.3 for
details.

18. Service Step

19. Battery Box

20. Fuel Tank Assembly

370 gallon (1400 litre) capacity.

21. Mast Rest

Support for the mast.

22. Proheat Module

See Section 2 of the Maintenance Manual for details.

23. Thread Greasing Pump

Located at the front of the machine, the system sprays the drill pipe thread with thread lubricant.
It is activated from inside the cab. It is usually mounted on the front right of the drill. See Fig
2.1.18

24. Grease Injection System

Grease injection for DTH hammers. The reservoir has an 22 gal (83 L) capacity. See also Fig 2.1.14
and Fig 2.1.15 for close view.

25. Engine Filter Mounting Plate

All of the engine filters have been located on the fuel tank in one spot for ease of maintenance.
See Fig 2.1.13 for details.

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 Fuel/Water Engine Coolant
Separators Filter

Engine Oil Filters

Fig 2.1.13 Engine Filters (close view)

Fig 2.1.14 Grease Injection System Fig 2.1.15 Grease Tank and Pump

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 Emergency Stop
(located beside
grease injection)

Fig 2.1.16 Grease Injector Bank Fig 2.1.17

Fig 2.1.18 Thread Greasing Pump Fig 2.1.19 Receiver Tank Regulators

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 Front

5 7
6

2 3

Fig 2.1.20 Inside of Frame

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 2.1.2.1 Inside of Frame
Refer to Fig 2.1.20 to Fig 2.1.26

1. Return Filter

A single filter assembly installed at the rear of the unit on the radiator frame.
See Fig 2.1.23 for close view.

2. Main Hydraulic Pumps

Three variable displacements, pressure compensating, load sensing piston pumps for tramming,
set-up, and drilling. See Fig 2.1.21

3. Gear Box

4. Coupling Drive

5. Belt Guard

6. Cummins Engine

See the supplied Cummins manuals.

7. Compressor

See Fig 2.1.22 for close view.

8. Grease Pump

Not shown in Fig 2.1.20. See Fig 2.1.24 for location. See Fig 2.1.25 for close view.
Grease pump for the Automatic Machine Lubrication. See also Section 5.2.3 for more information.

9. Remote PLC Panel

Not shown in Fig 2.1.20. See Fig 2.1.24 for location. See Fig 2.1.26 for close view.
See also Section 2.1.2, item 3 for more information.

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 Fan

Feed/Left Rotation/
Tram Right Tram

Fig 2.1.21 Hydraulic Pumps

Fig 2.1.22 Compressor Fig 2.1.23 Return Filter

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 9

Fig 2.1.24 Front of Frame

Fig 2.1.25 Grease Pump Fig 2.1.26 Remote PLC Panel

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 2

Fig 2.1.27 Rear

Fig 2.1.28 Fans from inside

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 2.1.3 Rear
Refer to Fig 2.1.27 to Fig 2.1.30

1. Radiator

2. Oil Cooler

3. Fuel Cooler

4. Lights

5. Battery Disconnect Box

Fig 2.1.29 On rear inside, right side Fig 2.1.30 Battery Disconnect Box

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 3
4

Fig 2.1.31 Operator’s Cab

4
5

10

11

12
14 13 8

Fig 2.1.32 Operator’s Cab (rear)

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 2.1.4 Operator’s Cab
Electrical controls are located inside the cab. Two joysticks are used for tramming, set-up, and drilling. These
joysticks are mounted in the control pods of the chair.
All operations performed by an operator are automatically displayed on the touchscreen display panel attached to
an articulated arm inside the cab.
Refer to Fig 2.1.31 to Fig 2.1.34

1. Cab Boom Swing Cylinder

2. Cab Boom Accumulator

3. Operator’s Cab

4. High Intensity Lights (drilling)

5. Air Conditioner

6. Cab Step

7. Lights, 24V (tramming)

8. Cab Boom

9. Cab Pressurizer

10. Air Filter

11. Grease Injector Bank

12. Cab Boom Lift Cylinder

13. Horn

14. Portable Fire Extinguisher

15. Joysticks

See Section 2.2.1 for details.

16. Engine Control Panel

Gauges, indicators, and controls for the engine. See Fig 2.1.35 for details.

17. DTI Angle Blaster Display Screen

18. Touchscreen

19. Radio/CD Player

20. DTI Control Module

21. Warning/Caution decals

Read all Warning/Caution decals carefully.

22. Operator’s Seat

23. Buddy Seat

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 20
21
19

18

23 22

17

16

15

Fig 2.1.33 Operator’s Cab (inside)

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 2.1.4.1 Engine Control Panel
Refer to Fig 2.1.34

1. Cab Pressurizer 9. Coolant Temp Gauge 17. Top Window Wiper

2. Battery Voltage Gauge 10. Oil Pressure Gauge 18. Chair Heater
3. Fuel Gauge 11. 12V Auxiliary Plug 19. Floor Heater
4. Engine Tachometer 12. Computer On/Off Switch 20. Tram Lights
5. Engine Run 13. Emergency Stop Switch 21. Drill Lights
6. Engine Stop 14. Engine Throttle 22. Ignition Switch
7. Engine Diagnostic 15. Tram Window Wiper 23. Engine Start Switch
8. Engine Wait to Start 16. Drilling Window Wiper 24. Horn

6
7
5 8

1 2 3 4 9
10

11
14
13
12

15 16 17 18 19 20 21 22 23
24

Fig 2.1.34 Engine Control Panel

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 Display
Touchscreen

Throttle Control

Engine Control
Panel

Joysticks

Fig 2.2.1 Electrical Controls

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2.2 Electrical Controls
Electrical Controls are located inside the cab. Two joysticks are used for tramming, set-up, and drilling. These
joysticks are mounted in the control pods of the chair.
All operations performed by an operator are automatically displayed on the touchscreen display panel attached to
an articulated arm inside the cab.
Refer to Section 2.1.4 for further information about the Operator’s Cab.

2.2.1 Joysticks
Refer to Fig 2.2.2 and Fig 2.2.3

Right and left joysticks are used for Tramming, Set-Up, and Drilling from the cab. These joysticks have
six buttons each as shown in Fig 2.2.2. Each button is programmed for a specific function depending
on tramming, set-up, or drilling mode.

Fig 2.2.2 Joystick Fig 2.2.3 Joystick Controls on screen

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 2.2.2 Engine Control Panel (Inside Cab)
Refer to Fig 2.2.4

Fig 2.2.4 Engine Control Panel

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2.3 Manual Hydraulic Controls
All hydraulic controls can be operated manually.

2.3.1 Set-Up, Drilling, and Tramming Valve Bank

Located on the left side of the unit.

Fig 2.3.1 Set-up Valve Bank

2.3.2 Carousel and Drilling Valve Bank

Located on the mast.

Fig 2.3.2 Carousel Valve Bank

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 Fig 2.4.1 System Screen

Fig 2.4.2 Status Bar

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2.4 Display Screens
2.4.1 System Screen
A colour display screen is used for graphical illustration of various functions activated by an operator
using joysticks. Four screens have been programmed to control all functions of the drill. A menu bar
for the four control screens is always visible at the top of the display. They are accessed by using the
touch screen. Just touch the appropriate tab at the top and that screen will be displayed.

The default screen (Fig 2.4.1) that appears when the system is turned on is the System Screen.

2.4.2 Status Bar

There is also a status bar with symbols that are always visible when in the each of the control
functions. These symbols represent and display information about the various systems of the DR.
Refer to Fig 2.4.2

1. Rotation Speed
2. Feed Rate – displayed in feet per minute
3. Weight on Bit – displayed in pounds
4. Carousel – rods in string
5. Pulldown Pressure – displayed in psi
6. Holdback Pressure –displayed in psi
7. Rotation Pressure – displayed in psi
8. Air Pressure – displayed in psi
9. Hole Depth – Top displays depth of current rod in feet; can be reset by touching icon. Bottom
displays pre-set depth in feet
10. Total footage – can be reset in pre-set menu or by touching icon

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 Fig 2.4.3 Menu Buttons

Outer Ring - Canbus

gateway
Green – functioning
Orange – not functioning

Inner Circle - Safety Bar

at door
Green – engaged (down)
Orange – disengaged (up)

Fig 2.4.4 Status Indicator

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 2.4.3 Menu Buttons
On the right side of the display, various configuration and display menus can be accessed by touching
the screen.
Refer to Fig 2.4.3

Operate – will display the ERIS operating interface for controlling the DR
Config – will display various configuration options for the DR
Diagnostic – will display various diagnostic options
Engine – will display various engine parameters and any fault codes
Error – will display various errors that have occurred while operating the equipment

2.4.4 Status Indicator

At the top right hand corner of every operating screen, there is a status indicator. Green means the
status is fine while orange means there is an issue with the corresponding system. Please refer to Fig
2.4.4 for the different systems that are monitored.

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 1 2 3 4 5

6 7 8 9 10

11 12 13 14 15

16 17 18 19 20

21 22 23

Fig 2.4.5 Error Screen

Water Level Sensor

Water Tank Assembly

Fig 2.4.6 Water Tank Fig 2.4.7 Water Tank Sensor

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 2.4.5 DR Shutdowns and Warnings
There is a comprehensive instrumentation and protection group on this unit to protect both the operator and the
machine. This package includes visual aids, shutdown protection devices, and visual alarms. The shutdowns will
shut the engine down in the event that they are activated. Warning indicators warn the operator whenever the
system is not operating within its parameters.
Whenever a shutdown or warning has been activated, it will be necessary to acknowledge it by touching the
PanelView on the Acknowledge symbol. The problem must be diagnosed and repaired before continued use. In
the event of a shutdown, allow the receiver tank to bleed down before restarting the unit.
NOTE: Start up should never be attempted until the receiver tank has fully bled down. If start up is attempted
with high receiver pressure, damage could result.

Refer to Fig 2.4.5

1. Engine Oil Pressure Low

Shutdown

Activated when the engine oil pressure drops below the acceptable level (based on xx psi at xx
rpm). To repair this error, please contact Cummins.

2. Compressor Oil Pressure Low

Shutdown

Activated when the compressor oil pressure drops below 90 psi.

3. Compressor High Interstage Temp

Shutdown

Activated when the compressor interstage temperature rises above 280°F.

4. Compressor High Discharge Temp

Shutdown

Activated when the compressor discharge temp rises above 300°F.

5. Low Water Level

Warning

Activated when the water level in the water tank is below 1 ft (approx).

6. Hydraulic Oil Low Level

Warning

Activated when the hydraulic oil level drops below 30 inches.

7. Hydraulic Oil High Temp

Warning

Activated when the hydraulic oil temperature rises above 180°F.

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 Engine Air Filter
Compressor Air Filter

Fire Suppression Actuator

(if equipped with fire
suppression)

Fig 2.4.8 Rear of drill, left side

Hydraulic Tank Assembly

Hydraulic Tank Sensor

Fig 2.4.9 Hydraulic Tank Fig 2.4.10 Hydraulic Tank Level/Temp Sensor

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 8. Low Rock Oil Level

Warning

Activated when the rock oil level drops below the bottom sight glass on the tank.

9. Cab E-Stop

Shutdown

Activated when the cab e-stop button is pushed

10. Tram Step E-Stop

Shutdown

Activated when the tram step e-stop button is pushed.

11. Engine Air Filter

Warning

Activated when the engine air filter requires replacement.

12. Cable Safety Mast E-Stop

Shutdown

Activated when the mast e-stop cable is pulled.

13. Fire Suppression

Shutdown

Activated when the fire suppression actuator is pushed.

14. Chassis Grease Pressure Switch

Warning with Alarm

Activated when the correct grease pump pressure has not been reached before the pre-set time
cycle is complete.

