Operation and Maintenance Manual

EVERDIGM Down The Hole Drill Rig

D700

1

Document No.: MURAUS.0007 Revision Date: 2015-01-30

FOREWORD

IMPORTANT!It is very important for you to read and understand this manual before operating and to keep the instructions provided herewith. Never fail to follow the instruction related to safety.

This manual contains instructions and information on safe and correct use of EVERDIGM crawler drill.

Please read and understand this manual before operation, inspections and maintenance of the crawler drill.

Keep this manual with your equipment all the time for your quick and easy reference, and read it regularly.

Do not operate the equipment until you have been trained in the use of all operating controls and understand the equipment operation.

Get a replacement manual from EVERDIGM dealer if you lost it.

If you transfer the equipment to the other, do transfer this manual as well.

The figures in this manual are for better understanding and may not correspond exactly to the equipment. For exact shape, refer to the parts list or ask EVERDIGM.

For the purpose of constant product improvement, some parts of this manual may be changed. If you found the parts unclear or not corresponding to the equipment, call and consult EVERDIGM dealer or authorized service center

Important information on safety is described in the safety information chapter of this book. Be familiarized with the instructions on the safe operation and observe the instructions before and during operation

Injury, death or damage caused by unauthorized product modifications and operation under unallowed application will not be responsible by EVERDIGM. Consult EVERDIGM for such modifications and applications.

Use EVERDIGM genuine parts. EVERDIGM takes no responsibility for damages caused by use of non-EVERDIGM spare parts.

For warranty, we refer you to the warranty conditions provided separately.

We always exert all our efforts for your satisfaction, and promise you quick and constant service.

We thank you for using EVERDIGM products and wish you a good luck in every your job,

Dec. 2014

EVERDIGM Corp.

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Copyright © 2014 Everdigm Corp. All rights reserved.This manual is copyrighted by Everdigm Corp. with all rights reserved in accordance with prevailing law. It is positively prohibited to use or reproduce its contents in whole or in part without prior written permission.

TABLE OF CONTENTS

1. Safety Information...............................................................................................................................................8Basic Safety Information...................................................................................................................................9

Safety decals................................................................................................................................................172. Product information..........................................................................................................................................21

Names of components....................................................................................................................................21Dimensions (unit : mm)...................................................................................................................................22Technical specifications..................................................................................................................................24Optional Equipments.......................................................................................................................................25Information for ordering parts and service...................................................................................................26

3. Towing, lifting and transporting method.........................................................................................................27Towing............................................................................................................................................................... 27Lifting................................................................................................................................................................ 28Transportation.................................................................................................................................................. 29

4. Daily check......................................................................................................................................................... 30Before operation..............................................................................................................................................31

Breakout table / Support...............................................................................................................................32Drill rig.......................................................................................................................................................... 32

Functionality test after start............................................................................................................................33Function test while drilling.............................................................................................................................33

Down-the-hole rock drill (DTH).....................................................................................................................33Display for engine, compressor and mast angle..........................................................................................34Dust collector................................................................................................................................................34Drill rig.......................................................................................................................................................... 34Pressure gauges..........................................................................................................................................35

5. Controls..............................................................................................................................................................36General.............................................................................................................................................................. 36

Travel levers.................................................................................................................................................36Engine RPM adjuster...................................................................................................................................37Cigar Jack....................................................................................................................................................37Air conditioner / Heater.................................................................................................................................38Beacon.........................................................................................................................................................38Auto rod changer and compressor controllers.............................................................................................39Operating mode selection dial switch...........................................................................................................40Auto rod changer joystick.............................................................................................................................41Break out control switches...........................................................................................................................43Rear stabilizer indicating lamp.....................................................................................................................45Support operation switches..........................................................................................................................46Hood slide and oscillation lock switches......................................................................................................47Compressor and dust collector operation switches......................................................................................48Drilling control joystick..................................................................................................................................49Emergency, Ignition, Horn, Grease switches...............................................................................................51Engine Ignition..............................................................................................................................................51Boom and mast positioning control levers....................................................................................................52Pressure controllers.....................................................................................................................................55Display monitor (Touch screen)....................................................................................................................56Date and time setting...................................................................................................................................57Compressor failure log check.......................................................................................................................58Engine failure log check...............................................................................................................................59Mast angle gauge.........................................................................................................................................60

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Dust collector air pulsing time control...........................................................................................................616. Operation............................................................................................................................................................ 62

Safety................................................................................................................................................................ 62Loading pipes on magazine...............................................................................................................................62Setting up for drilling..........................................................................................................................................66DTH hammer lubricator and air compressor pressure settings.........................................................................68

DTH hammer lubricator setting....................................................................................................................68Air compressor pressure setting...................................................................................................................72

Drilling................................................................................................................................................................ 75Drilling start..................................................................................................................................................76Check points during drilling..........................................................................................................................78Adding tubes................................................................................................................................................79Extracting tubes............................................................................................................................................80

7. Options............................................................................................................................................................... 81Centralized grease pump................................................................................................................................81

Components.................................................................................................................................................81Working principle..........................................................................................................................................82Check valve..................................................................................................................................................82Function of safety valve................................................................................................................................83Filling the pump............................................................................................................................................84Timer setting.................................................................................................................................................84Technical data..............................................................................................................................................96

8. Maintenance....................................................................................................................................................... 97Signs for outsourced components.....................................................................................................................97Dismantling and assembly.................................................................................................................................97Scrapping........................................................................................................................................................... 98Steel ropes......................................................................................................................................................... 98Tension of track................................................................................................................................................105Trucking........................................................................................................................................................... 106Rope tension adjustment.................................................................................................................................107Replacing the slide pieces in the feeder..........................................................................................................108Replacing the slide pieces in the feeder..........................................................................................................109Cleaning and replacing dust collector filters.....................................................................................................110Cleaning and replacing pre air filters................................................................................................................111Replacing engine filters....................................................................................................................................111Fuel filter replacement......................................................................................................................................112Drain water on water separator........................................................................................................................112Maintenance schedule.....................................................................................................................................113Daily maintenance............................................................................................................................................119

Engine and related parts - every day..........................................................................................................119Dust collector and receiver tank - every day..............................................................................................120Electrical system - every day......................................................................................................................121

Every 50th of engine hour.............................................................................................................................122Mast - every 50th of engine hour................................................................................................................122Hydraulic and air hoses - every 50th of engine hour..................................................................................123Tube handling system - every 50th of engine hour....................................................................................123Boom - every 50th of engine hour..............................................................................................................124Track frame - every 50th of engine hour....................................................................................................125Track frame / Rig frame - every 50th of engine hour..................................................................................126Compressor and compressor filters - every 50th of engine hour...............................................................127Engine cooler and oil cooler - every 50th engine hour...............................................................................128

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Hydraulic oil tank - every 50th engine hour................................................................................................129Cabin - every 50th engine hour..................................................................................................................130

Every 250th engine hour..................................................................................................................................131Mast - every 250th engine hour..................................................................................................................131Break out table / Support - every 250th engine hour.................................................................................132Boom - every 250th engine hour................................................................................................................133Electrical system - every 250th engine hour..............................................................................................134Track frame - every 250th engine hour......................................................................................................135Dust collector - every 250th engine hour....................................................................................................136Filters on engine, Clamps - every 250th engine hour................................................................................137Hydraulic oil tank - every 250th engine hour..............................................................................................138

Every 500th engine hour..................................................................................................................................139Break out table / Support - every 500th engine hour.................................................................................139Track frame - every 500th engine hour......................................................................................................140Engine mounting - every 500th engine hour..............................................................................................141Compressor and compressor filter - every 500th engine hour...................................................................142Air filters for engine and compressors - every 500th engine hour..............................................................143Cabin - every 500th engine hour................................................................................................................144

Every 1000th engine hour................................................................................................................................145Mast - every 1000th engine hour................................................................................................................145

Every 2000th engine hour................................................................................................................................146Dust collector filters - every 2000th engine hour........................................................................................146Receiver tank - every 2000th engine hour.................................................................................................147Hydraulic tank suction filters - every 2000th engine hour..........................................................................148

Torque table..................................................................................................................................................... 1499. Options.............................................................................................................................................................. 150

Water Injection................................................................................................................................................. 15010. Trouble shooting..............................................................................................................................................153

Engine.............................................................................................................................................................. 153Traveling......................................................................................................................................................... 154Air compressor.................................................................................................................................................155Dust collector................................................................................................................................................... 155Oil cooler.......................................................................................................................................................... 156Hydraulic cylinders...........................................................................................................................................156

* Specifications and features presented in this document are subject to change without notice.

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1. Safety Information

This manual describes the correct use of the product and basic safety instructions. Important instructions in this manual are marked with this symbol . When you see this symbol in this manual or stickers on the product, you must be alert to the possibility of personal injury or death. Be sure to observe the instruction in the safety message.

The safety messages in this manual do not describe all the possibilities that could cause personal injury, death or damage to the product. These safety messages are intended to provide basic instructions for safe operation and service.

Although this manual does not cover all the possible situations, it is the operator’s responsibility to observe the safety instructions and regulations.

Remember! Safety is up to you.

Safety Alert Symbol

The Safety Alert Symbol represents that ATTENTION is involved.

If you see the mark in this manual or on the products, never fail to read and observe the instructions for safe operation.