15. Pulldown Out of Range

Warning

Activated when the pulldown pressure is out of range (0 – 5000 psi range).

16. Holdback Out of Range

Warning

Activated when the holdback pressure is out of range (0 – 5000 psi range).

17. Rotation Out of Range

Warning

Activated when the rotation pressure is out of range (0 – 5000 psi range).

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 Tram Step
E-Stop

Cab E-Stop

Fig 2.4.11 Operator’s Cab Fig 2.4.12 Tram Step

Mast Rest

Fire Suppression
Actuator (if
equipped with
fire suppression) Fire Suppression
Actuator (if
equipped with fire
suppression)

Mast Rest E-Stop

Fig 2.4.13 Mast Rest Fig 2.4.14 Operator’s Cab (beside door)

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 18. Drill Air Out of Range

Warning

Activated when the drill air pressure is out of range (0 – 1000 psi range).

19. E-Stop Mast Rest

Shutdown

Activated when the mast rest e-stop button is pushed.

20. Safety Relay

Shutdown

Activated when any shutdown is triggered; eliminates electrical power to any moving parts on the
unit – lights, gauges, sensors remain active.

21. Compressor Air Filter

Warning

Activated when the compressor air filter requires replacement.

22. Right Auxiliary E-Stop

Shutdown

Activated when the right side auxiliary e-stop button is pushed.

23. Left Auxiliary E-Stop

Shutdown

Activated when the left side auxiliary e-stop button is pushed.

Cable Safety Mast E-Stop

Fig 2.4.15 Cable E-Stop on Mast

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 2.4.6 Configuration Menu
Using the touch screen, press the Config symbol on the main display to access the configuration menu.
See Fig 2.4.16

Fig 2.4.16 Configuration Menu

This menu is used to access and change the various settings available for the options on your DR. This
menu is limited as shown above. If you log in with the admin password, the following parameters can
be set:

 Tram settings  Accra-Feed Configuration settings

 Makeup/Breakout settings  Lube/Grease/Water settings
 Weight on Bit settings  Pre-set – Setting Hole Depth
 Hourmeter settings  Misc settings

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 2.4.6.1 Tram Settings
Refer to Fig 2.4.17
In this menu, you can set the following using the pop-up keypad:

 Default tram speed (default maximum tram speed for single joystick tramming) -
entered as a value between 0-100%. Default is 75%.
 Set-up tram speed maximum (maximum set-up {two joystick} tram speed) - entered as a
value between 0-100%. Default is 65%.
 Left track Forward Bias (used to adjust and offset left track forward speed) - entered as
a value between 0-100%. Default is 100% (full speed).
 Left track Reverse Bias (used to adjust and offset left track reverse speed) - entered as
a value between 0-100%. Default is 100% (full speed).
 Right track Forward Bias (used to adjust and offset right track forward speed) - entered
as a value between 0-100%. Default is 100% (full speed).
 Right track Reverse Bias (used to adjust and offset right track reverse speed) - entered
as a value between 0-100%. Default is 100% (full speed).

Fig 2.4.17 Configuration Menu, Tram Settings

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 2.4.6.2 Make-up / Breakout Settings
Refer to Fig 2.4.18
In this menu, you can set the following using the pop-up keypad:

 Makeup rotation – default is 80%

 Makeup feed – default is 30%
 Breakout rotation – default is 80%
 Breakout feed – default is 33%

Fig 2.4.18 Configuration Menu, Make-up/Breakout

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 2.4.6.3 Weight on Bit Settings
Refer to Fig 2.4.19
In this menu, you can set the following using the pop-up keypad:

 Weight of top drive – default is 1100 lbs

 Weight of hammer and starter rod – default is 730 lbs
 Weight of one rod – default is 390 lbs
 Number of rods in string

Fig 2.4.19 Configuration Menu, Weight on Bit

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 2.4.6.4 Hourmeter Settings
Refer to Fig 2.4.20
In this menu, you can set the following using the pop-up keypad:

 Engine Hours – hours on engine

 Tram Hours – hours unit has been used in tram mode
 Set-up Hours – hours unit has been used in set-up mode
 Drill Hours – hours unit has been used in drill mode

This screen should only be used to adjust hours to proper values if they have become mismatched or a
major component such as the engine has been replaced.

Fig 2.4.20 Configuration Menu, Hourmeter

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 2.4.6.5 Accra-Feed Configuration Settings
Refer to Fig 2.4.21
In this menu, you can set the following using the pop-up keypad:

 Feed Forward - % of feed rate – default is 50%

 Feed Reverse - % of feed rate - default is 50%
 Rotation – Set default rotation speed for Accra-Feed here

These values are adjusted to maximize the drilling efficiency of the DR when it is using the Accra-Feed
function. This screen can be accessed at any time from the drilling screen in any mode.

Fig 2.4.21 Configuration Screen, Accra-Feed

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 2.4.6.6 Lube/Grease/Water Configuration Settings
In this menu, you can set the following using the pop-up keypad:

 Hammer Lubrication Off Time (default: 20 seconds)

 Hammer Lubrication On Time (default: 20 seconds)
 Water Line Air Flush Time (default: 20 seconds)

Fig 2.4.22 Configuration Screen, Lube/Grease/Water

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 2.4.6.7 Pre-set Configuration - Setting Hole Depth

Using the touch screen, press the Pre-set symbol on the main display to access the pre-set
configuration menu.
Touch the hole depth symbol to access the swing and dump pre-sets. The hole depth symbol will now
be displayed.
To set the hole depth, touch the hole depth symbol and a keypad will pop-up. Enter the desired depth
in feet for each hole and touch the accept symbol to set the depth.

Fig 2.4.23 Pre-set Configuration Screen, Setting Hole Depth

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 2.4.6.8 Miscellaneous Settings
Using the touch screen, press the Misc symbol on the main display to access the miscellaneous settings
menu.
In this menu, you can select your preferred language for the screen display. You can also choose your
preferred units of measure (bar or psi; feet or meters).

Fig 2.4.24 Misc Screen, Language

Fig 2.4.25 Misc Screen, Units of Measure

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 2.4.6.9 Diagnostic Screen
If you log in with the Config password, the ‘Diagnostic’ button becomes available. Press the
‘Diagnostic’ button to open the Diagnostic screen.
On this screen, each VMM is shown. If there is any kind of problem with a VMM, it will be shown
outlined in red.
The ‘Engine Communication’ button will also be shown outlined in red if the engine becomes
disconnected (i.e. if an emergency stop is activated).
The ‘Input Device’ button shows the status of the joysticks. If it is outlined in red (see Fig 2.4.26), this
indicates there is a problem with the joysticks. Also, an orange image of a joystick will appear at the
top right of the screen when there is a joystick issue.

Fig 2.4.26 Diagnostic Screen

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 2.4.7 Tramming and Oscillation
From the Tram screen, oscillation and high speed tramming are controlled.

Oscillation is controlled by the left joystick. The unit is oscillated up or down (from front to back) by
moving the joystick forwards or backwards while in this screen.
At the bottom of the screen, there is a graphical representation of the buttons of the left joystick
(except for the yellow selector button). Oscillation can be locked by pressing the corresponding
button on the joystick as represented on the screen.

Tramming is controlled with the right joystick. The axis and buttons of the right joystick are
graphically represented on the screen.
NOTE: Tramming is disengaged by default. To engage tramming, press the ‘Tram Enable’ button on
the left joystick. See Fig 2.4.24. When tramming is enabled, the button will show red.
To perform a function for tramming, the right joystick is moved and/or buttons are pressed for the
corresponding function needed as represented on the screen. A red arrow indicator will move
proportionally on the screen, showing you the current position of the joystick.
When buttons are depressed, they will first turn red, showing that the button is depressed. When the
function is fully engaged, a green indicator will show up on the screen to confirm that the function is
activated and engaged.

Fig 2.4.24 Tram Screen

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 2.4.8 Set-up Screens

Set-up Screen – Layer 1

The default screen when switching to the Set-up screen is Layer 1. There are a total of three layers in
the Set-up screen. Layer 1 displays the functions for tramming the left and right tracks individually
(set-up mode tramming). Oscillation and tramming are controlled by the joystick axis. At the bottom
of the screen, the joysticks buttons are represented showing you the available functions of each
button. Refer to Fig 2.4.25 for details.

Fig 2.4.25 Set-up Screen, Layer 1

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 Set-up Screen – Layer 2
Set-up screen Layer 2 can be selected from the main set-up screen (Layer 1) by pressing and holding
the Layer 2 button on the left and right joysticks. These layers can be brought up independently left
or right.
The controls in Layer 2 are:
 Left joystick controls cab positioning.
 Right joystick controls the position of the mast boom: up, down, left, and right.
NOTE: This screen will default back to Layer 1 if layer button is released.

Fig 2.4.26 Set-up Screen, Layer 2, left joystick

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 Set-up Screen – Layer 3
Set-up screen Layer 3 can be selected from the main set-up screen (Layer 1) by pressing and holding
the Layer 3 button on the left and right joysticks. These layers can be brought up independently left
or right.
The controls in layer are:
 Left joystick controls mast dump and swing.
 Right joystick feed extension up or down.
NOTE: This screen will default back to Layer 1 if layer button is released.

Fig 2.4.27 Set-up Screen, Layer 3, left joystick

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 2.4.9 Drill Screens

Drill Screen – Layer 1

The default screen when switching to the Drill screen is Layer 1.
 Left joystick controls functions for the carousel arm and clamps.
 Right joystick controls functions for the feed and rotation.
Stage 1 and 2 top drive position indicators are also displayed, along with a Carousel Arm Out indicator.
The buttons also control various functions for drilling, such as turning on drill air and water. Refer to
Fig 2.4.28 for details.

Fig 2.4.28 Drill Screen, Layer 1

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 Drill Screen – Layer 2
Pressing and holding the Layer 2 button on each joystick will display Layer 2 of the Drill screen as
shown in Fig 2.4.29.
 Left joystick controls the winch.
 Right joystick controls the slip plate, and centralizers.
NOTE: This screen will default back to Layer 1 if layer button is released.

Fig 2.4.29 Drill Screen, Layer 2

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 Drill Screen – Layer 3
Pressing and holding the Layer 3 button on each joystick will display Layer 3 of the Drill screen as
shown in Fig 2.4.30.
 Left joystick controls carousel rotation, and pipe breakout functions.
 Right joystick controls the breakout wrench, and divertor functions.
NOTE: This screen will default back to Layer 1 if layer button is released.

Fig 2.4.30 Drill Screen, Layer 3

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 Drill Screen – Manual Drilling Layer 1
Manual drilling is accessed from the main drill screen. See Section 4.3.1 for details.

Fig 2.4.31 Drill Screen, Manual Drilling

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 2.4.10 Accra-Feed Screen – Layer 1
The Accra-Feed screen can be accessed from the Drill menu.
Please see Section 4.3.2 for details.

Fig 2.4.20 Accra-Feed Screen

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Section 3 Start-Up and Tramming
This section describes the operating procedure in sequence as they occur during normal drilling.

3.1 Operating Procedures for Start-Up

WARNING!
Before attempting to operate or service the drill, one must read and understand the warnings and
cautions listed in Section 5.

3.1.1 Pre-start Inspection

The drill must be inspected thoroughly at the beginning of a shift or a project. All items on the DR
Operators Pre-Start Checklist (next page) must be OK before starting the engine and subsequently
drilling. It may be necessary to inspect all these items when the drill has to be stopped and started
several times during a shift.

WARNING!
Check for obstructions before moving the mast or the machine. Do not allow contact or come
near electrical power lines. Be sure the mast is high enough to clear ground obstacles and low
enough to clear overhead obstacles when tramming.