Signal WordsThe words “DANGER”, “WARNING”, “CAUTION” and “IMPORTANT” appeared with the above Safety Alert Symbol indicate degree of risk of hazards or unsafe practices. All four degrees of risk indicate that safety is involved. Observe precautions indicated whenever you see the Safety Alert Symbol, no matter which signal word appears next to the “Exclamation Point” symbol.

DANGER! Indicates imminent hazard of a situation that, if not avoided, is very likely to cause death or extremely serious injury. It may also be used to alert against product that may exploded or detonate if handled or treated carelessly.

WARNING! Indicates potential of a hazardous situation that, if not avoided, could result in serious injury or death. It may also be used to alert against a highly unsafe practice.

CAUTION! Indicates potential of a hazardous situation that, if not avoided, could result in minor or moderate injury. It may also be used to alert against a general unsafe practice.

IMPORTANT! Indicates potential of damages that, if not avoided, could be caused to the product or shorten the product life.

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Basic Safety InformationWARNING!The following instructions are those that should ALWAYS be observed in operation of demolition equipment.

Before operation

The operators and servicemen should read the manual and instruction and obey the rules. Neglecting safety instruction can cause death or serious injury. The carrier, hydraulic and electric requirements should be matched with manufacturer’s recommendation as described in the manual.

Improper modification can cause damage on the equipments.

Figure 1

Safety equipments are required to protect yourself.For instance, you may need:

• Hard Hat • Heavy Gloves• Safety Shoes • Eye protection• Ear Protection • Face Protection• Reflector Vests • Respirators

Figure 2

Know what conditions you will likely encounter:• Insufficient clearances• Traffic congestion• Type of surface• Steep grades• Restricted visibility

Determine appropriated warnings to be used.Know whether you will need to be escorted.

Figure 3

For emergency, fire extinguisher and first-aid kit should be kept on the operator’s cabin.

Figure 4

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Alert to others that the service or maintenance is being performed and tag operator cabin control or equipment.

Working site safetyObey the rules which recommended on the site.

Figure 6

Explosive material can be nearby you. Pay special attention to working area.

Figure 7

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Figure 5

Check the ground condition where the equipment will work.

Figure 8

Do not approach or touch high voltage cables with equipment.

It is not recommended operating machine under thunder storm.

High voltage electricity may cause personal injury or death.

Figure 10

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Travelling, Towing and LiftingOnly trained person can allow to move the equipment.

Figure 11

Do not operate boom and mast while traveling.

Locate and hold the boom with correct position before traveling.

Figure 12

Special attention is highly required for traveling when the machine is on a slope, or machine is driving uneven ground.

Figure 13

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Do not lift and move heavy objects with equipment.

Do not support whole equipment with mast.

Figure 14

Clean glasses and window before operation.

Move machine after secure the clear view.

Figure 15

Alert to others before machine being started and traveled.

Do not stay nearby equipment during operation.

Figure 16

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The equipment should be parked on secure and firmed ground.

Lock windows and cabin door before leaving from the equipment.

Figure 17

For towing and lifting equipment, consult with specialist for safety.

Figure 17

OperationMake sure the working area should be safe.

Do not stand nearby or touch equipment while it is running.

Figure 18

Protect your eyes, ears, nose and mouth from flying rock splinters and dust.

Cover your body with safety equipments

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Figure 19

Do not touch equipments with bare hands while it is running.

Never attempt touch moving parts or ride equipment while it is in motion.

Figure 20

Maintenance and serviceWait until moving parts have stopped completely.

Before service, please turn off equipments first.

Figure 21

Hydraulic lines may be pressurized.

Please be caution always. Parts or objects can be dropped suddenly.

Figure 22

Do not touch parts with bare hand until it being cooled.

Dismantling pressurized parts which is not indicated on the manual is highly prohibited.

For repairing parts, please consult with authorized Everdigm service outlet.

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Figure 23

For welding, turn off master switch and disconnect battery line in advance.

Please consult Everdigm or official service outlet for welding instruction. Failure caused by unauthorized modification can not be covered by warranty.

Figure 24

Battery can be exploded by fire and spark.

Liquid inside of battery contains highly dilute sulfuric acid solution. Do not contact with bare skin.

Figure 25

Safety decals

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2. Product informationNames of components

No. Description No Description

1 Hood 10 Guide shell

2 Support Assy 11 Boom

3 Auto rod changer 12 Track

4 Breakout table 13 Track motor

5 Rod handler 14 Dust collector

6 Rotary head 15 Pre cleaner

7 Hose reel 16 Muffler

8 Mast 17 Engine coolers (Radiator + Intercooler)

9 Cabin 18 Oil coolers (Hydraulic + Compressor)

* For more details, please refer to parts manual.

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12

3

4

5

6

7

8

9

10

11

12 13

14

15

16

1817

Dimensions (unit : mm)Coverage Areas(mm)

Mast Swing Angels

Dimensions(mm)

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Technical specificationsMODEL D700

DIMENSIONSWeight 52910 lbs (24,000 kg)

Overall height 14' (4,270 mm)Overall length 36' (11,000mm)

Transportation height 11.5' (3,500mm)Transportation width 8.2' (2,500mm)

Overall width 9.9' (3,020mm)

HOLE RANGERecommended hole diameter 4"~6.5" (102~165mm)

Hole depth 170' (52m)Tube length 20',16',13' (6m,5m,4m)

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Tube diameters 3",31/2",4" and 41/2" (76,89,102 and 114mm)DTH hammer 6",5",4"

ROTARY HEADModel ERD65 (Made by EVERDIGM)

Max RPM 53 rpmMax Torque 5,700 Nm

TRAMMINGTramming speed max 2.2 mph (3.5 km/hr)

Track oscillation 20° (F10° / R10°)Gradeability 30°

Ground clearance 1.5' (450mm)

ENGINEModel Caterpillar C13

Rated output 328 kw (440hp) / 1,800 rpmEmissons Tier 3

Fuel tank capacity 206 gal (780 liter)

COMPRESSORModel HR2.5 (GHH land)

Type Two stage screw type, high pressures 25 bar Free Air Delivery 883cfm (25 m³/min)

DUST COLLECTORSuction capacity 2472 cfm (70 m³/min)Number of filters 18

Extraction methods Auto air pulse jetPre-cleaner standard

HYDRAULIC SYSTEMVariable discharge Axial piston pump (load sensing) X 1

Fixed discharge Gear pump X 5Hydraulic oil tank capacity 98 gal (370 liter)

BOOMType Fixed boom

Length 6.3' (1,920mm)Swing angle L10° / R20°

FEEDTravel length 24.8' (7,570mm)

Feed extension 4.3' (1,300mm)Feed rate, max 217 ft/min (1.1 m/s)

Feed force, max 8,992 lbf (40 kN)Tractive pull, max 11,240 lbf (50 kN)

Swing angle L30° / R30°

CAROUSELCapacity,standard 8+1

CABINStandard Accessories Air conditioner, heater

Certificate ROPS and FOPS

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Optional Equipments

ITEM STANDARD OPTIONFixed boom O -Carousel system prepared for 1 X 6,000 mm 4" tube O 3.5",4.5" tubeTripple grouser shoes O -Work lights(LED) O -Back up alarm O -Warning horn O -Ladder(rear) OEngine Throttle adjuster O -Battery disconnect switch O -Cab O -Cab air conditioning system O -Monitoring system O -Back mirror O -Safety shutdown device on feed O -Vertical sliding dust hood O -Tube handling system O -Dust collector O -Electric Angle indicator(monitor) O -Dust pre-cleaner O -Thread greasing device O -UNF hydraulic hose couplings O -Indicator for fuel, hyd. oil and compressor oil O -Standard tool kit O -Lincoln Quicklub O -Auto lubrication system O -Two-speed traction motors O -Air-flow control switch O -Hydraulic support jack(rear) O -Break out system O -Portable fire suppression O -Test kit - OWater mist system - OElectric refueling pump - OManual pump for filling hydraulic oil - OElectrical preheating - OReversing camera - OHydraulic winch system - OCab guard - OBeacon - O

Information for ordering parts and service IMPORTANT!Parts may subject to changed for improvement. It is highly recommended ordering parts with equipment serial number.

Using non-genuine or improper parts may cause shorten equipment parts life, or serious damages on related parts.

The equipment serial number is marked with the type and serial number on the nameplate. It is important to

24

make correct reference to the serial number of the equipment when making repairs or ordering spare parts. Identification by serial number is the only proper means of maintaining and identifying parts for specific equipment.

Model Code and Serial Number ( : Number)

Model code: D700 Serial Number :

3. Towing, lifting and transporting method

DANGER!Follow local road safety regulations on weight, width and height limits. (Transporting)

Check strength of wire and hook condition and weight capacity before towing and lifting equipment.

Do not stay inside of cabin or operate equipment while it is towed, lifted and moved by trailer.

Towing

25

P N= RJ 12 5 -00 02

Before releasing brake, the equipment should be stand on flat ground, or supported firmly with high ① strength wires on uneven ground.

Dismantle plug on travel motor.② Remove shaft from travel motor.③ Assemble and tighten plug.④

Hook points▶

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< Side> < Rear >

Lifting

• Wires and blocks which support the equipment should be strong to lift it.• Mast should be firmly settled on the supporter above bonnet. No movement of mast is allowed.• Wires should not touch cabin or bonnet during lifting procedure.• Do not wind wire on hook. Wire should be securely hold.

Transportation Guideline for transportation▶

Mast should be firmly settled on the supporter above bonnet. If possible, tied up the mast with ①supporter and trailer.