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66 Copyright © Sandvik Mining and Construction
 DR Operator Pre-Start Checklist
Serial Number: Date:
Operator Name: Hour meter reading start of shift:
Foreman: Hour meter reading end of shift:
Set-up location:

Pre-start Inspection
Check the underside of the drill for broken or loose hoses; loose bolts; leaking fuel, oil, or water.
Tighten any loose hoses or bolts and do not operate the drill until all leaks have been found and
corrected.
Check all grease points and apply grease if necessary.
Check the battery disconnect switch. The switch should be in the “ON” position.
Check the compressor oil level in the receiver tank. Fill, if necessary.
Drain any water from the receiver tank and control air line filter.
Check and fill the rock drill grease tank, if required, using only clean grease. Repeat this check every
eight (8) hours of operation.
Check the top drive oil level and fill, if required.
Check the engine crankcase oil level and fill, if required. Do not mix types of oil.
Check radiator coolant level and add a 50/50 mixture of permanent antifreeze and water, if necessary.
Check battery electrolyte levels and fill with distilled eater, if necessary. Ensure cable connections are
clean and tight.
Check diesel fuel level. To avoid priming and restarting problems, do not allow engine to run out of fuel.
Drain the water from the tank prior to starting.
Check the oil level in the track planetary drive. Fill with 80-90 wt. gear oil. Do not mix types of oil. With
the machine on level ground, tram forward until the level plug is at the 3 or 9 o’clock position. The oil
level should be at the bottom of the plug hole. Fill, if necessary, through the plug at the 12 o’clock
position.
Check the hydraulic oil level. Add oil if necessary, using the oil fill pump.
Ensure that all drilling, set-up, and tramming controls are in the off or neutral position.
Check all gauges for proper operation.
Check V-belt tension. Belts should deflect 3/8” (10 mm) to 1/2” (13 mm) maximum.
Check the chain tension on the mast. Adjust if necessary.
Check slider adjustment on top drive and mast mounting plates. Adjust if needed.
Check centralizer jaws and slip plate for wear.
For units with a dust collector: Check hoses, pickup pot skirts, and rod wipers. Replace items if worn.
For units with water dust suppression: Check all water lines and water pump oil level; clean suction
screen; fill tank with water.
Comments:

67 Copyright © Sandvik Mining and Construction

68 Copyright © Sandvik Mining and Construction
3.2 Start-Up
WARNING!
It is not recommended to shut off the engine immediately after starting unless there is an
emergency. The compressor needs time to stabilize after starting and may become damaged if
not allowed to do so.

3.2.1 Inside Cab

1. Conduct pre-start check as outlined in the Pre-Start Checklist.
2. Be sure all controls are in the off position.
3. Turn the battery disconnect switch to the On position.
4. Turn on the computer.
5. Allow the computer to fully boot or the engine will not start.
6. Sound horn before starting engine.
7. Press the engine start switch on the engine control panel.
Once the engine warms up, the throttle can be moved all the way to the right for full rpm. When
drilling, the engine rpm will change accordingly when the air pressure is selected on the
touchscreen.

NOTE: If there is an issue starting the machine due to a low battery condition, the unit should be
started from outside the cab as described in Section 3.2.2. This will protect the computer
system from any problems that might arise from booting in a low battery condition.

3.2.2 Outside Cab

1. Conduct pre-start check as outlined in the pre-start checklist.
2. Turn the battery disconnect switch to the On position.
3. Turn ignition switch in cab to the On position.
4. Make sure all E-stops are in the Run reset.
5. Make sure the throttle lever is in the idle position all the way to the left.
6. Go to the manual control panel on the left side of the machine and press the engine start button.
If the engine fails to start (engine cranks but no smoke), check that all the E-stops are pulled out.
There is one on the right hand side of the machine by the mast rest; another one is located on the
left hand side of the machine above the tram step. There is also one on the engine control panel in
the cab. Also, make sure that the dead-man switch on the mast hasn't been activated.

NOTE: If the engine fails to start within 10-15 seconds, release the start switch. Wait for about
one minute and turn the start switch again. After about 45 seconds, the compressor low oil
pressure light should go out.

69 Copyright © Sandvik Mining and Construction

 Fig 3.3.1

Fig 3.3.2

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3.3 Tramming
Tramming can be done from the tram station at the left side of the drill or from the cab. The
tramming controls are spring-loaded and will automatically return to the neutral position when
released. These controls are proportional and are infinitely variable from 0 to full speed of 5 km/hr.
The tram speed can also be controlled by changing engine speed. Also, the load sensing components
of the hydraulic system maintain the torque on the tracks at a constant level.
The brakes are spring applied/hydraulic released. They are always on and are disengaged when the
tram lever is pushed away from neutral position allowing hydraulic pressure to release the brakes.
Before tramming, raise the mast to clear ground obstacles using the feed extension cylinder or boom
lift cylinder or both.

NOTE: For tramming long distance, it is recommended to lower the mast into the mast cradle to
achieve the best stability.
Normally when tramming, the oscillation control switch is in the “Float” position; however, when
tramming on slopes, the oscillation control switch must be in the “Fixed” position.

WARNING!
DO NOT tram the drill on steep inclines, or crosswise to grades; this greatly increases the risk of
drill rollover. DO NOT tram the drill on soft or unstable ground, or close to unsupported
excavation.

3.3.1 Tramming from the Tram Station

1. Select oscillation control (Float/Fixed or Up/Down) depending on the distance to be trammed and
condition of ground.
The left and right tracks are steered by the left tram and right tram levers respectively.

3.3.2 Tramming from the Cab

1. When starting, the ERIS system will display the System screen by default. Select the Tram screen
by touching the “TRAM” tab on the upper part of the touch screen.
2. Tramming function is disengaged by default. To tram, press the ‘Tram Enable’ button on the left
joystick (see Fig 3.3.2). To disengage tramming, press this button a second time.
3. Oscillation is in the unlocked position by default. To change oscillation, press the “Oscillation
Lock” button on the left joystick. This will set oscillation to “locked” indicated by the function
engaged symbol. Move the left joystick to right or left as well as forward or backward to change
oscillation. To unlock oscillation, press the Oscillation Lock button a second time.

71 Copyright © Sandvik Mining and Construction

 To tram forward or reverse, move the right joystick forward or backward. Tram forward or reverse
will be indicated on the screen with the red indicator arrow along the appropriate axis. To turn
either right or left, move the joystick forward and then to right or left.
The tram speed is set at low as default. It can be set to high by pressing the “Tram Low Speed”
button. Tram speed can be increased or decreased by pressing the tram speed increase or tram
decrease buttons.
Tramming controls are also available from the set-up mode. In Set-up mode, tramming speed is much
lower than the low speed in the Tram mode.

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 3.3.3 Tramming Stability
When tramming on a slope, the possibility of tip-over exists. In order to reduce and eliminate this
possibility, DR stability limits have been documented. Refer to Fig 3.3.3 for stability requirements.
Fig 3.3.3 is a label found in the Operator’s Cab. Familiarize yourself with the limits and
recommendations shown on the label BEFORE operating the drill.

Fig 3.3.3

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 Fig 3.4.1 Set-up screen

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3.4 Set-up
One the drill is trammed to the desired location, the mast can be set-up to drill at a specific angle.
Set-up controls include the following:

 Cab Swing: Right or Left

 Cab movement: Up or Down
 Mast Boom movement: Up or Down
 Mast Boom swing: Right or Left
 Mast Dump: Down or Up
 Mast Swing: Right or Left
 Feed Extension: Up or Down
 Oscillation: Fixed, Float, or Up / Down
 Tram: Right Tram or Left Tram, or Both

3.4.1 Set-Up from the Cab

Refer to Fig 3.4.1

1. With engine running, use the touchscreen to select SETUP. The set-up screen will appear as shown
in Fig 3.4.1.

2. Tramming controls are also available in set-up mode. Tramming speed in this mode is much lower
than the speed available in tramming mode.

3. Two joysticks accomplish all set-up and tramming controls.

Left joystick has the following controls:

Layer 1: Left Oscillation and Left Track steering

Layer 2: Cab swing right/left and Cab movement up/down
Layer 3: Mast dump down/up and Mast swing right/left

Right joystick has the following controls:

Layer 1: Right Oscillation and Right Track steering

Layer 2: Boom right/left and Boom up/down
Layer 3: Feed extension up/down

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To raise the mast vertically up, activate Layer 3 with the left joystick and move the left joystick forward (Fig
3.4.2). Mast can be positioned from horizontal to 45° underneath the drill along its axis (Fig 3.4.3).

Fig 3.4.2

Fig 3.4.3

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Swing the cab out to the left of the machine for better visibility and maximum movement of the boom and mast.
To swing cab to left, activate Layer 2 of the left joystick and move the left joystick to the left (Fig 3.4.4).

To move mast boom to right or left, activate Layer 2 of the right joystick and move the right joystick to the right
or the left.

Fig 3.4.4

Fig 3.4.5

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To swing the mast, activate Layer 3 of the left joystick and move the left joystick to left or right (Fig 3.4.6 and Fig
3.4.7).

Once the mast has been positioned, bring the mast into firm contact with the ground by lowering the boom or
extending the mast with the feed extension cylinder. To lower the mast, move the right joystick forward while
layer 3 is activated.

NOTE: Using the boom to bring the mast into contact with the ground will change the drilling angle and the
mast would have to be repositioned.

Fig 3.4.6

Fig 3.4.7

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 3.4.2 Indexing the Swing Cylinder
If you have a special drilling application that requires repositioning of the mast, use the following procedure to
change the mast position:

1. Bring the top drive to the midpoint of the mast.

2. Level the mast horizontally (see Fig 3.4.8).
3. Install locking pin (see Fig 3.4.8) to secure the mast and prevent movement.
4. Remove the ¾” keeper bolt located on the mast swing cylinder pin (see Fig 3.4.10).
5. “Wiggle” the cylinder to loosen the pin and then remove it.
6. Move the cylinder to the other position (see Fig 3.4.9).
7. Re-install the mast swing cylinder pin and ¾” keeper bolt.
8. Remove the locking pin.

Locking Pin

Mast horizontal

Fig 3.4.8

Locking pin through these holes

Keeper Bolt
Mast Swing Cylinder Pin

Cylinder other position

Fig 3.4.9 Fig 3.4.10

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 Computer On/Off button

Ignition Switch
Fig 3.5.1

Touchscreen

DTI Angle Blaster

display screen

Fig 3.5.2

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3.5 Shutdown Procedure
The following is a step by step procedure for the proper shutdown of a DR drill.

1. Turn the ignition switch off in the cab. See Fig 3.5.1 for switch location.

2. Push the computer on/off button and wait for two minutes for the computers to shut down. See Fig
3.5.1 for button location.

3. Once the ignition switch is off and the computer on/off button has been pushed, ensure that the
touchscreen is off before proceeding to step 4. If the touchscreen is still on, repeat step 2. It is
acceptable for the DTI Angle Blaster display screen above the control panel to still be on. See Fig
3.5.2.

4. Proceed to the right rear of the machine to the main battery disconnect box (see Fig 3.5.3 for
location). The main disconnect box will have a rod key handle inserted into it (see Fig 3.5.4). Turn
the key from the ON position to the OFF position and pull the key out. Now put the lock cover over
the slot for the key (see Fig 3.5.4). This will ensure that the power has been isolated.

5. The drill has now been shut down properly.

Lock Cover

Rod Key Handle

Fig 3.5.3 Disconnect Box location Fig 3.5.4

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 Tracks

Cover Plate with 4 bolts

Fig 3.6.1

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3.6 Towing
These towing instructions are for moving a machine for a short distance at low speed. Move the machine at a
speed of 2 km/h (1.2 mph) or less to a convenient location. Always haul or tram the machine if long distance
travel is required.

WARNING!
Personal injury or death could result when towing a machine incorrectly.
Block the machine to prevent movement before final drives are disengaged. The machine can roll
freely if it is not blocked. With final drives disengaged, the machine cannot be stopped or
steered.
Relieve the hydraulic tank and line pressure before any disassembly. Operate the tram levers
back and forth with the engine stopped to relieve pressure.
Removing the plugs from the brake cover of the travel motor without first relieving the internal
pressure will cause hydraulic oil to squirt out.
Evan after the machine has been turned off, the hydraulic oil can still be hot enough to burn.
Allow the hydraulic oil to cool before draining.

NOTE: To tow the machine, both final drives must be disengaged.

Do not operate the travel motors with the final drives disengaged. Damage could result.

3.6.1 Towing Guidelines and Precautions

Shields must be provided on both machines (drill unit and towing machine). This will protect the
operator if the tow line or the tow bar breaks.
Do not allow an operator to be on the machine that is being towed.
Before you tow the machine, make sure that the tow line/tow bar is in good condition. Make sure
that the tow line/tow bar has enough strength for the towing procedure is involved. The strength of
the tow line/tow bar should be at least 150% of the gross weight of the towing machine. This
requirement is for towing a machine that is stuck in the mud and for towing on a grade.
Attach the cable to the towing eye on the front of the machine if you are towing the machine
forward. Attach the cable to the drawbar pin on the rear of the machine if you are towing the
machine backward.
Do not use a chain for towing a machine. A chain link can break and cause personal injury. Use a wire
cable with ends that have loops or rings. Put an observer in a safe position to watch the towing
procedure. The observer can stop the procedure if the wire cable starts to break. Stop pulling
whenever the towing machine moves without moving the drill unit.
Keep the tow line angle to a minimum. Do not exceed a 30° angle from the straight ahead position.

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 Sun Gear

Insert bolt here

Fig 3.6.2 Fig 3.6.3

Sun Gear removed

3/8” Bolt

Fig 3.6.4 Fig 3.6.5

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 Quick machine movement could overload the tow line/tow bar. This could cause the tow line/tow bar
to break. Gradual, steady machine movement will be more effective.
Normally, the towing machine should be as large as the machine being towed. Make sure that the
towing machine has enough brake capacity, enough weight, and enough power. The towing machine
must be able to control both machines for the grade and distance that is involved.
You must provide sufficient control and sufficient braking when you are towing a machine downhill.
This may require a larger towing machine or additional machines that are connected to the rear of
the drill unit. This will prevent the drill unit from rolling away out of control.
All situation requirements cannot be listed. Minimal towing machine capacity is required on smooth,
level surfaces. Maximum towing machine capacity is required on inclines or on surfaces in poor
condition.

3.6.2 Tow Disconnect – Sun Gear Removal Procedure

1. Ensure that the gear oil has been drained.

2. Remove bolts on the cover plate located on the tracks. See Fig 3.6.1

3. Screw a 3/8” bolt (use a bolt with a long shaft) into the hole in the centre of the sun gear (see Fig
3.6.3). Once it is secure, remove the sun gear by pulling on the bolt. Leave the bolt in the sun gear
until it is re-installed.

4. Re-install the cover plate to avoid contamination in the system.

5. The drill is now ready for towing. Be sure to follow all the Towing Guidelines and Precautions listed
in Section 3.6.1.

3.63 Sun Gear Re-install

1. Remove the cover plate.

2. Re-install the sun gear by fitting the gear teeth into the teeth of the planetary gear.

3. Unscrew the bolt from the sun gear. Ensure that the sun gear remains seated completely to the
back.

4. Re-install the cover plate and bolts; torque bolts to 35 ft-lbs (47.5 N-m).

5. Refill the gear oil.

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 Fig 4.1.1 Drill Screen, Layer 1

Fig 4.1.2 Drill Screen, Layer 2

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Section 4 Drilling

4.1 Drilling Procedures

This section describes how to perform the operations required for drilling. During drilling, a number of
functions and controls are available to the operator. To access these functions, switch to the drilling
screen as described in Section 2.4.5. The drilling screen with default layer 1 will appear as shown in
Fig 4.1.1.

The left and the right joystick are used to access the makeup and breakout functions.

The left joystick has been programmed for the following functions and controls:

Layer 1: Pipe Clamp Close /Open and Carousel Arm In /Out (see Fig 4.1.1)
Layer 2: Winch In or Out (see Fig 4.1.2)
Layer 3: Carousel Rotation In / Out and Pipe Makeup / Breakout

Control Buttons: Collar Air On/Off, Drilling Air On/Off, Water Pump On/Off, and Reverse
Breakout.

The right joystick has been programmed for the following functions and controls:

Layer 1: Rotation Reverse /Forward and Feed Forward /Reverse (see Fig 4.1.1)
Layer 2: Centralizer Out /In and Slip Plate In /Out (see Fig 4.1.2)
Layer 3: Breakout Wrench Out /In and Divertor Down /Up (see Fig 4.1.3)

Control Buttons: Manual Drilling OFF/ON, Accra-Feed OFF/ON, Rotation Torque LOW/HIGH, and
Thread Greaser OFF/ON.

Fig 4.1.3 Drill Screen, Layer 3

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 Fig 4.1.4 Manual Drilling

Fig 4.1.5 Drill Lock On

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 To access the Manual Drilling screen (Fig 4.1.4), press the Manual Drilling button.
This will give you access to the following on the joystick axis:

 Holdback Pressure: Increase or Decrease

 Pulldown Pressure: Increase or Decrease
 Rotation: Reverse or Forward
 Feed: Forward or Reverse

The feed rate and rotation in percentage will be displayed on the status bar at the top of the screen.
Once the desired feed rate and rotation speed are achieved, press the drill lock button to maintain
them.
Once the Drill Lock button is pressed, the new drilling screen (Fig 4.1.5) will appear. Fine adjustments
of feed rate and rotation speed can still be made from this screen.

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 Fig 4.1.6 Drill Screen, Layer 1

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 4.1.1 Hammer Installation Procedure
There are many different types of hammers available but they all have a piston that hammers on the bit. The
differences are the piston size, air porting, and assembly requirements. The installation is the same and is done
as follows (see Fig 4.1.6):

1. Slowly rotate the top drive while opening and closing the drill air. Top drive speed will increase
with the distance the joystick is being moved. Drill air is switched off by default. Pressing the drilling
air button on the left joystick will open the air line.
2. Examine the exhaust air from the top drive for lubrication oil/grease. If no oil/grease is detected,
adjust the injection system until oil/grease appears. See section on grease injection procedures.
3. Stop rotation of the top drive by releasing the joystick. The joystick will return to neutral position.
Raise the top drive to about five feet from the drilling table using the right joystick. This is done by
moving the right joystick backward to reverse feed.
4. Close the slip plate. Activate layer 2 of the right joystick and move the joystick forward.
5. Place the hammer on the slip plate and lubricate the top sub thread and the thread in the top
drive. If using a bit basket, the bit hammer is lowered into it.
6. To makeup the top joint (between the top drive and the hammer), activate layer 3 of the left
joystick and move the joystick forward. When joint makeup is complete raise the hammer off the
slip plate. If using a bit basket, use full forward rotation pressure to makeup the joint.
7. Rotation speed and feed defaults can be changed, if needed, in the configuration screen.
8. Open the slip plate (retract) by moving the right joystick backward in layer 2. Move the hammer
down until the bit is aligned with the centralizer jaws.
9. Clamp the bit with centralizer jaws by moving the right joystick to the left in layer 2 and rotate the
top drive full forward to makeup the top driver with the hammer case.
10. Open the centralizer jaws by moving the right joystick to the right in layer 2. Lower the hammer
through them by moving the right joystick forward in layer 1.
11. Close the centralizer jaws around the hammer to centralize it in preparation for collaring the hole.

91 Copyright © Sandvik Mining and Construction

 4.1.2 Drill Pipe Installation (Adding Rods)

Refer to Fig 4.1.7

1. In Drill mode, drill down until the top drive stops
advancing. Turn off drill functions.
2. Hoist drill string until the top of the pin end of the rod
is located slightly above the clamping jaws.

Fig 4.1.7

Refer to Fig 4.1.8

3. Using the Clamp Drill String function, close the clamps
securely holding the rod.
4. Use Breakout function to reverse rotate and hoist the
top drive until it is disconnected from the rod.

Fig 4.1.8

92 Copyright © Sandvik Mining and Construction

 Refer to Fig 4.1.9
5. Hoist the top drive to the top of the mast.
6. Close the carousel arm clamp to insure it is tightly
clamped on the rod.

Fig 4.1.9

Refer to Fig 4.1.10

7. Move carousel arm and rod into the mast.

Fig 4.1.10

93 Copyright © Sandvik Mining and Construction

 Refer to Fig 4.1.11
8. Using Makeup function, forward rotate and lower the
top drive until the joint is made up.
9. Crack the clamp jaws open slightly.

Fig 4.1.11

Refer to Fig 4.1.12

10. Lower the top drive and rod until it is close to pin end
of the rod in the clamping device.
11. Use Makeup function to forward rotate and lower the
top drive until this joint is made up.

Fig 4.1.12

94 Copyright © Sandvik Mining and Construction

 Refer to Fig 4.1.13
12. Open carousel arm clamps and move carousel arm out
to the mast.
13. If another rod is required, rotate the carousel in.

Fig 4.1.13

NOTE: Make sure that the thread connection is tight before drilling (1600 psi max).
Do not allow the rotary action of drilling to tighten the threaded connections. This may result in thread
damage and will require a higher breakout force.

95 Copyright © Sandvik Mining and Construction

 4.1.3 Drill Pipe Removal

Refer to Fig 4.1.14

1. Position rods in Triple Jaw Breakout (TJBO). Joint
between top and bottom rods is to be located between
the TJBO clamping jaws and TJBO top breakout jaws.

Fig 4.1.14

Refer to Fig 4.1.15

2. Use Clamp Drill String function to grip the lower pipe
with the middle jaw.

Fig 4.1.15

96 Copyright © Sandvik Mining and Construction

 Refer to Fig 4.1.16
3. Use the Breakout Clamp Engage function on the right
joystick to break the pipe joint.
4. After the joint is broken, use the Breakout Clamp
Release function on the right joystick to partially
release the jaws from the pipe.

Fig 4.1.16

Refer to Fig 4.1.17

5. Use the Breakout Pipe function on the left joystick to
finish breaking out the two drill pipe clearing the
threads.

Fig 4.1.17

97 Copyright © Sandvik Mining and Construction

 Refer to Fig 4.1.18
6. Use the Breakout Clamp Engage function again to
clamp the drill pipe again.
7. Use reverse rotation to breakout the joint between the
saver sub and the drill pipe.

Fig 4.1.18

Refer to Fig 4.1.19

8. Use the left joystick to open the carousel clamp.
9. Use the Arm In function to bring the carousel arm into
the feed.
10. Close the carousel clamps completely, then partially
release.

Fig 4.1.19

98 Copyright © Sandvik Mining and Construction

 Refer to Fig 4.1.20
11. Use the right joystick and reverse the feed until the
stage 1 indicator comes on.
12. Use the right joystick to activate the Breakout Clamp
Release function to allow the drill pipe to move freely.

Fig 4.1.20

Refer to Fig 4.1.21

13. Use the left joystick to activate the Breakout Pipe
function until the stage 2 light becomes active.
14. Close the carousel clamps completely on the drill rod.

Fig 4.1.21

99 Copyright © Sandvik Mining and Construction

 Refer to Fig 4.1.22
15. Use the Arm Out function on the left joystick to
return the drill pipe t the carousel. Repeat from step 1
if removing more drill pipe from the drill string.