Retract boom fully, and set the mast to horizontal position.② Tied up equipment with trailer bed correctly.③

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Supporting plate (Block):Width : 3600 mm or wider

Length of wires :approximately 5000 mm

1

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2

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CorrectIncorrect

3

• Width of trailer should be wider than equipment track.

• Pay special attention for driving when the equipment is loaded on the trailer.

• Fix ramps on the trailer tightly, and angle of slope need to be less than 15 degree from ground.

4. Daily check

DANGER!• Danger of moving parts

• Risk of serious personal injury

• Set all levers and switches in neutral position before preparing startup

• Perform the extra safety check without the engine running

DANGER!• The side door on the drill rig are not dimensioned for extra weight

• Standing, sitting or leaning on the side hatches can result in serious injury

• The side door must be closed when work is carried out on top of the rig

Foreword

This chapter provides instructions for daily inspection and maintenance to be carried out by the operator before each shift.

Regarding weekly inspections and other maintenance tasks, see separate instructions “ Maintenance schedules ".

Before each shift starts an extra and thorough visual safety check should be carried out in order to detect:

• Damage that could give rise to structural weakness or cracks.• Wear that could have the same consequences.• Cracks or fractures in materials or welded joints.

If the drill rig has been subjected to abnormally high stresses, vital load-bearing components may have been damaged. From a safety viewpoint, it is therefore especially important to check the following points (see illustration: Check points).

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Max 15˚

Stopper

Ramp

Figure: Check points.

Table: Check points.

1 Mast2 Feed wire3 Hose drum and sliding plate4 Cylinders5 Boom6 Cabin and controllers7 Track shoe and tension8 Rotary head and sliding plate

Before operationWARNING!• Danger of moving parts

• Can cause serious injuries

• Set all levers and switches in NEUTRAL position before startup preparations

• Carry out the procedures with the engine switched off

WARNING!• Dangerous compressed air

• Can cause serious injury

• Release the pressure in the tank before removing the filler plug

Breakout table / Support

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7

1

2

3

4

5 6

8

3

Figure: Breakout table / Support

Table: Breakout table / Support

Check point Control object Action- Grease nipples Fill grease into the grease nipples1 Cylinder, breakout table Check the torque, 600 Nm2 Cylinder, support Check the torque, 120 Nm3 Lock nut for adjusting screw,

pipe guideCheck the torque, 185 Nm

NoteIf central lubrication is installed then the function and connections must be checked.

Drill rigT able: Drill rig.

Check point Inspection InstructionsDrill rig. Visual check Check for any signs of leaks,

damage, breakage or cracks.

Functionality test after startChecks

NoteThe emergency stop buttons and wires must be checked before each shift and after tramming.

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1 2

Table: Checks

Check point Inspection InstructionEmergency stop buttons(all) and the emergency stop wire on the mast.

Function Check each emergency stop button individually. The engine must stop!Between testing each emergency stop, the previous stop must be reset before restarting the rig. For the location of the stops, see “Safety”

Display for engine and directional instruments

Visual check Check that no fault indicator symbols come on. If a fault indicator shows in the status field, stop the drill rig and rectify the fault.

Function test while drilling

Down-the-hole rock drill (DTH)

Figure: Down-the-hole rock drill.

Table: Down-the-hole rock drill.

Check point Inspection InstructionDown-the-hole rock drill (DTH)

Function Lubrication oil should seep out of the drill bit. Place a plank in front of the drill bit and activate air flushing. The plank should become oily after a short time.

Display for engine, compressor and mast angle

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Figure: Display.

Table: Display.

Check point Inspection InstructionDisplay for engine, compressor and mast angle.

Visual check Check that none of the fault indicator lamps is on. If a fault is indicated in the status bar, stop the unit and rectify the fault.

Dust collector

Table: Dust collector.

Check point Inspection InstructionDust collector. Suction ability

and filter cleaning

In case of dust formation: Check the filter in the filter holder and suction hose and also the drill- steel support's drill gasket.

Drill rig

Table: Drill rig.

Check point Inspection InstructionDrill rig. Visual check Look for any signs of leaks.

Pressure gauges

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Table: Drill rig.

Check point InstructionPercussion pressure Lubricating pressure

Check that the lubricating pressure does not deviate from the percussion pressure.

Return oil filter pressure If the needle on the pressure gauge is in the red zone, then the return oil filter must be replaced. Contact a service technician.

NoteThe pressure gauge for return oil filter pressure gives dependable readings only when the oil has reached a temperature of at least 40 °C (104 °F)

5. ControlsGeneralThe controls and gauges for operating the drill rig are located inside the operator's cab.(Equipment for filling fuel, hydraulic oil and compressor oil is located near the respective tank.)

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Symbol Description

Feed pressure

Lubricating pressure

Return oil filter pressure

Water injection pressure (Option)

Rotary head rotation pressure

Air pressure (Percussion pressure)

Travel levers

Figure: Travel levers.

A Forward B Neutral C Backward

NoteIf one crawler track is operated while the other is stationary the tracks are subjected to unnecessary stresses. This should therefore be avoided.

Engine RPM adjuster

Figure: Travel levers.

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AB

C

Symbol Description

Left track (from operator seat) control lever

Right track (from operator seat) control lever

Symbol Description

Engine RPM adjuster

Right turn : RPM increased Left turn : RPM decreased

NoteEngine RPM should be set to idle before turn off engine.When equipment is started, set idle rpm for warming up system.

Cigar Jack

Figure: Cigar Jack.

Push : Heat up Pull out : Removal

NoteBefore connecting electric device on cigar jack, check the rated capacity of the device.

Air conditioner / Heater

Figure: Air conditioner / Heater.

Fan Speed : Air flow control (0 : OFF) A / C : Cooling air in cabin Heater : Heating air in cabin

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A

B

Symbol Description

Cigar Jack

Symbol Description

Fan Speed

Air conditioner

Heater

NoteBefore staring engine, turn off air conditioner / heater

Beacon

Figure: Beacon.

A : Beacon ON B (neutral) : Beacon OFF

Auto rod changer and compressor controllers

Figure: Control panel.

Table: Check points.

1 Operating mode selection dial switch2 Auto rod changer joystick3 Rear stabilizer indicating lamp4 Break out control switches5 Hood slide and oscillation lock switches6 Support operation switches7 Compressor and dust collector operation switches8 Lamp and wiper operating switch

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BA

1

2

3

4

5

6

7

8

Symbol Description

Beacon operating switch

Operating mode selection dial switch

Figure: Air conditioner / Heater.

No working mode : Boom and arm operation Drilling mode : Drilling with air hammer Travel mode : Machine traveling

NoteWhen drilling or traveling can not be operated, check dial switch condition.

37

Symbol Description

No working mode

Drilling mode

Travel mode (Normal)

Travel mode (Fast)

Auto rod changer joystick

Figure: Auto rod changer joystick.

A : Putting rod into magazine

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A

BC

D

E Symbol Description

A : Rod in (magazine)

B: Rod out (magazine)

C : Magazine rotation (right turn)

D : Magazine rotation (left turn)

E : Rod gripper open

B : Take out rod from magazine and centering rod on the mast

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C,D : Magazine rotation

E : Rod gripper open after centering rod in the mast

NoteCheck rod and magazine condition before putting or taking out rod.

Break out control switches

40

A

Symbol Description

Lower break out cylinder closing and opening

Upper break out cylinder closing and opening

Upper break out table rotation

Figure: Break out switches.

A : Lower cylinder closing and opening

B : Upper cylinder closing and opening

41

B

D

C

C : Upper break out cylinder rotation for release rod D : Upper break out cylinder rotation for returning to original position

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Rear stabilizer indicating lamp

Figure: Rear stabilizer indicating lamp.

Lamp "ON" : Stabilizer extended Lamp :OFF" : Stabilizer folded

NoteBefore traveling, check the rear stabilizer indicating lamp, and fold stabilizer completely.

Support operation switches

Figure: Support operation switches.

A : Lower support closing B : Lower support opening

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A

B

D

C

Symbol Description

Rear stabilizer indicating lamp

Symbol Description

Upper support close and opening

Lower support close and opening

C : Upper support closing D : Upper support opening

Hood slide and oscillation lock switches

Figure: Hood slide operation switches.

A : Hood forward B : Hood backward

C : Oscillation lock "OFF" → Oscillation enabled D : Oscillation lock "ON" → Oscillation disabled

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A

B

D

C

Symbol Description

Hood slide forward & backward

Oscillation lock on & off

Figure: Oscillation.

NoteIt is recommended lock the oscillation during drilling for safety.

Compressor and dust collector operation switches

Figure: Compressor and dust collector operation switches.

A : Air suction to dust collector "ON", Reverse side "OFF" B : Pulse on dust collector "ON", Reverse side "OFF" C : Dust collector "ON", Reverse side "OFF" D : Compressor "ON", Reverse side "OFF"

NoteWhen water come out from the drilled hole, stop air suction immediately to prevent blockage of suction line and damages on dust collector filters.

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A

B

D

C

B

Symbol Description

Compressor ON / OFF switch

Dust collector ON / OFF switch

Pulse on dust collector ON / OFF switch

Suction to dust collector ON / OFF switch

Drilling control joystick

< Rear View > < Side View >

Figure: Drilling control joystick.

A : Rotary head normal rotation for drilling B : Rotary head reverse rotation for uncoupling rod

46

A B C D

A

B

C

D

E

F G

E

F

Symbol Description

Rotary head rotation (Normal rotation)

Rod coupling (with "G" button)

Rotary head rotation (Reverse rotation)

Rod uncoupling (with "G" button)

Feed backward

Fast feed backward (with "G" button)

Feed forward

Fast feed forward (with "G" button)

Low air pressure to percussion.

High air pressureTo percussion

Function switch

C : Feed backward D : Feed forward

E : Low air pressure to percussion F : High air pressure to percussion

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G : Function button (Fast feed, Rotary head rotation speed control)

Emergency, Ignition, Horn, Grease switches

Figure: Emergency, Ignition, Horn, Grease switches.

A : Emergency switch for stop and release B : Engine ignition switch by key C : Horn for alarm D : Grease for rod thread

Engine Ignition

48

A

B

C

D

Symbol Description

Emergency Stop

Engine ignition switch by key

Horn switch

Grease switch

Temperature(ambient) Instruction

15˚C or aboveTurn starter key and hold for 3 seconds "ON" position.Start engine and release key after starting

0˚C or below Hold starter key "ON" position for 10 seconds before staring engine.

Figure: Engine ignition switch.The followings are the conditions which engine can not be started to protect systems.A : Emergency switch is activatedB : Operating mode selection dial switch is not positioned to "OFF"C : A operating switch is turned OND : Remained air pressure on receiver tank.

IMPORTANT!Do not set high engine RPM immediately after starting engine. Warming up the engine and equipment properly before operation.

Boom and mast positioning control levers

Figure: Boom and mast positioning control levers.

A : Mast swing and mast tilt operation lever

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AB

D

C

Symbol Description

Mast swing

Mast tilt

Boom lift

Boom swing

Oscillation

Mast lift

Stabilizer operation

Winch operation

Figure: Mast tilt.

Figure: Mast swing.

B : Boom lift and boom swing operation lever

Figure: Boom lift.

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Figure: Boom swing.

C : Oscillation and mast lift lever

Figure: Oscillation.

Figure: Mast lift.

D : Rear stabilizer and winch operation lever

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Figure: Rear stabilizer and winch operation.

NoteObserve mast and boom movement always. It may hit cabin or other object around equipment.

Pressure controllers

Figure: Pressure controllers.

A : Feed pressure control under high air percussion pressure B : Feed pressure control under Low air percussion pressure C : Rotary head rotation pressure control D : Feed pressure adjuster for rod coupling E : Feed pressure adjuster for rod uncoupling F : Air pressure control

52

A

D

FE

B

C

Symbol Description

Feed pressure adjuster(under high air pressure)

Feed pressure adjuster(under low air pressure)

Rotation pressure adjuster

Rod coupling pressure adjuster

Rod uncoupling pressure adjuster

Air pressure control

NoteRequired pressure can be different according to rock condition or operator skill. Achieve optimal pressure setting during drilling.

Display monitor (Touch screen)

< Initial screen >

53

A

Symbol Description

Percussion air pressure

* High / Low : Pressure status

Rotary head rotation pressure

Feed pressure

*Anti jamming : Anti jamming is activated.

Engine RPM

Coolant temperature

Compressor oil temperature

Hydraulic oil temperature

Fuel level indicator

E : Empty, F : Full

Compressor status

* Green : Normal* Red : Failure detected

Engine and system status

* Green : Normal* Red : Failure detected

Mast Angle gauge

Figure: Display monitor (Touch screen).

A : Current date and time / Touch : Time setting B : Compressor status / Touch : Detail status and failure log check C : Engine and system status / Touch : Detail status and failure log check D : Touch : Mast angle check

Date and time setting

54

BC D

Touch

Figure: Date and time setting menu.

1. Touch the current date and time for resetting 2. Input correct date and time 3. Touch "SAVE" and finish setting

NoteDrill rig may be located in different time zone. When drill is arrived in the job site, set the local date and time.

Compressor failure log check

55

Touch

Figure: Compressor failure log check menu.

1. Touch "COMP" to check current status. 2. Touch "LIST" to see the previous failure log. 3. Touch "BACK" to return previous page.

NoteIt is not allowed to 'SETTING' the conditions by operator own decision. It is already set by EVERDIGM.

Engine failure log check

56

Touch

Figure: Engine failure log check menu.

1. Touch "RIG" to check current status of engine diagnosis. 2. Touch "LIST" to see the previous failure log. 3. Touch "BACK" to return previous page.

Mast angle gauge

57

Touch

Figure: Mast angle menu.

1. Touch "ANGLE" to see the current drilling angle. 2. Adjust mast to reach designated drilling angle. 3. Touch "BACK" to return previous page.

Dust collector air pulsing time control

Figure: Dust collector air pulsing time control.

1. Air pulse time (50 mS ~ 500 mS) 2. Dwell Time (Air pulse time interval, 3S ~ 12S) 3. Factory Setting

- Pulse time : 500 mS (Range 9)- Dwell time : 3 S (Range 00

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* S = Seconds

6. OperationSafety

WARNING!• May cause severe personal injury

• Ensure that unauthorised personnel are not within the working area

• Do not approach the area surrounding rod/pipe gripper or carousel

• Always use lifting assistance when loading and unloading the carousel

• Do not approach the area surrounding rod/pipe when the drill-steel support is closed

during loading

• Two persons are required to load and unload the carousel

• Follow the instructions carefully

Loading pipes on magazine 1. Lower mast to put pipes on magazine. Note that the pipe is heavy, and it is highly recommend carrying pipes

carefully.

59

Figure: Levers for positioning / mast position for filling pipes on magazine.

2. Move rod handling arm into the magazine.

Figure: Auto rod changer joystick and arm position

3. Move rotary head to lowest position, and connect pipe by rotation.

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Figure: Pipe connection and drilling joystick control lever

4. Move rotary head to backward fully, and grab pipe with rod handler. Then, rotate rotary head to release pipe.

Figure: Grab pipe and release pipe from rotary head

4. Putting rod on the magazine and open the gripper

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Figure: Putting pipe on magazine

5. Rotate magazine and repeat the procedure until the desired number of pipes are installed on the magazine.

Figure: Magazine rotation

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Setting up for drilling

WARNING!• Risk of tipping

• May cause severe personal injury and damage to property

• Keep the track oscillation cylinders locked

• Do not lower the hydraulic jack too much, the rear sections of the track frames must stand

firmly against the ground

• The angles for Downward/Upward/Lateral, specified in Technical data, must NOT be

combined

• Do not exceed the tilt angles, see Technical data

• Note the gradient meters' values

• Never operate the drill rig from the downhill side

• Ensure that unauthorised personnel are not within the working area

1. Move the machine and placing mast to designated drilling angle.

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2. Lock oscillation

Figure: Oscillation lock

3. Lower rear stabilizer, and put it firmly on the ground without lifting the drill rig.

Figure: Stabilizer operation

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DTH hammer lubricator and air compressor pressure settings

DTH hammer lubricator setting

1. Open the electric main control panel and find timer relay as shown below drawing.

Figure: Main control panel and timer relay

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IMPORTANT!Improper lubrication on DTH hammer can cause damage, failure and wear of hammer components.

Adjust lubrication oil amount according to hammer size and application with timer interval setting.

2. Adjust lubrication oil amount with timer interval.

* Recommended lubrication oil amount. - 4" (inch) hammer : 0.4 liter per hour - 5" (inch) hammer : 0.5 liter per hour - 6" (inch) hammer : 0.7 liter per hour

NoteRefer to the DTH hammer operation and manual for setting correct lubrication oil amount.

* D700 Lubricator factory setting - 1 cc lubrication oil per 1 pulse time - 1 pulse per every seconds on timer interval (when timer interval is set to 1 - 10s) - Factory timer interval setting : 5

Under above condition, 12cc / min (0.7 liter / hr) lubrication oil is come out with air.

For water injection operation, the lubricants should be increased around 2 time more than normal operation. For more details, refer to " Water Injection" in Chap 9.

3. Refilling lubrication oilWhen "Low lubrication oil level" is shown in the monitor, check and refill the lubrication oil on the lubrication oil tank.

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A

B

C

NoteDo not change timer range or timer function by own decision.Only timer interval setting change can be allowed for efficient lubrication of DTH hammer.

Description

ATimer range setting(Do not adjust it)Factory setting : 1 - 10S

B Timer interval settingFactory setting : 5

CTimer function setting(Do not adjust it.)Factory setting : Di

Figure: Low lubrication oil level warning in monitor.

Figure: Lubrication oil tank.

4. Lubrication oil specification The following is the recommended specification of lubrication oil according to ambient temperature.

5. Lubrication oil output check Before operation, check output lubrication oil with air. Place a plate and blow air with machine. Then check plate if oil is come out with air correctly.

Note that moisture may come out with air in humidity climate. Do not confuse with oil and moisture.

Figure: Lubrication oil output check

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Temperature(ambient) ˚C Viscosity grade (ISO3448)

-30 ~ 0 VG 32 ~ 68

-10 ~ 20 VG 68 ~ 100.

10 ~ 50 VG 100 ~ 150

6. When lubrication tank is empty It is highly recommended checking and filling up DTH hammer lubricants before operation.

When DTH hammer lubricant on the tank is empty, it is important to fill up empty area immediately for supply lubrications continuously. Proceed followings when oil is empty on the lubricator tank.

① Fill up lubrication oil on the tank

② Loose nut and loose screw (1) around 1 turn on lubricator pump. Then operate air switch on the control joystick for 10 seconds. Then close screw and tighten nut.