Fig 4.1.22

100 Copyright © Sandvik Mining and Construction

4.2 Delivery Systems
Drilling operations are performed from the control panel in the cab using the electric/hydraulic
controls. They can also be performed from the mast by operating the hydraulic valves directly.
The DR can be fitted with water injection or a dust collector or both. All DR’s are equipped with oil or
grease injection systems.

4.2.1 Water Injection Procedure

The water injection procedure is as follows:

1. Make sure that the water tank is full. The water tank has a sight tube on one side to indicate
the water level in the tank.
2. Start drilling.
3. Turn on the water by pressing water pump button on the left joystick. This activates the
hydraulic valve that directs the flow of oil to the water pump drive motor.
4. Use the proportional hydraulic valve to control the pump speed. This controls water flow. The
water flow should be just enough to suppress the dust.
5. The water pressure should always exceed the air pressure. Adjust the operating pressure of
the pump to approximately 100 psi (7 bar) above the drilling air pressure.

4.2.2 Grease Injection Procedure

The grease injection system is designed so that the grease pump and injector will operate only when
the drill air is ON. The system is programmed to energize the air solenoid valve for 20 seconds in
order to admit air to the grease pump. Grease is pumped to the injector and the injector discharges
grease to the drill air stream. Grease injection cycle is 30 seconds (10 second ON and 20 second
OFF).
Grease injection procedure is as follows:

1. Start drilling.
2. Set drilling air ON.
3. Set the regulator at 80 psi (5.5 bar), if not already set.
4. Check if grease is coming out of the top drive shaft with the drilling air. Adjust injector nozzle
if more grease is needed.

NOTE: The injection rate for hammer is 0.7 qt (0.7 l) of grease per hour for a 6” hammer.

101 Copyright © Sandvik Mining and Construction

 4.2.3 Oil Injection Procedure
The air supply line to the oil injection pump is designed so that the pump will operate only when the
rotation is on.
The oil injection procedure is as follows:

1. Close ball valve on air supply line. Remove top of tank and fill with rock drill oil. Reinstall top
and turn on air.
2. Set the air supply regulator at the tank to 60 psi.
3. Adjust the oil flow with the metering valve located on the discharge line of the pump. Open it
1/4 turn to start.
4. Check if the oil is coming out of the shank at the water swivel with rotation on. If not, open
the valve further until there is noticeable oil in the drilling air.

NOTE: The injection rate for hammer sizes are as follows:

For a 4" hammer, it is 1 qt (1 l) per hour.

For a 6" hammer, it is 2-1/2 qt (2.5 l) per hour.

102 Copyright © Sandvik Mining and Construction

4.3 Drilling
Now all the systems are in operation and are ready for drilling. Select the drilling screen using the touchscreen
interface to active the drilling tab.
Refer to Fig 4.3.1 and Fig 4.3.2 (next page).
Use the following procedures while drilling.

4.3.1 Manual Drilling

1. Increase engine throttle.
2. Lower the hammer until the bit touches the rock using the Forward Feed function of the right
joystick.
3. Close the centralizer jaws loosely around the hammer using the Centralizer IN function of the right
joystick.

NOTE: This assures that the hammer will not deviate from the target angles and is one of the most
important steps in maintaining hole accuracy.

4. Set the air pressure to High on the control panel.

5. Turn manual drilling on.
6. Turn collar air on.
7. Prior to commencing of the initial drilling sequence, decrease both the pulldown and holdback to
the lowest settings.
8. Rotate the top drive slowly using the Rotation Forward function of the right joystick.
9. Lower the hammer slowly until it contacts the rock using Feed Forward function of the right
joystick.
10. As the bit starts breaking the rock, increase the down feed slowly. It may be necessary to increase
the pulldown pressure to accomplish this. Continue drilling to a depth of at least 3 feet (1 m)
depending on ground conditions.

NOTE: This step must be performed carefully and slowly or the drilling angle may change.

11. After the hole is collared, turn drill air on (collar air will turn off automatically).

103 Copyright © Sandvik Mining and Construction

 Fig 4.3.1 Manual Drilling Screen, Drill Lock Off

Fig 4.3.2 Manual Drilling Screen, Drill Lock On

104 Copyright © Sandvik Mining and Construction

 12. Increase feed to full feed forward and set rotation speed as required. The desired values of feed
rate and rotation speed can be locked by pressing the drill Lock button. A new screen will appear as
shown in Fig 4.3.2. Final adjustments can be made to rotation speed by moving the right joystick left
or right, and changes to pulldown pressure by moving the left joystick forward or backwards.
13. Continue drilling until the top drive mounting plate contacts the mast stops. Turn water off prior
to the end of travel to insure that all the water is removed from the air lines.
14. At the end of travel, turn off the Manual Drill Lock and the feed will automatically lift to a pre-set
value allowing the hole to blow out. Raise and lower the drill string to clear the hole as required.
15. Refer to drill pipe installation procedures given in Section 4.1.2 to add another drill rod.
16. Turn on drilling air and water and feed the hammer down to resume drilling.
17. When the required hole depth is reached, follow rod removal procedures given in Section 4.1.3.

105 Copyright © Sandvik Mining and Construction

 Fig 4.3.3 Accra-Feed Screen

106 Copyright © Sandvik Mining and Construction

 4.3.2 Drilling with Accra-Feed Feature (Optional)
Accra-Feed is a patented system developed by Cubex Limited for automatic control of feed, rotation,
and torque during drilling. This allows for drilling a straighter hole with minimal drill bit wear. The
basic principle of operation of the Accra-Feed system is as follows:

Accra-Feed allows feed rate to decrease with the increase of drilling resistance encountered by the
drill bit in harder rocks. Conversely, it increases feed rate when drilling resistance becomes lower in
softer rocks. Increase of feed rate is limited to a maximum level. As a result, the drill bit will not
advance faster in voids.

Higher drilling resistance in harder rocks causes rotation pressure to go up. Once rotation pressure
reaches a set level, the feed reverses automatically and the top drive moves up. Forward feed
resumes again when a set time has elapsed. This cycle of feed forward and feed reverse continues
until any one of the following conditions is met:

 Harder rocks have been broken loose.

 Drilling is stopped.

The procedures for the employment of Accra-Feed features are as follows:

1. Select the drilling screen with the touchscreen interface.

2. Set all drilling parameters as needed for producing accurate hole efficiently. See Section 2.4.5
Configuration Menu.
3. Set Accra-Feed ON by pressing Accra-Feed button on the right joystick. Accra-Feed screen
appears as shown in Fig 4.3.3.
4. Change pull down, if needed, using the left joystick. Holdback will not work, as this is
automatic depending on rotation pressure.
5. Change rotation speed using the right joystick.
6. Continue drilling until the top drive mounting plate contacts the mast stops.
7. Turn OFF Accra-Feed.
8. Follow the steps described in Section 4.1.2 and 4.1.3 to move up the hammer, break joints
and to add or remove pipes into the drill string.

107 Copyright © Sandvik Mining and Construction

108 Copyright © Sandvik Mining and Construction
Section 5 Maintenance and Safety

5.1 Daily Maintenance Procedures

A program of preventative maintenance is vital to long component life and lower operating costs.
We recommend that the operator carry out, as a minimum, the maintenance procedures outlined in
this section.

 Check underside of drill. Look for loose or broken hoses. If dripping fuel, hydraulic oil, or
coolant is evident, do not continue until the leak is found and corrected.
 Check that the tracks are tensioned properly. Clear any rocks, mud, or snow from the tracks
to prevent over-tensioning or other damage.
 Check for clean, tight battery connections. Check that the battery is fully charged. With the
ignition switch in the ‘Run’ position, the battery voltage meter should read 23 - 25 volts.
When the engine is running, the voltage should increase slightly to indicate that the
alternator is charging.
 Look for loose or missing bolts and tighten any loose ones.
 Check fill caps, tank covers and dipstick. They should be in place and seated properly.
 Check air-piping clamps; be sure they are tight to prevent any damage.
 Check engine belts, maximum deflection should be 3/8” - 1/2” (10-13 mm).
 Check engine and compressor air filters. Clean if necessary.
 Check coolant level in radiator.
 Check oil level in crankcase.
 Check fuel level and fill if required.
 Drain accumulated water in fuel tanks.
 Check and grease all pivot points.
 Check feed chain and adjust if required.
 Check slider adjustment on top drive mounting plate and mast mounting plate. Adjust if
required.
 Check water tank; fill if required (if equipped with water injection).
 Check rock drill oil/grease tanks and fill. Oil level in the rock oil tank should be checked
every day. Grease level in the rock grease tank should be checked every 4 hours.
 Check oil level in water pump.

109 Copyright © Sandvik Mining and Construction

 Safety Instructions for Servicing

1. Follow all service procedures at recommended intervals.

2. Before inspecting, disconnecting, or removing any hydraulic or mechanical components, secure the mast by
placing it on solid ground or floor. Move the top drive assembly to the lowest position on the mast. Secure the
mast with a hoist or restraining equipment. Follow proper shutdown procedures.

3. High-pressure leaks from hydraulic and pneumatic systems could result in injuries. Use protective gear when
inspecting leaks.

4. Secure all moving components with proper restraining devices before removing or loosening any hydraulic
components. This is to prevent components from shifting when hydraulic components lose pressure.

5. Relieve pressure from track tensioning system before servicing. Unscrew relief plug slowly to allow the high
pressure grease to escape. Use extreme caution when working on tracks. Keep fingers away from track shoes.

6. Tag the drill and pump to prevent accidental start-up. Signs must be clearly visible to alert of service in
progress.

7. Tag or mark hoses, wires, or components to assist in reinstallation.

8. Cap or plug all hydraulic or pneumatic connections immediately after removal.

9. Cap fluid ports to keep foreign material from entering components during servicing.

10. Clean grease fittings with a clean cloth before greasing.

Perform these Safety Checks when completing maintenance:

Check that all hose fittings are tight.

Check that all pressurized air hoses are secured with hose connection safety devices.

Check that all controls are in the off position before starting the engine.

Check that all valves are in the off position before connecting the air system to the drill
unit.

110 Copyright © Sandvik Mining and Construction

REMEMBER
 Follow all service procedures at recommended intervals.
 Check all fluids at recommended intervals.
 Keep foreign material from entering any critical components of equipment.
 Clean grease fittings with a clean cloth before lubricating.

Fluid Notices

Fill with Hydraulic Fluid Only

Decal is on hydraulic tank

Fill with Rock Oil Only

Decal is on rock oil tank (if so equipped)

Fill with Rock Grease Only

Decal is on rock grease tank (if so equipped)

111 Copyright © Sandvik Mining and Construction

 15
7
2 13 17

10 14
8

3 5

16

1
11 12 6 4

Fig 5.2.1 Lubrication Points

112 Copyright © Sandvik Mining and Construction

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

5.2.1 Rock Drill Grease

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

5.2.2 Lubrication Points and Intervals

Refer to Fig 5.2.1 and the following table for lubrication points and intervals.