Figure: Lubricator pump

③ Set timer range to 0.1 - 1 s on timer relay. Then, operate air switch on the control joystick until oil is come out with airWhen oil is come out with air, then set the timer range to 1-10s.

Figure: Timer range in timer relay.

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1

Air compressor pressure setting

IMPORTANT!Air compressor pressures are already set in Everdigm factory.

The measured pressures may different according to DTH hammer model and specification.

Improper pressure settings will cause low efficiency of DTH hammer. Check the required air pressure of DTH hammer, and set the pressure correctly to optimize drilling condition.

1. Turn on the engine. Then wait and check the air pressure on receiver tank if pressure is set to 7 ~ 8 bar.

2. Disconnect solenoid two electric lines connections(marked "1" and "2") with screw driver from air valve block

Figure: Air valve block

3. Loose valves (marked "3" and "4") on pressure control valve by 2 ~ 4 turning to counterclockwise.

Figure: Air pressure control valve

4. Turn on air compressor switch and wait until pressure is charged.

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1

2

4

3

Figure: Compressor switch

5. Check and adjust pressure by turning pressure adjuster (marked "3"), and set the pressure to 15 bar. To increase pressure, turn the valve to clockwise. To decrease pressure, turn the valve to counterclockwise.After pressure adjustment, fix the valve by tightening fixing nut (marked "5") on the pressure adjuster.

Figure: Pressure adjuster

6. After adjusting the low air pressure, connect electric line marked "1" with screw driver.

Figure: Air valve block

7. Operate air high switch and check the air pressure on receiver tank.

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5

1

Figure: Air high switch

8. Check and adjust pressure by turning pressure adjuster (marked "4"), and set the pressure to 23 bar. To increase pressure, turn the valve to clockwise. To decrease pressure, turn the valve to counterclockwise.After pressure adjustment, fix the valve by tightening fixing nut (marked "6") on the pressure adjuster.

Figure: Pressure adjuster

9. After adjusting the high air pressure, turn off air high switch on the joystick. Then connect electric line marked "2" with screw driver.

Figure: Air valve block

10. Find air regulator on dust collector and check the pressure. Then adjust pressure to 7 bar by turning lever (marked 7).

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6

2

Figure: Air regulator

11. Install DTH hammer and check the air pressure on Low and High air mode. The measured pressure during DTH hammer operation may different with original settings according to hammer specification and models.

Drilling

Drilling start

1. Turn operating mode selection dial switch to drilling mode.

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7

Figure: Operating mode selection switch

2. Turn on air compressor, dust collector and pulse switch. Wait until compressor receiver tank is fully charged.

Figure: Compressor, Dust collector and Pulse operating switch

3. Put DTH hammer on the ground by feed operation.

4. Close support slightly to hold hammer and rod.

Figure: Support operation

5. Run DTH hammer by pushing low air pressure switch, and check DTH hammer operating condition.

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Figure: Low air pressure switch

6. Operate drill control joystick for rotation and feed (forward) of DTH hammer.

Figure: Drill control joystick

7. High percussion by high air pressure switch can be started once homogenous rock has been reached. When rock has uneven condition, change air pressure to low and check drilling condition.

Figure: High air pressure switch

8. Adjust pressures to optimize drilling condition.

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Figure: Pressure controllers

9. Cover drilling hole with hood. Raise the hood from time to time to check that the drilling hole.

Figure: Hood slide

Check points during drillingMonitoring the drilling performance and pay attention to the points describes below. When anything out of standard condition is noticed, stop drilling and clear up the trouble, or ask service personnel to investigate.Check lubrication pressure and amount during drilling.

1. Oil or air leakage from rotation unit (rotary head).

2. Check hydraulic and air pressures through gauges inside of cabin. When abnormal pressure is noticed, stop drilling immediately, and investigate the cause.

3. Check warning signals on the monitor (pressure, temperature and etc.)

4. If water come out from the drilled hole, operate 'Stop Suction' switch to prevent damages on the filters and suction line.

Adding tubes

1. Stop operation of feed, rotation and air supply to DTH hammer.

2. Locate tube joint area between break out table jaws, and hold tube and sub on the rotation unit by jaws.

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Figure: Break out table jaw operation

3. Rotate break out table and release rotary head sub and tube.

4. Rotate rotary head to release sub from tube completely.

5. Move the feed to backward to allow tube from magazine.

6. Operate joystick to move tube from magazine to rotation unit.

Figure: Rod out operation

7. Tight tube and sub on rotary head by rotation operation. 8. Move feed and tight tubes with rotary head rotation operation.

9. Open break out jaw after tightening tubes.

Extracting tubes

1. Stop operation of feed, rotation and air supply to DTH hammer.

2. Locate tube joint area between break out table jaws, and hold tube and sub on the rotation unit by jaws.

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Figure: Break out table jaw operation

3. Rotate break out table and release rotary head sub and tube.

4. When rotary head sub and tube is loosen a little bit by break out table, move rotary head feed backward, and hold tube with gripper.

5. Rotate rotary head to unthread tube from the sub.

6. Operate joystick to move tube from rotation unit to magazine..

Figure: Rod in operation

7. Move rotation unit feed to forward to hold next tube from the ground. 8. Tighten tube and move feed backward, then follow guideline describes 2 ~ 7 on above.

9. Note that tube or DTH hammer can be dropped inside of drilled hole by wrong operation.

7. OptionsCentralized grease pump

Centralized grease pump is adapted as option to supply grease on various greasing points automatically.Lincoln grease pump is a compact multi-line pump consisting of reservoir with agitator, pump housing with built-in motor, timer, pump element, safety valve and filler nipple.

Components

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Figure: Centralized grease pump.

A : Reservoir B : Pump element C : Safety valve D : Filler nipple

Working principleElectric motor rotate eccentric shaft, and pump is moving forward and backward by spring force. Piston draw grease from reservoir, and deliver grease to distributor.

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A

B

C

D

A B C D A B C D

Figure: Pump element.

A : Eccentric shaft B : Piston C : Return spring D : Check valve

Check valveEnsures that the pump element functions as it should. Prevent lubricant from returning to the pump housing or reservoir.

Figure: Hydraulic diagram for the pump.

A : Reservoir with agitator

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BC

D

A

B

C

D

B : Pump C : Check valve D : Safety valve R : Return line P : Pressure line

Function of safety valveThe safety valve limits pressure in the system by opening at 350 bar hydraulic pressure. Lubricant leaking from the safety valve is an indication of a blockage in the system.

Filling the pumpFill grease up to the "MAX" mark on the reservoir by using the filler nipple. Recommended grease specification is NLGI 2.

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Timer setting

Table : Interval time

Range Interval

Hours 1 to 15 hours

Table : Propagation time

Range Interval

Minutes 2 to 30 minutes

Figure : Timer adjusterInterval time can be adjusted in 15 steps with the blue rotary switch. Propagation time can be adjusted in 15 steps with red rotary switch.

Table : Interval time setting

Switch position 1 2 3 4 5 6 7 8 9

Hours 1 2 3 4 5 6 7 8 9

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Switch position A B C D E F

Hours 10 11 12 13 14 15

Table : Propagation time setting

Switch position 1 2 3 4 5 6 7 8 9

Minutes 2 4 6 8 10 12 14 16 18

Switch position A B C D E F

Minutes 20 22 24 26 28 30

Table : Everdigm factory setting - Interval time : 4 hour - Propagation time : 2 minutes

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Figure: Timer LEDs and rotary switches. A : Battery diode B : Rotary switch for interval time C : Rotary switch for propagation time D : Motor diode E : Push button for test / extra lubrication

Figure: Timer LEDs and rotary switches. A : Earth B : Ignition switch C : Motor D : Low level indication E : Level indication F : Extra lubrication G : Lamp in push button

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A B C DE

A B C D E F G

Figure: Electric circuit. A : Timer B : Pump housing C : Terminal D : Cable contact E1 : Pump without extra push button E2 : Pump with extra push button F : Ignition switch G : Fuse H : Cable, black I : Cable, brown K : Terminal 2 L : Cable contact M : Push button with lamp

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Figure: Progressive lubricant distributor.

What is a progressive lubricant distributor?

The word “progressive” comes from the special way this type of lubricant distributor works, e.g. it is the lubricant that is pressurized and then drives the pistons inside the distributor. The pistons move in a predetermined manner and this pattern of movement is repeated over and over again. Each piston must complete its movement before the next piston can move, regardless of whether the flow of lubricant is constant or irregular. The pistons are dependent on one another and it is technically impossible for a connected lubrication point to be skipped.

Progressive lubricant distributor, type SSV• Have pistons as the only moving part, i.e. no springs, balls or gaskets that can break• Reliably distributes lubricant to the connected lubrication points• Gives 0.2 cm 3 lubricant per output and piston stroke• Can be plugged to obtain double, triple, etc. the amount per output (see “Plugging the outlet”)• Can have 6 to 22 outputs• Makes it possible to connect several lubrication points to one lubrication area.

Flow in the distributor• The following 5 illustrations show what happens inside the distributor step by step.

Note)For purposes of simplification, lubricant distribution to outputs 2, 7, 5, 3 and 1 are shown. The other

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outputs receive their amounts in order, but are not shown here.

Step 1• Lubricant enters the distributor and then follows the direction of the arrow to the right-hand end of

piston A • The pressure of the lubricant presses piston A to the left. The lubricant in front of the left-hand end of

the piston is pressed out through output 2.

Figure: Step 1. D-Output 2.

Step 2• When piston A has reached its left end position, a channel opens to the right-hand end of piston B.• The lubricant moves in the direction of the arrow and moves piston B to the left. The lubricant in front of the left-hand end is pressed out through output 7.

Figure: Step 2, A=output 7.

Step 3• When piston B has reached its left end position, a channel opens to the right-hand end of piston C• The lubricant moves in the direction of the arrow and moves piston C to the left. The lubricant in front of the left-hand end is pressed out through output 5.

86

Figure: Step 3 B=output 5.

Step 4• The channel to the right-hand end of piston D is now open.• The lubricant presses piston D to the left. The lubricant in front of the left-hand end of the piston is

pressed out through output 3.

Figure: Step 4, D=output 1.

Step 5• Piston D opens the channel to the left-hand side of piston A.• The lubricant presses the piston to the right. The lubricant in front of the piston is pressed out through

output 1.• Pistons B to D are then moved in order from left to right.• A complete lubrication cycle has now been completed and will begin again.

Figure: Step 5, D=output 1.

When lubricant flow has been interrupted

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• The pistons stop• No lubricant reaches the lubrication points• When the flow starts again, the pistons begin to move from the exact spot they stopped.

Functionality check• The primary distributor (Fig. 23) and secondary distributors are connected with main lines (G). The

pump is connected to the primary distributor.• If a piston in any of the blocks gets jammed or if an output is blocked, the lubricant distributor will

stop.• Thanks to the design of the system, a blockage in the primary distributor will propagate and the entire

lubrication system will stop (all pistons in all distributors stand still).• The simple design also ensures that a blocked lubrication point is never forgotten.• Since the pump is still pumping out lubricant and the distributors have stopped, the lubricant must go

somewhere. Pressure in the system increases and the block becomes apparent when lubricant leaks from the safety valve.

Figure: Example of lubrication system. A : Safety valve B : Primary distributor SSV 6 C : Secondary distributor SSV 8 D : Secondary distributor SSV 6 E : Secondary hose F : Secondary distributor SSV 12 G : Primary hose

• Lubricant distributors can be equipped with an indicator pin. The pin is secured in the end of a piston and follows its movements.

• When the system is blocked, the pin also stops.

88

Figure: Indicator pin.

• The pump's safety valve is used to check the entire lubrication system. If the pump is working and lubricant leaks from the valve, there is a stop in the system.

Figure: Safety valve.

Plugging the outlet

89

Figure: Outlet couplings and plugs. 1 : Inlet coupling 2 : Channel from piston 3 : Plug, screwed in 4 : Plug, for piston 5 : Check valve kit 6 : Brass cone 7 : Valve body 8 : Ferrule 9 : Coupling nut 10 : Connection channel 11 : Copper washer 12 : Plug

• The amount of lubricant can be increased by plugging outputs.• Set a complete outlet coupling in each output that is to be used.• The plug (4) that sits at the piston is recognizable by its beveled edge. It must never be unscrewed.• Never replace plug (12) with plug (4).

NoteThe valve body (7) must be used together with the brass cone (6).

• The brass cone (6) closes the connection channel (10) and must never be used together with plug (12).

NoteFor distributors SSV 6 to SSV 12, you must never use plugs in outputs 1 and/or 2. For distributors SSV 14 to SSV 22, you must never use plugs in the outputs with the highest number. Should one of these outputs be plugged, the entire distributor will become blocked.

90

Figure: Outlet couplings and plugs. 1 : Inlet coupling 2 : Channel from piston 3 : Plug, screwed in 4 : Plug, for piston 5 : Valve body 6 : Connection channel 7 : Plug 8 : Copper washer

Single amount of lubricant• The single amount of lubricant is the amount that comes from one output with one piston stroke. The

amount is 0.2 cm 3

Outputs linked in series• If any of the lubrication points require more lubricant, one or more outputs can be plugged.• In Fig. 28, output 10 is plugged. The amount of lubricant that should have come out here goes

through the connection channel and out through output 8.• Total amount in output 8:

- output 8's “own” amount- plus the amount from output 10

• Outputs that are above the output from which lubricant comes out, etc. See next figure outputs 1, 3 and 5.

Figure: Single, double and triple amount of lubricant for distributor SSV 10.

Technical data

Pump QUICKLUB 203 CS-ZSOperating temperature -25 °C to 70 °C

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Number of outputs 1, 2 or 3Reservoir size 2 LFilling up Via filler nipple or cartridgeLubricant Grease up to NLGI2

EngineMotor DC motor geared down (radio interference suppressed)Voltage 12V DC or 24V DCMax. current consumption 12V 6.5A

24V 3AMotor speed 17rpmProtective class IP54Output transistor 5A short-circuit protectionProtected from faulty polarisation: counter-voltage polarisedTemperature range -30 °C to 85 °C

Pump elementPiston diameter, standard K6 6 mmAmount of lubrication* approx. 2.8 cm 3 /min

Note* The amount of lubrication is based on NLGI 2 grease at a temperature of +20 °C, counter pressure 100 bar and a voltage of 12/24 V. At other temperatures and pressures the amount of lubrication will be slightly different. The design of the lubrication system is based on the above.

Piston diameter, K5 7 mmAmount of lubrication approx. 4 cm 3 /minMax. working pressure 350 barConnection thread G 1/4”Suitable hose diameter 6 mm

Electronic timer in pump model E1 or E2 QUICKLUB 203CS-ZS, ZS/ADRNoteThis electronic timer is polarized.

Nominal voltage 12/24 V DCWorking voltage

12V 9V - 15Vmax. 18V

24V 18V - 30VProtective class IP66Ripple in relation to voltage 5% acc. as per DIN 41755

8. Maintenance

DANGER!It is highly recommended turning off the engine before performing maintenance. Do not approach on the moving parts. It may cause serious injury or death.

Some parts may be hot after turn off the engine. Cool down equipment sufficiently in the air before maintenance.

CAUTION!Do not try to replace or repair parts which is not described in this manual. Improper machine

92

condition or failure is detected, contact to official Everdigm distributor for repairing.

Register the engine warranty to official engine service which is located nearest by machine. Engine warranty registration should be done before 200 engine hour on tachometer.

IMPORTANT!Check and replace parts periodically as guided in this Chapter. Lack of maintenance on the equipment may lead failures or shorten the life of related parts.

Use only genuine Everdigm parts.

Use recommended oils and grease. Do not mix oil.

Use high grade diesel which is recommended by engine manufacturers.

Signs for outsourced componentsSigns are placed on the larger components of the drill rig. When ordering spare parts or making enquiries in regard to the drill rig, the type designation and serial number must always be stated. Type designations and serial numbers are specified in a name plate or shipping documents. Spare parts can always be ordered through Everdigm.

Dismantling and assemblyBefore transporting in shafts or the like it may be necessary to fully or partially dismantle the drill rig. Observe the following when dismantling, lifting and assembling:

• Before dismantling, hose the entire rig clean with water and/or detergent containing a grease solvent.• Observe the strictest cleanliness when dismantling hydraulic, compressed air and water flushing hoses. Immediately plug all hoses, nipples and hydraulic oil pipes, or seal and protect them from dirt in some other suitable way.• Mark hoses, pipes and other connections, where this has not already been done, to make

reassembly easier and prevent mix-ups.• Use properly secured lifting tackle of generous dimensions.

NoteWhen the drill rig is scrapped, all materials that are harmful to the environment must be disposed of in a manner prescribed by the authorities.

ScrappingWhen the entire drill rig or part of the rig is to be scrapped, local regulations in force regarding handling, waste management, recycling and destruction must be followed.Collect and dispose of:

• Rest oil and oil spill• Oil waste such as filters• Rest fuel and fuel spill• Rest grease and grease spill• Batteries• Discarded refrigerant, air conditioning• Chemicals such as flushing additives, other additives and coolants• Metals, e.g. steel and aluminum (metals that are recyclable)• Plastics and rubber (often marked in various classifications for recycling)• Electrical components such as cables, electronics

Steel ropes

Scrapping Guideline for steel ropes

93

Steel ropes should be scrapped when they display any of the following:• Wire break at attachment• Occurrence of strand breaks• Concentrations of wire breaks• Effects of heat• Occurrence of wire breaks due to operating time.• Reduced elasticity• Decreased rope diameter• Certain number and type of wire breaks• Corrosion• Surface wear• Deformation of the rope• Permanent extension of the rope

Wire break at rope attachmentIf there are strand breaks, the rope must be scrapped.

Occurrence of strand breaksIf there are strand breaks, the rope must be scrapped.

Concentrations of wire breaksIf there are concentrations of rope breaks, the rope must be scrapped.If such concentrations occur within a length less than 60 cm or on an individual strand, the rope must be scrapped.If this is the case, the rope must be scrapped even if the number of wire breaks is less than the maximum specified in the table.

Effects of heatRopes exposed to extreme heat must be scrapped. The effects of heat can be established through annealing color.

Occurrence of wire breaks due to operating timeWire breaks occur first after a certain operating time depending on operating conditions and subsequently occur more frequently.If this is the case, the number of wire breaks in relation to the operating time should be determined and documented.This can then be used to estimate the future increase in wire breaks and the foreseeable time point for scrapping.