Table 1 Lubrication Points and Intervals

Key Component Type Interval/Hrs Service By

1 Water Pump Oil Esso NUTO 46 8 Operator

2 Rock Oil Tank Rock Oil 8 Operator
Rock Grease Tank Rock Grease 8 Operator
3 Top Drive Oil SAE 80W-90 8 Operator
4 Torque Hub SAE 80W-90 250 Maintenance
5 Air Swivel Extreme Pressure Grease 8 Operator
6 Track Tension Extreme Pressure Grease 250 Maintenance
7 Mast Boom Fittings Extreme Pressure Grease 8 Operator
8 Cab Boom Fittings Extreme Pressure Grease 8 Operator
9 Cylinder Pin Extreme Pressure Grease 50 Operator
10 Intake Valve – Comp. Extreme Pressure Grease 8 Operator
11 Osc. Pivot – Outside Extreme Pressure Grease 8 Operator
12 Osc. Cylinder Extreme Pressure Grease 8 Operator
13 Engine Esso XD3 Extra 15W-40 8 Operator
14 Compressor Mobil Rarus SCH1024 8 Operator
15 Osc. Pivot – Inside Extreme Pressure Grease 8 Operator
16 Hydraulic Tank Esso Nuto 46 8 Operator
17 Hyd. Pump Drive Gear Case SAE 80W-90 8 Operator

113 Copyright © Sandvik Mining and Construction

 5.2.3 Automatic Machine Lubrication
The Automatic Machine Lubrication system installed in the DR uses an air operated pump. Operation is controlled
by the DR’s PLC.
The system uses 59 SL32 and 10 SL1 injectors for grease delivery to lubrication points on the unit. These injectors
are mounted together in banks of 2 to 6 depending upon location and the number of grease points in the area
where the bank is mounted. Each injector is individually set to deliver the correct amount of grease to the point
it is servicing, which depends on pin size and usage.

Refer to Fig 5.2.2 for grease injector bank location. See Fig 5.2.3 for grease injector bank.
Lubricate all points every 8 hours.
Inspect pins and/or bushings at all points marked every PM (250 hours).

On Mast

On Mast Boom

On Cab Boom

On Frame

Fig 5.2.2 Grease Injector Bank Location

114 Copyright © Sandvik Mining and Construction

 Asco Valve Grease Pump

Asco Valve allows

air to the pump…

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

Mast Boom Frame

And to the mast and cab boom…

Mast Cab Boom

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

pressure switch automatically shuts down the system.

Pressure Switch –
located on the mast

Fig 5.2.3

115 Copyright © Sandvik Mining and Construction

Panelview Settings
The settings for the Auto-Lube system are through the Panelview display.
1. Touch the Config (configuration) button on any screen to access the Password screen. Refer to Fig 5.2.4 and Fig
5.2.5.

Config button

Fig 5.2.4 Config button on drilling screen

Press the Password

button

Fig 5.2.5 Password screen

116 Copyright © Sandvik Mining and Construction

2. Press the Password button; this will bring up two options, Config Password and Admin Password. See Fig 5.2.6.

Press the Config

Password button

Fig 5.2.6 Config Password and Admin Password

3. Press the Config Password button and a keypad will appear on your screen. Enter 129124 and press the Accept
button. 129124 is the standard password. Refer to Fig 5.2.7.

Password
display

Accept button

Fig 5.2.7 Keypad

117 Copyright © Sandvik Mining and Construction

4. Several new options will appear on the left side of the screen. For the Auto-Lube settings, press the
Lube/Grease/Water button. See Fig 5.2.8.

Press the
Lube/Grease/
Water button

Fig 5.2.8 New options

5. Once inside the Lube/Grease/Water screen, you can select from three Auto-Lube options; Chassis Grease On
Time, Chassis Grease Off Time, and Chassis Grease Settings. Press the Chassis Grease Settings button to open the
Auto Cycle and the One Cycle options. See Fig 5.2.9.
Pressing the Auto-Cycle button will cause the system to run automatically with the settings provided in the Chassis
Grease On Time and the Chassis Grease Off Time screens.
Pressing the One Cycle button will cause the system to run through one cycle only. This is generally done for
troubleshooting and maintenance purposes.
Other options are available in this screen, however only the Chassis Grease On Time, Chassis Grease Off Time, and
Chassis Grease Settings buttons relate to the Auto-Lube system.

Autolube
options

Press the Chassis Grease Settings button to

open the Auto-Cycle and One Cycle options.

Fig 5.2.9 Lube/Grease/Water screen

118 Copyright © Sandvik Mining and Construction

6. Press the Chassis Grease On Time button to set the maximum on time for the Auto-Lube cycle. The keypad will
open; use it to input your settings. See Fig 5.2.10.

Press the Chassis Grease Off Time to set the off time for the Auto-Lube cycle. Again, use the keypad to input your
settings. See Fig 5.2.11.

NOTE: The Chassis Grease On Time screen and the Chassis Grease Off Time screen are virtually identical.
Ensure you are in the correct screen for the time you are setting; the active button will be outlined in green
(refer to Fig 5.2.10 and Fig 5.2.11).

Active button

Fig 5.2.10 Chassis Grease On Time screen

Active button

Fig 5.2.11 Chassis Grease Off Time screen

119 Copyright © Sandvik Mining and Construction

Alarms
The Auto-Lube system uses a pressure switch to control the length of the grease cycle. Once the pressure switch
detects the system at the pre-set pressure, the system is automatically shut down until the next cycle. If the pre-
set pressure has not been reached by the maximum on time (set in the Chassis Grease On Time screen – see Fig
5.2.10), the system will shut down and your screen will show an error (the error button will be outlined in red).
See Fig 5.2.12.

Example – the
applicable error will be
Reset button
outlined in red

Error button
outlined in red

Fig 5.2.12 Error indicated

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

120 Copyright © Sandvik Mining and Construction

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

Pressure
Gauge

Regulator

Grease Pump

Fig 5.2.13 Grease Pump Regulator and Pressure Gauge

121 Copyright © Sandvik Mining and Construction

Setting the Pressure Switch
The pressure switch for the Auto-Lube system is located at the bottom of the mast (see Fig 5.2.14).

Pressure Switch

Fig 5.2.14 Pressure Switch location

At the factory, the pressure switch is set to 2200 psi (151.7 bar) for use with Mobilith SHC 007 grease (rated for -
40°). Using thinner or thicker grease will require the pressure switch setting to be adjusted. Refer to Fig 5.2.15
and Fig 5.2.16.

Switch is provided with scale

showing both psi and bar.

Remove
protective cap

To adjust the pressure setting of the switch, turn

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

Fig 5.2.15 Step 1 Fig 5.2.16 Step 2

122 Copyright © Sandvik Mining and Construction

Adjusting the SL1 Injectors
The locknut must be loosened to make the adjustment. Turning the adjustment screw in (clockwise) will decrease
the displacement of the injector (see Fig 5.2.17).
The SL1 injectors are located on the frame (see Fig 5.2.18). These injectors are set at one turn out from the
minimal setting, which displaces approximately 0.012 in3 of grease per cycle.

Adjustment Screw
Locking Nut

Fig 5.2.17 SL1 Injectors

Fig 5.2.18 Injectors on Frame

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Adjusting the SL32 Injectors
The locknut must be loosened to make the adjustment. Turning the adjustment cap in (clockwise) will decrease
the displacement of the injector. Refer to Fig 5.2.19. Output with the adjustment cap hand tightened is 0.001
in3. Maximum output is achieved with five turns clockwise at 0.0014 in3 per turn.
The SL32 injectors are located on the mast, the mast boom, and the cab boom (see Fig 5.2.20, Fig 5.2.21, and Fig
5.2.22). These injectors are set at the maximum setting, which displaces approximately 0.008 in3 of grease per
cycle.

Adjustment Cap

Locking Nut

Fig 5.2.19 SL32 Injectors

Fig 5.2.20 Injectors on Mast Boom Fig 5.2.21 Injectors on Mast

Fig 5.2.22 Injectors on Cab Boom

124 Copyright © Sandvik Mining and Construction

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

5.3.1 Personal Protection Equipment

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

5.3.2 Overhead and Buried Utilities

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

125 Copyright © Sandvik Mining and Construction

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

5.3.4 Safety Shutdowns

Your drill is equipped with feed mounted safety shutdowns. In the event of an emergency, either cable
can be pulled to shutdown drill power and rotation instantly.

Safety Shutdown

Fig 5.3.1 Feed Mounted Safety Shutdown

126 Copyright © Sandvik Mining and Construction

Functionality
When the cable is pulled in any direction along its length, the switch is tripped and power is cut to
the electric motor on the unit. The 24 volt power to the drilling functions is cut at the same time,
providing immediate stopping of the rotation and feed. The drill will not start until the reset switch
or switches are reset.

Operator Checks and Maintenance

The Safety Shutdown System should be tested each time before drilling by the operator to ensure that
it is functioning properly. Maintenance personnel should inspect the system as part of a regular
maintenance schedule to ensure proper functionality.

1. Install spring on top eye and secure one end of cable with supplied cable clamp as shown in
Fig 5.3.2.

Fig 5.3.2 Step 1

127 Copyright © Sandvik Mining and Construction

 2. Cut the cable to length at the button in order to obtain the length necessary for correct
winding (1.5 turns minimum).

Fig 5.3.3 Step 2

3. Engage the cable on the tensioner.

Fig 5.3.4 Step 3

128 Copyright © Sandvik Mining and Construction

 4. Turn the adjustment nut clockwise until the index is in the center of the operating zone. Reset,
release, and repeat the operation. Check the position of the index and re-center if necessary. The
indicator on the left should be showing green when E-stop is set and yellow when pulled (set off).

Indexer
Reset
button

Operating zone for indexer

Fig 5.3.5 Step 4

5. To slacken the cable, push on the retainer, then loosen the nut.

Turn nut counter-

clockwise to
loosen cable.

Push retainer
outwards to allow
cable to be
loosened.

Fig 5.3.6 Step 5

129 Copyright © Sandvik Mining and Construction

 6. Remove the front cover of the new E-stop assembly to access the wiring terminals. Connect
existing wiring to terminals 21 and 22 of the new E-stop assembly. Re-install cover and gasket.

Fig 5.3.7 Step 6

130 Copyright © Sandvik Mining and Construction

 5.3.5 Safety Labels
Read and understand all warning labels before operating this equipment.
Check that path is clear and supply lines have free movement.
Place mast on T-rest before tramming.
Keep personnel away from drill.
Advise supervisor if equipment does not operate properly.

Fig 5.3.8 Warning labels inside operator’s compartment

131 Copyright © Sandvik Mining and Construction

 Be sure to read all safety labels before operating any external controls.
Keep personnel away from mast when performing mast set-up functions.

Fig 5.3.9 Safety label

Make sure personnel stay clear of all pinch points when operating equipment.
They are all clearly marked with warning labels.
Be sure to familiarize yourself and others of various pinch points around the machine. This includes
the Mast, Mast Boom, and Cab Boom.

Fig 5.3.10 Safety label, Pinch Point

132 Copyright © Sandvik Mining and Construction

 There are various Rotating Drive hazards around the machine. Watch for the label.

Fig 5.3.11 Rotating Drive Hazard (Compressor Drive)

Lift Points
Use designated lifting points.
Look for this decal on the track frame for designated lift points. There are lifting eyes
attached to the track frame for the specific purpose of lifting the drill. Improper lifting of
the equipment could cause serious personal injury and damage to the drill.

133 Copyright © Sandvik Mining and Construction

 5.3.6 General Safety and Maintenance Instructions

 Inspect hoses, whip check devices, fittings and supply lines at frequent intervals for wear or
damage indications. Repair damaged components immediately.
 Use care when mounting and dismounting from the drill. Always face the machine, use access
ladders and hand rails and maintain 3-point contact.
 Be completely familiar with operating procedures before inspecting or operating the drill. You
must read and understand all procedures described in this manual and on instruction decals
mounted on drill.
 DO NOT inspect or service any components without properly shutting down drill.
 DO NOT move the drill if it is in a potentially unstable condition or if visibility is obscured in
any way.
 Check for overhead restrictions and ground clearances before moving drill. DO NOT tram over
electrical cords or pressurized hoses or allow any vehicles to do so at any time.
 Relieve pressures in hydraulic and pneumatic systems prior to servicing.
 Check that personnel are away from drill before starting system.
 High-pressure leaks from hydraulic and pneumatic systems could result in injuries. Use
protective gear when inspecting leaks.
 Keep safety and instruction decals clean. Replace them if they are not clearly legible.
 Modifications to controls or operating procedures must be noted clearly on equipment. All
operators must be advised of changes.
 Observe all safety procedures when operating and servicing the equipment.
 Keep hands, clothing, rags and tools away from moving machinery.
 Keep shields and guards in place.
 Repair any damaged components immediately.
 Keep all non-essential personnel away from operator’s controls and work area while operating
the drill.
 Wear protective gear when operating or servicing the equipment.
 DO NOT stand under mast at any time.

134 Copyright © Sandvik Mining and Construction

Section 6 Troubleshooting
If the performance is lacking, action must be taken to correct any problems. The operator is expected
to be able to repair minor problems that are within his/her responsibilities. Any problem beyond that
must be repaired by certified maintenance people.
This section is intended for the use of the operator and a more detailed Troubleshooting Guide can be
found in the Maintenance Manual.
It is the operator's responsibility to report any apparent problems to the maintenance personnel.

6.1 Troubleshooting the Tram Drive

Crawler Does Not Run but Tramming Motors Are Operating

Check for sheared off bolts at the final drive sprocket.
Check for mud build up at the crawler tracks.
Check if the tracks are off the front idler. Loosen the track and move it back onto the wheel. Adjust
tracks to proper tension.
Check for frozen tracks and thaw the ice as required.

Crawler Does Not Move and Tramming Motor Does Not Run
Check items 1, 2, and 3 as above.
Check for damaged parts in the tram drive and the final drive gearbox.
Check if tram motor is running.

Crawler Does Not Tram Straight

Check if both torque hubs are engaged.
Perform checks as outlined in "Crawler Does Not Move".

135 Copyright © Sandvik Mining and Construction

136 Copyright © Sandvik Mining and Construction
6.2 Troubleshooting the Hydraulic System

Pump Does Not Deliver Oil

Check for proper fluid level and appropriate oil viscosity in hydraulic reservoir. In extreme cold
conditions, it may be necessary to heat the oil.
Check for proper pump rotation as marked on coupling guard.
Check for flow restriction by inspecting the suction line, strainer, and reservoir.
Check for air leaks at pump intake. Oil level must be above bottom of sight glass.
Check for sheared off pump drive shaft.
Check pump load sense line for oil flow. Test each function separately.

Pump is Running Hot

Check for any function stuck open.

Cavitation or Pump Noise

Check for air leaks at the pump intake or shaft packing. Pour oil on joints and around drive shaft then
listen for change in operation.
Check for proper oil viscosity.

Insufficient Pressure
Check for proper oil level in reservoir.

Slow Rotation at Top Drive

Check for low pump delivery (see "Pump Does Not Deliver Oil").
Check for malfunctioning of hydraulic motor.

No Rotation at Top Drive Assembly

Check for hydraulic motor malfunctioning.
Check for damaged gears or bearing.
Check for pump flow (see "Pump Does Not Deliver Oil").

137 Copyright © Sandvik Mining and Construction

 Slow or No Feed
Check for low pump delivery (see "Pump Does Not Deliver Oil").
Check for oil insufficient pressure.
Check pulldown relief valve for high setting. Pulldown pressure must be approximately 100 psi (6.9
bar) higher than holdback pressure.
Check for high setting of holdback relief valve.
Check for internal leaks in feed cylinder.
Check for binding in top drive mounting plate.

Mast Does Not Rotate

Check for restrictions in set up control valve by removing hoses.
Check for collapsed hydraulic hose to actuator.
Check main pressure in hydraulic pump.

Actuator Allows Mast to Move after Being Set

Check for bypassing of directional control valve. Inspect the valve spool.
Check for damaged counterbalance valve cartridge.

138 Copyright © Sandvik Mining and Construction

6.3 Troubleshooting the Water Injection Pump

Discharge Pressure is Too Low

Check for restrictions in suction line or relief valve.
Check for incorrect valve adjustment or damaged relief valve.
Check for low pump speed. Pump should run at 225 rpm to deliver 3 gpm (12 l/min). Adjust the
hydraulic control valve.

Cavitation Problems
Cavitation occurs in the pump when the cylinders do not fill completely with water during the suction
stroke. This condition creates a pressure pulsation, which may damage the pump and equipment if not
repaired immediately.

Check for proper diameter of water supply line. This line must be the same or larger than pump
suction plumbing.
Check for air leaking into the suction system by tightening fittings and inspecting hoses.
Check for weak or worn plunger packing. Partially worn plunger packing may draw air on the suction
stroke but these may not leak during the discharge stroke, creating a similar condition as in
cavitation.

No Water Discharge
Check for restrictions in the suction line.
Check if suction line valve is closed.

Excessive Pump Noise

Check for loose suction line connection.
Check for over speeding of pump. Reduce the flow to the hydraulic motor by adjusting the flow
control valve.

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140 Copyright © Sandvik Mining and Construction
6.4 Troubleshooting the Air Driven Oil Injection Pump

Air Motor Does Not Operate

Check for restrictions in the air supply line.

Air Seepage from Air Exhaust While Pump is Not Working

Check for leaking inlet valve.

Loss of Pressure, Volume, or Continuous Operation of Pump when Not in Normal

Use
Check for foreign particles on the piston seat or on the ball of the foot valve.
Check for damaged piston or foot valve.
Check for scorn pump tube wall and replace if required.

Excessive Amount of Air in Lubricant or Excessive Amount of Lubricant in Air

Check air leakage at gland packing, gland gasket, O-ring and U-cup packing.

NOTE: Some lubricant in the exhaust air is required.

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142 Copyright © Sandvik Mining and Construction
6.5 Troubleshooting the Air Driven Grease Injection

Air Motor Does Not Operate

Check for restrictions in the air supply line.
Check air pressure on regulator.

Grease Is Not Delivered to the Drilling Air Line

Check if grease level is low.
Check for grease output from vent when open. Prime the line if air is trapped.
Check for grease injection from the injector. Prime and adjust if required.

143 Copyright © Sandvik Mining and Construction

144 Copyright © Sandvik Mining and Construction
6.6 Troubleshooting the Air Delivery System

Air Pressure Builds too Slowly

Check for leaks in air line.
Check for restrictions in the air filter or inlet.
Check for improper operation of 3-way valve on air inlet. Ensure that the valve opens and closes fully.
Check for unloader plunger being stuck in open position.

Compressor Shuts Down with Air Demand Present

Clean compressor fluid cooler and check for poor ventilation.
Check fluid level, add fluid.
Check compressor fluid, change fluid.
Check temperature-regulating valve.
Check for a short or open circuit in discharge temperature switch. Change if discharge temperature
switch is malfunctioning.

Compressor Does Not Build-Up Full Discharge Pressure

Check for leaks in air line or open valves.
Check for restrictions in the air filter or inlet. Check the filter indicator and change element if
required.
Adjust pressure regulator and replace if necessary.

Compressor Unloading with an Excessive Pressure Build-Up

Readjust pressure-regulating valve.
Check for cracks in unloader line.
Check inlet valve.
Check for worn seals or unloader plunger.

Excessive Compressor Fluid Consumption

Check return line; clean orifice and strainer.
Check and replace separator element if necessary.
Check all pipes, connections, and components in lubrication system.

145 Copyright © Sandvik Mining and Construction

 Compressor Overheating
Clean fluid cooler core.
Change thermostat element in thermal valve.
Clean fluid cooler tubes.
Check and fill sump fluid.
Clean orifice and strainer in plugged Return line.

146 Copyright © Sandvik Mining and Construction

6.7 Troubleshooting the Hammer

Tool Does Not Start

Check for correct assembly of tool.
Check if piston is binding in the piston case or against the valves. Remove all burrs, gall marks, and
scratches.
Check for damaged check valves springs. Clean rust, burrs, and scratches from valve dart.
Check for broken foot valve assembly.

Tool Stops Operating

Check for "collared" or "bridged" hole. Lift the drill assembly off the bottom of the hole, then clean
the hole with water injection.
Check for damaged parts such as piston case, pistons, driver sub, and drill bit. Polish galled spots and
replace parts as required. Insure that the piston slides freely inside the piston case.
Check for clogged air passages in the drill bit.
Check for obstructions in the drill pipe, air hoses and top drive.

Operating Pressure is Lower than Specifications

Check if correct type of choke is installed.
Check for wear of choke. Install a smaller choke to bypass less air. If wear is excessive, replace any
worn parts.
Check for restrictions in the air delivery system.

Low Penetration Rate

Check for dull drill bit.
Check for broken or missing carbides in bit. Before using a new bit, clean out the drilling hole.
Check for excessive back pressure in the drill hole. Remove any collaring around the hole, then flush
the hole with the drill's water injection.

Galling of Internal Parts

Check for proper lubrication and adjust the oil injection rate.
Check for uneven lubrication. Repair injection pump if required.
Check for foreign material inside of tool.
Check for warpage in the piston case.

147 Copyright © Sandvik Mining and Construction

148 Copyright © Sandvik Mining and Construction
6.8 Troubleshooting the Drill Bit

Abrasive Wear
Check for worn carbides in bit. Use the proper rotation speed and drill weight to suit the drilling
conditions.

Loss of Carbides in Bit

Check the bit for loss of carbides. If any are missing and no damage is apparent, it indicates that the
piston was striking the bit while the bit was not in full contact with the rock formation. This force
tends to loosen the inserts. This condition may occur when the bit encounters broken or loose
formation.
To avoid these conditions, control the drill to minimize these heavy blows when the bit is not in full
contact.

Bit Breakage and Carbide Failure

Check for hairline cracks and breakage around the buttons in the bit. Gauge buttons are most prone to
such failures. This condition may be due to excessive weight on bit, improper rotation speed, or a
lack of sharpening the bit.
Inspect the bit face periodically and sharpen the bits when required.

Carbide Breakage
Breakage may occur due to the following:

A piece of carbide may have been left in the socket when a new bit was installed.
The carbide may have been pinched while being pushed into an undersized carbide hole.
The bit may have been pushed through a bent drill hole casing.
Excessive use between recommended sharpening periods.

NOTE: Drilling in hard formation requires more frequent sharpening.

149 Copyright © Sandvik Mining and Construction

 Uneven Wear Conditions
Uneven wear conditions may be due to the following:

Check for uneven wear spots at the gauge row buttons.

The drill bit may remove the rock chips too slowly. Increase the air volume to avoid this condition.
Check for a bent drill rod and replace as required, then check the machine set-up.
Check for bit erosion just above the gauge buttons. This creates spiraling into the rock and poor hole
cleaning. Adjusting the rotation speed and frequent hole cleaning may help but the bit should be
replaced at this time.
Check for excessive button wear or breakage indicating dry drilling conditions. The buttons may
overheat due to extreme weight on the bit or due to improper rotation speeds. Increase the water
injection and adjust the drilling speed to avoid these problems.
Check for powdery cuttings, which indicate that the bit requires sharpening.
Check for squealing of bit during drilling. The bit steel at gauge may be rubbing. Grind any projections
or deformations on the bit steel. Cutting relief slots in the bit skirt may also be helpful.
Check for shank failure due to insufficient drill weight, uneven drill feed, or excessive operating
pressure.
Operate the drill at the proper air pressure and maintain a steady down pull on the bit to prevent
shock loading.

150 Copyright © Sandvik Mining and Construction

6.9 Troubleshooting Depth Laser

Laser appears not working. No red light is coming out of aperture.

Possible causes:

Power supply could be disrupted.

Power supply wiring polarity is not in right order.
Laser unit burnt out. Short condition, Nearby Arc-welding performed, Reverse-polarity power
introduced, water short-condition in junction box …etc.

Solution suggestion:

The unit requires 24VDC power supply.

Red wire must be connected to Positive, and Green wire must be connected to Negative.
Replace the laser unit.