Reduced elasticityUnder certain conditions, the rope loses its elasticity. Reduced elasticity is difficult to detect. If in doubt, consult a specialist.If the rope has lost elasticity, the following characteristics usually appear:

• Decrease in rope diameter• Extension of the rope• No gap between individual wires and between the strands. This is caused by its components being pressed together.• Fine, brown dust inside the strands.• Even if there are no visible wire breaks, the rope is noticeably stiffer.• The rope's diameter decreases more quickly than during normal wear of the individual rope strands.

Reduced elasticity can lead to sudden rope breaks during heavy loads. The rope should be scrapped.

Decrease in rope diameterDecrease in rope diameter through material fatigue in the rope can have the following causes:

• Inner surface wear and surface wear nicks

94

• Inner surface wear through friction between the strands and wires in the rope• Fatigue of plastic core• Break in steel core• Break in inner layer in multi-strand rope

If the rope's diameter decreases more than 10% in relation to the nominal diameter of the rope, it must be scrapped. It should be scrapped even if no wire breaks have been detected.

Certain number and type of wire breaksThe rope drums are designed in such a way that the ropes do not have an unlimited service life. Wire breaks can therefore occur during operation.On 6 and 8-strand ropes, wire breaks are primarily superficial.The ropes should be scrapped if the number of wire breaks specified in the table have been detected.

Table.

Number of load-bearing wires in the outer strand 1

n

Number of visible wire breaks 2 that require scrappingMachine groups M1 and M2Cross lay Equal layOver a length of Over a length of6d 30d 6d 30d

201 - 220 9 18 4 9221 - 240 10 19 5 10

d = Rope diameter1 = Filler wire is not considered load-bearing.In ropes with several layers of strands, only the outer, visible layer is considered.In ropes with steel cores, the core is regarded as an inner strand and is not included.2 = In the event of a wire break, two ends can be visible.

CorrosionCorrosion is especially problematic in marine environments and in areas where the air is polluted by industrial emissions.Corrosion can reduce operational strength through rust spots and static tensile strength through a reduction in the cross section of the metallic rope.Severe corrosion can reduce elasticity.

Outer corrosion: Outer corrosion can be easily detected through visual examination.

Inner corrosion: Inner corrosion is more difficult to detect. Inner corrosion is characterized by the following:

• Absence of gap between the strands in the outer layer of the rope, often in combination with wire breaks in the strands.• The rope diameter varies.

The parts of the rope that are bent over discs usually have a decreased diameter. At any sign of corrosion, the rope should be checked by an authorized person. If inner corrosion is detected, the rope must be scrapped.

CorrosionInner surface wear is caused by friction between the wires and the strands.

95

Outer surface wear is caused by friction between the rope drums (rolls) and the rope under pressure (acceleration and braking). Outer surface wear is visible through the formation of reflected images on the outer wires.Surface wear is increased through faulty or no lubrication, thereby increasing the effect of dirt and dust.Surface wear reduces static tensile strength through reduction in the rope's metallic cross section and dynamic strength through surface wear nicks.If the rope's diameter decreases more than 7% in relation to the nominal diameter of the rope, it must be scrapped.It should then be scrapped even if no wire breaks have been detected.

Deformation of the ropeDeformations are characterized by visible deviations from the rope's normal form that lead to uneven voltage distribution in the rope.

The following are the primary types of deformations:• Wire displacement• Strand displacement• Waviness• Cracking• Kinks• Flattening• Local rope diameter decrease• Local rope diameter increase• Basket formation

Wire displacementIndividual wires or wire groups stick out like hairpins on the side facing away from the drum. Wire displacement is caused by spasmodic loads.

Ropes with wire displacement must be scrapped.

Figure: Example of wire displacement

Strand displacement Strand displacement, which often occurs in conjunction with basket formation, is when the steel core pushes out between the strands.Ropes with strand displacement must be scrapped.

WavinessWaviness is a deformation that gives the rope's longitudinal axis a helical curve. Even though wave formation does not necessarily cause weakening of the rope, such a deformation can cause a pulsing movement.

96

After a long time of operation, this can increase surface wear and wire breaks. In the event of waviness, the rope should be scrapped ifd 1 > 4d/3

d = Rope's nominal diameter

d 1 = Diameter of the circle that would be formed if the rope were not deformed. Check over a length not exceeding 25d.

Figure: Waviness

CracksCracks are deformations through outer, violent influences. Ropes with cracks must be scrapped.

Figure: Cracks

KinksA kink is a deformation caused by the rope forming an eye that is contracted with out the rope being able to rotate around its own axle.

Strand pitch is altered, which leads a great deal of surface wear and, in severe cases, very low static strength.

Ropes with kinks must be scrapped.

Figure: Kinks

97

FlatteningFlattening is deformation caused by mechanical damage. Ropes with severe flattening must be scrapped.

Figure: Flattening

Local rope diameter decreaseLocal decrease in rope diameter is often connected to core break.

The area near the end attachments must be inspected especially carefully as it can be difficult to detect rope diameter decrease at these spots.

Ropes with severe rope diameter decrease must be scrapped.

Figure: Local rope diameter decrease

Local rope diameter increaseThis means repeated thickening of the rope over a long stretch. At the thicker spots, the core pushes out of the rope and causes unevenness of the outer strands.

Ropes with severe rope diameter increase must be scrapped.

Figure: Local rope diameter increase

Basket formationBasket formation occurs on ropes with steel reinforcement or steel core when the outer strand layer becomes longer than the inner strand layer.

Basket formation can also be caused by shock loads on slack ropes. Ropes with basket formation must be scrapped.

98

Figure: Basket formation

Tension of track

Figure: Tension of track measurement. A : Support roller B : Straight wooden bar C : Idler D : Grease nipple

Place drill rig on flat and firm ground. Put straight wooden plate between support roller and idler as shown above figure.

Check gap between bottom of wooden plate with top of track shoe. The gap should be between 25

99

AB C

D

Gap

mm ~ 50 mm.

If track is too loose, put grease on the grease nipple until the gap is reached to recommended specification. If track tension is too tight, discharge grease by dismantling grease nipple.

TruckingDANGER!Check the height and weight limit of the road where drill rig is transported.

Secure the drill rig on the truck or low bed not to slip during transportation.

Mast and other components should not move during transportation. Tied up and support all parts firmly.

Figure: Position for trucking.

Before loading the drill rig onto the transport vehicleRun the rotation unit/rock drill to its lowest position.Use the boom and feed controls alternately to bring the feed down into the transport position and firmly down on its jack (A).

Once the drill rig is loaded onto the transport vehicle• Lower the hydraulic jack (extra equipment).• Track oscillation cylinders to LOCKED position.• Support the feed beam against the vehicle to prevent overloading.• Switch off the diesel engine• Strap the drill rig securely onto the vehicle. Attach straps or chains to the lifting eyes on the machine and vehicle.

100

Rope tension adjustment

NoteThe ropes must not rotate during tensioning and slackening. Counter hold the turning with a 19 mm wrench on the flat part of the rope end.

1. Run the drill cradle to stop in the upper end position.2. Remove the protective cover over rope end A.3. Undo the bolts to the lock plates that prevent the ropes from twisting or rotating when loaded.4. Adjust the rope ends A and B so that the measurement F between the drum cradle and stop lug is

obtained in accordance with the table above. If the distance needs to be increased then rope 4 is slackened at tensioning point B and rope 3 is tensioned at tensioning point A. Rope 6 may also require slackening at tensioning point C in order to increase the distance. To reduce the distance, rope 3 is slackened and rope 4 is tensioned.

5. Tension rope 3.6. Run the drill cradle to stop in the lower end position. Load the cylinder (150 bar feed pressure) and

check that rope 4 does not slacken during loading. If the rope slackens the cradle is run up to upper end position, and rope 3 is tensioned further.

7. The drum cradle pull rope is adjusted so that the slack is not greater than that of the hydraulic hoses.

8. The drum cradle return rope is adjusted so that it is not tensioned more that the drill cradle return rope.

9. Tighten the bolts for the lock plates.10. Refit the protective cover.

101

Replacing the slide pieces in the feeder

Figure: Replacing sliding pieces.A : HolderB : BoltC : Slide pieceD : Key

1. Take off the slide pieces from the holder using a screwdriver and remove the keys.2. Slide a new slide piece into the holder track and fit the new keys.3. Makes sure that the holders are refitted to the cradle correctly and that they are adjusted so that

the total lateral play is 2-3 mm.

Each holder has replaceable slide pieces. The slide piece is kept in place by two keys. The slide pieces must be replaced at regular intervals so that the steel in the holder does not wear against the beam. Replace if there is less than 1 mm of wear allowance on the slide piece. It is a good idea to change all the slide pieces at the same time, even if some of them are slightly thicker.

102

A

B

C

D

Replacing the slide pieces in the feeder

cFigure: Replacing slide rails.

The slide rails are divided up to facilitate replacement.Before replacing the front slide rails, run the rock drill/rotation unit to its rear end position.Before replacing the rear slide rails, run the rock drill/rotation unit to its front end position.

1. Remove the cradle for the rock drill, intermediate drill-steel support and the hose drum from the beam.

2. Remove the old slide rails A by pressing the lower edges of the bars outwards using a screwdriver.

3. Clean the beam surfaces thoroughly.

4. Fit the new slide rails. The larger edge on the slide rail must be facing upwards.The rails should be pressed in place by hand.

5. Refit the rock drill cradles, intermediate drill-steel support and water-hose drum.Adjust the holders on the cradles as described in the instructions.

NoteAlways replace the slide pieces when replacing slide rails!

Cleaning and replacing dust collector filters

103

Slide rail

Figure: Cleaning and replacing dust collector filters.