Laser appears working, red light is pulsing in even intervals, no output signal.
Possible causes:

Short condition cable.

Analog output wiring is reversed.
Laser beam is not reaching/reading the target correctly.

Solution suggestion:

All four connecting wires must be free of insulation damage and in no contact between them.
White wire is Analog positive output; Black wire is Analog ground output.
Laser beam must be able to reach the target surface throughout the entire travel. If laser bounces of
any surface at any time, the readings would be incorrect or zero output (Error condition for analog
output) appears. Target surface cannot be reflective or polished surface.

151 Copyright © Sandvik Mining and Construction

 Laser appears working, red light is pulsing but in un-even intervals
Possible causes:

Laser beam is not reaching/reading the target correctly.

Loose or missing target.

Solution suggestion:

Laser beam must be able to reach the target surface throughout the entire travel. If laser bounces of
any surface at any time, the readings would be incorrect or zero output (Error condition for analog
output) appears. Target surface cannot be reflective or polished surface.
Target must be “visible” to the laser beam at all the time. Surface of the target might need re-
painting. (Satin/flat finish spray paint in neutral colors are recommended such as primer gray,
primer yellow, primer red).If used in location where direct sun light is present, olive green (Military)
color is recommended. Loose target plate creates undesirable readings.

General notes:
Check for the condition of the protective lens. The glass must be free of cracks, dirt, grease and other
obstructions. Order and replace lens if required.
To test and inspect the functionality of the TERRA DP-1 laser sensor, you must have the ANALOG
output wires disconnected at the sensor closest mast junction box. First make sure that laser light is
hitting the target and flashing evenly. Use digital meter instrument to measure the 4-20 mA signal
direct from the disconnected wires. Some digital meters cannot measure this way. If so, connect the
wires back to the PLC input and install the meter leads between the black signal wire and the PLC
signal input wire.

152 Copyright © Sandvik Mining and Construction

Service and Maintenance

Terra DGS Operation Manual

153
154
TABLE OF CONTENTS
Section 1 Introduction ........................................................ 157
1.1 Features 157
Section 2 Software Removal and Installation............................. 158
2.1 Removal / Installation Procedure 158
2.2 Sensor Installation 165
Section 3 Operation ........................................................... 175
3.1 ZERO-OFFSET Calibration Procedure 182
3.2 Local and Absolute Heading Measurements 185

155
156
Section 1 Introduction
This manual will cover the installation and operation of the Terra DGS angle alignment system.

1.1 Features
Digital resolution: 0.1° for all axis.
Coverage (Axis): Three axis (Ring, Dump, Heading)
Ring axis coverage: ± 43° from vertical position.
Dump axis coverage: ± 43° from vertical position
Heading: 360° ( 0 – 359.9 )
Power rating: 24 VDC
Digital output (PLC feed): Yes
Number of sensor units: 1
Number of cables: 1
Number of central units: 1

157
Section 2 Software Removal and Installation
The Terra DGS alignment system already comes with the software pre-installed. However, the software can be
updated via a USB memory stick. Therefore, any program updates could be easily emailed, then installed on the
unit.

2.1 Removal / Installation Procedure

Open up the Terra DGS processor box that is installed in the cab.
Install the USB memory stick in a free USB slot.
Optionally, a PS2 style mouse and keyboard can be plugged into the computer main board.

Fig 1 Terra DGS Processor Box

158
 You must first access the Desktop to install the software update.
On the main menu, touch the Exit button on the screen to exit to the Desktop.

Fig 2 Main Menu

159
 First, the old software has to be removed from the system. Refer to Fig 3
To do this click on START (1) – SETTINGS (2) - CONTROL PANEL (3) – ADD REMOVE PROGRAMS (4). Look
for DTI Angle Blaster (5) in the list.
Highlight and click on the Remove button (5) to uninstall the software.
Follow any onscreen prompts.
Once the removal of the program is complete, please close ADD/ REMOVE PROGRAMS and the
CONTROL PANEL.

Fig 3

160
 Once the USB key is installed in the USB port, the following screen should pop up (see Fig 4).
Double click on the setup.exe file to start the installation.

Fig 4

161
 After double-clicking the setup.exe file, the following screen should pop up (see Fig 5).
Click on the OK button to continue.

Fig 5

162
 The following pop-up will appear (see Fig 6).
To continue the installation, click on the button red-circled in Fig 6.

Fig 6

Once the installation is finished, click on the OK button shown in Fig 7 to complete the installation.

Fig 7

163
 To start the program without rebooting, click on the DTI Angle Blaster icon in the DTI Angle Blaster
Setup folder as shown in Fig 8.

Fig 8

164
2.2 Sensor Installation
Fasten the sensor unit to the mast in the location shown in Fig 9 with the provided mounting
hardware. A drill bit and tap have been provided for making the mounting holes in the carousel
brace. Use the holes in the sensor mounting pole as a guide for marking the holes.

Fig 9

165
 2.2.1 Installing Wires in Sensor Box
Open the junction box on the sensor assembly and install the wires as shown in Fig 10.

Fig 10

Run the signal wire from the mast to the cab through the mast hose loop and into the cab.
Refer to Fig 11, Fig 12, Fig 13, Fig 14, Fig 15, and Fig 16 on the pages following.

166
 Fig 11

Fig 12

167
 Fig 13

Fig 14

168
 Fig 15

Fig 16

169
 In the cab, install the main control box in the position shown below (Fig 17) with the provided bolts.
A drill bit and tap have also been provided to make the holes to mount the box.

Fig 17

170
 Install the Sensor Cable to the port labeled Sensor on the main control box.
See Fig 18.

Fig 18

171
 Monitor power connection terminals are located inside the control box.
See Fig 19.

Fig 19

172
 Install the power wire from the main computer box into the local PLC cabinet inside the cab (see Fig
20 below).

Fig 20

173
 2.2.2 Screen Installation
Install the screen underneath the panelview monitor using the existing hardware as shown below in
Fig 21 and Fig 22. The excess strapping for the mount will have to be cut off. Plug the VGA cable
from the computer box into the back of the screen to complete the installation.

Fig 21

Fig 22

174
Section 3 Operation
To start DTI-Angleblaster guided alignment set-up procedure, use the following steps:

Use your conventional (different for each operation) method to set up for the first blast-hole.
Before drilling the first hole you must record the angle information, turn the DGS system on. The
“MASTER POWER” toggle switch is located on system’s processing unit enclosure box (see Fig 23 and
Fig 24). The box is installed inside the operator’s cabin. Wait for the system power-up sequence.

Fig 23

Fig 24

175
 Use the features on the MAIN MENU (Fig 25) to set up initial system settings. (Not all presented
options are available in basic package. Ask your dealer for details.)

IMPORTANT: Every time you wish to disconnect the main battery switch, you have to shut down
the system first (on the MAIN MENU screen, press the “SHUT DOWN” button). Power outages
could cause your system undesirable operations. Usually, system restart will fix that problem.

Fig 25 Main Menu

Press DRILLING SCREEN button to start drilling set-up (see Fig 25). The following screen (Fig 26)
appears.

Fig 26 Drilling Screen

176
 The DRILLING SCREEN shows RING and DUMP angle values. Expressed in decimal degrees, the values
are equal to angular inclination from the center of earth’s gravity for both components of
compound angle taken.
NOTE: In some cases, initial “zero-offset” calibration is required (see ZERO-OFFSET calibration
procedure). The Heading “HDNG” value is for reference only. It is not necessarily true to the
actual local compass measurements. For more detailed information, see “Local and Absolute
Heading Measurements”.
Store your first hole angle elements into the memory by pressing “SET” button (see Fig 27). The
button turns inactive to prevent accidental pressing, thereby preventing losing the original settings.
By pressing set, you are recording the angles of the first hole to be repeated for the rest of the
pattern.

Fig 27 Drilling Screen

177
 If needed, the “SET” button could be re-activated from the “MAIN MENU” by pressing the “ACTIVATE
SET POINT” button (see Fig 28 below) This will re-initialize the system to accept new set-up initial
values when accessing the drilling screen.

Fig 28 Main Menu

After drilling of the first hole, the operator moves to the location of the second hole. It is important
to remember that position of the drill body is irrelevant from this point. The mast could be moved
in any directions in order to make the quickest or the most convenient approach.

178
 Once drill rod is above the next marking, operator can press the “TARGET” button (see Fig 29). The
digital gyroscope sensing package shall reckon and calculate target angle values needed to be
taken.

Fig 29 Drilling Screen

You have to match “ACTUAL” with “TARGET” values for both RING and DUMP angles to be lined up
with the first hole.
Two visual options are offered to help the operator complete this task; one is to match ACTUAL and
TARGET numerical angle values on the DRILLING SCREEN, and second, to use dynamic graphic
gauges, located on the upper left corner of the DRILLING SCREEN. The white arm represents the
ACTUAL angle value and green arm represents the TARGET angle. Operator moves the drill mast
until gauge arms overlap.

179
 To further enhance the operation, “GAUGE ONLY VIEW” button opens the blow-up view of the
current gauge (see Fig 30 below). To return to the DRILLING SCREEN, press the “BACK” button.

Fig 30 Gauge Only View

When the gauge arms are overlapping (see Fig 31), drill mast is in the right position for drilling.

Fig 31

180
 Often, with final positioning, the very tip of the drill rod moves from the hole marking. Some
corrections are needed. Naturally, by moving the mast boom (or drill body itself) in order to
correct, drill mast azimuth changes too. That requires additional angle corrections. Operator can
use the “TARGET” button again, or activate the “AUTO TRACK” function. This function
automatically calls the “TARGET” function every second. With the “AUTO TRACK” function
activated, actual and target angles match the tip of the drill rod.
See Fig 32 below.

Fig 32

181
3.1 ZERO-OFFSET Calibration Procedure
Regular wear of the mast moving components can cause certain mast/drill-rod misalignment.
Sometimes during the operations, you should check on accuracy of the RING and DUMP angle shown.
This is also recommended procedure after the installation of the sensor.
To correct this problem, operator should use the following procedure:
Bring the mast to as accurate as possible vertical position.
Check and correct the position by using angle measuring tool.
Press Zero Offset RING and DUMP buttons (see Fig 33).

Fig 33

182
 The buttons shall turn inactive and zero values are set.
To reactivate the buttons, use “CLEAR” button (see Fig 34).

Fig 34

An “OUT OF RANGE” warning feature is built in to warn the operator that sensor is APPROACHING
(ORANGE) and/or IS OUT OF RANGE (RED).

Fig 35 Orange (Approaching out-of-range)

183
 If dump sensor is tilted over 45 degrees, red colour “RNG” error message appears for both, heading
and dump.

Fig 36 Red (Out-of-range)

If ring sensor is tilted over 45 degrees, the red colour “RNG” error message appears for both, heading
and ring.

Fig 37 RNG error message

184
3.2 Local and Absolute Heading Measurements
The DGS is equipped with precise gyroscopic sensing technology. Designed to deliver fine accuracy in
measurement of horizontal movement, the sensing head of the system is highly receptive to
changes in the intensity and direction of the earth magnetic field. Therefore, some discrepancies
between local and absolute azimuth could be present. The operator should use heading values as
reference only.
If some additional equipment is mounted around the sensor, a magnetic field disruption might occur.
To retain quality of system performance, sensor should be moved out of influence range.
Strong magnets, variable polarity magnetic field components, or large ferrous metal mass will affect
the accuracy of the sensor. The equipment such as electrical motors, generators, permanent
magnetic parts, electric coils, and solenoids radiate magnetic field strong enough to effect
accurate readings of the earth magnetic field.
When strong magnetic field is present in sensor’s vicinity, the Heading error “RNG” appears. The
sensor must be moved from the source.

Fig 38

185
186