1. Open rear bonnet doors, and loose fixing nut on the bottom of dust collector filters2. Clean the filters with air gun. Damaged filter should be replaced with new one.3. Put filters on the dust collector room, and assemble fixing nuts.

Cleaning and replacing pre air filters

Figure: Cleaning and replacing pre air filters.

104

1. Open side bonnet doors, and dismantle cover.2. Remove two filters and clean them with air gun. Damaged filter should be replaced with new one.3. Put filters and assemble cover

Replacing engine filters

1. Drain engine oil completely.2. Remove old engine oil filter, and replace with new one.

3. Close drain cock and fill new engine oil.4. Check and measure the oil level by Dipstick. Proper oil level is underneath of "H" level as shown

below.5. Running engine with idle rpm for 3 minutes. Check engine condition if there is leakage from engine.

Then, stop engine and wait for 5 minutes.6. Check and refill the engine oil.

Fuel filter replacement

1. Remove fuel filters on engine.2. Prepare new fuel filters, and fill oil inside of filter.3. Install new filter, and push fuel lift up pump several times.

Drain water on water separator

105

1. Open bonnet cover, and open water drain cock on water separator.2. It should be done before day work. Inserted water with fuel may cause serious damage on engine

injectors or fuel pump

Maintenance schedule

Lubricants

IMPORTANT!Do not mix lubricants of different brands with each other. Fully wipe off oil filler ports, grease nipples, hands, tools, etc. to prevent ingress of foreign substances during lubrication.

Compartment or System

Category and Classification Quantity

Ambient Temperature ( )℃-30 -20 -10 0 10 20 30 40 50

Fuel Tank Diesel Fuel 780 LiterNo.2-D

No.1-D or No.2-D

Engine oil PanEngine oil

APICH-4 or CI-4

34 Liter

SAE 0W30(-38~0 )℃

SAE 5W30(-28~22 )℃

Lubricants oil(DTH hammer) 15 Liter

SAE 10W30(-22~22 )℃SAE 0W40, SAE 5W40, SAE 15W40(-15~55 )℃

Hydraulic Tank Hydraulic oil 340 LiterISO VG32

ISO VG46ISO VG 68

Air Compressor Compressor oil 80 Liter

ISO VG15ISO VG 32

ISO VG 68

Travel MotorGear oil,

APIGL-4 or GL-5

1.8 Liter

SAE 90Idler 0.16 Liter

Track roller 0.1 Liter

Grease pump Grease 2 Liter NLGI No. 2 or above

106

Rod thread Grease 20 Liter EP 0

Coolant for radiator

WARNING!Antifreeze is poisonous; if ingested, it can cause serious injury or death.

Induce vomiting and get emergency medical attention immediately.

If antifreeze accidentally splashed in your eyes, flush eyes with water immediately.

The range of use can be changed according the weather to protect the freezing and boiling points of the antifreeze. Use distilled water with a low content of impurity for a coolant. EVERDIGM recommend to use antifreeze 50 % concentration in most climates and use antifreeze of 60-68 % concentration in a climate of maximum freeze prevention ( Antifreeze protection decreases above 68 %.)

ENGINE Quantity REMARK

Caterpillar 32 LiterESSENTIAL(PG

Antifreeze : Water 1:1 Ratio)

107

Engine and related parts○: Check : Clean : Lubricate : Replace ◎ ◆ ◈

Check List Inspection period Daily 50H 200H 250H 500H 1000H 1500H 2000H

Engine oil 1)◈ ◈Engine oil filter 1)◈ ◈

Fuel level ○

Fuel leakage ○

Fuel·water

separator filter 1)◈ ◈

Fuel filter 1)◈ ◈Drain of water

from fuel tank

separator

○ ◎

Leakage and

contamination of

Coolant

○ ◈

Core of radiator ◎Engine belt ○

Inter cooler and

hose○

Air cleaner

indicator○

Air suction line

and connector○

Check battery ○

Wiring and

connector

○

Primary air filter ◎ ◈Secondary air filter ◎ ◈

*1)Initial replacement

108

Air compressor○: Check : Clean : Lubricate : Replace ◎ ◆ ◈

Check List Inspection period Daily 50H 200H 250H 500H 1000H 2000H 4000H

Compressor oil ○ 1)◈ ◈Compressor filter 1)◈ ◈

Air cleaner

indicator○

Primary air filter ◎ ◈Secondary air filter ◎ ◈

Air suction line

and connector○

separator filter ◈Receiver tank ◎Drain of water

from receiver tank ○ ◎

Leakage of Cooler ○ *1) Initial replacement

TrackO: Check ◎: Clean ◆: Lubricate ◈: Replace

Check List Inspection period Daily 50H 200H 250H 500H 1000H 2000H 4000H

Tension of track

shoeO

Oil leakage O

Motor gear oil 1)◈ ◈Wear of roller and

idlerO

Bolts loosening O

*1) First replacement period

109

Hydraulic oil○: Check : Clean : Lubricate : Replace◎ ◆ ◈

Check List Inspection period Daily 50H 200H 250H 600H 1200H 1800H 2400H

Amount ○ ◈Cooler ◎

Hydraulic oil tank ◎Return filter 2)◈Air breather ○ ◈

Suction hose and

connector○ ◎

Suction filter ◈Drain of water from

hydraulic oil tank○

*2) Only it takes one time change after that you must check the indicator return filter for when you change next time

Mast and Feed cylinder○: Check : Clean : Lubricate : Replace◎ ◆ ◈

Check List Inspection period Daily 50H 200H 250H 500H 1000H 2000H 4000H

Oil leakage ○

Mounting bolt ○

Sprocket ◆Pully & Wire tension ○

Guide plate ○

Hose and connector ○

Liner ○

Winch Motor ○

*1) Initial replacement

110

Auto Rod Changer (ARC) and Boom○: Check : Clean : Lubricate : Replace◎ ◆ ◈

Check List Inspection period Daily 50H 200H 250H 500H 1000H 2000H 4000H

Cylinder ○

Mounting bolt ○

Welding part ○

Boom adjust bolt ○

Oil leakage in hose ○

Sensor ○

Dust Collector

Check List Inspection period Daily 50H 200H 250H 600H 1200H 1800H 4000H

Suction hose and

connector○

Air filter 3)○

Motor ○

Rubber ○

Suction stop air cylinder ○

Pulse valve ○

Air pressure ○

*3) Daily check, clean if it blocked. Damaged filters should be replaced.

Daily maintenance

Engine and related parts - every day

111

4

Figure: Engine and related parts

Table: Engine and related parts

Check point Control object Action

- Engine / Compressor Check for leakage around the engine and compressor

1 Hydraulic pump Check for signs of leakage2 Fuel - water separator Drain water

3 Engine oil level Check oil level with dip stick

4 Coolant Check level and condition

5 Lubrication oil for DTH hammer Check oil level and refill

- Remained grease on central lubrication system Check and refill

- Grease for thread lubrication Check and refill

Dust collector and receiver tank - every day

112

1

2

3

5

6

Table: Dust collector and receiver tank

Check point Control object Action

1 Dust collector

Open drain lever (1). Drain the water. The drill rig must have been standing still for one hour before the water can be drained.

2 Compressor oil level

Check the oil level. The gauge must be in the green zone. The drill rig must be level and must have been standing still for 10 minutes before checking.

Electrical system - every day

113

1

2

Figure: Electrical system

Table: Electrical system

Check point Control object Action

1 Emergency stop buttons/Wire( 4 places)

Attachment. Check each emergency stop button individually. The engine must stop. Before checking the next emergency stop button the previous one must be reset before restarting.

2 Working lights (11 pieces) Front, rear and on mast. Function

Every 50th of engine hour

Mast - every 50th of engine hour

114

1

2

Figure: Mast

Table: Mast

Check point Control object Action

1 Ropes Lubrication, Check tension.

2 Hose drum Lubrication, Check wear condition

3 Support, Break out chuck Check wear and adjustment

4 Rotary head cradle Check the clearance with feed beam (2~4 mm).

5 Sliding plates Inspect damages or wear

6 Sensors (10 each) Check sensing conditionAdjust distance (5 mm)

7 Rotary head Check tightness of bolt

Hydraulic hose Check wear condition, oil leakage

Hydraulic and air hoses - every 50th of engine hour

115

1

5

6

3

47

2

Figure: Hydraulic and air hoses

Table: Hydraulic and air hoses

Check point Control object Action

1 Hoses on hose drum Lubrication, Check tension and wear.

Tube handling system - every 50th of engine hour

Figure: Tube handling system

Table: Tube handling system

Check point Control object Action

- Greasing condition on joints and pins

Lubrication, Check wear and moving condition

NoteIf central lubrication is installed then the function and connections must be checked.

Boom - every 50th of engine hour

116

1

Figure: Boom

Table: Boom

Check point Control object Action

1 Greasing condition on joints and pins

Lubrication, Check wear and moving condition

2 Sliding plates Check the clearance (2 ~ 4mm). Adjust or replace wear plates.

NoteIf central lubrication is installed then the function and connections must be checked.

Track frame - every 50th of engine hour

117

1

2

Figure: Track frame

Table: Track frame

Check point Control object Action1 Travel motors Check oil leakage

2 Greasing on moving parts Check greasing conditions on moving parts.

3 Gear on travel motorCheck oil leakage. First oil change after 150 hours, clean the gears with flushing oil before filling with new.

4 Roller Check wear condition and leakage

NoteIf central lubrication is installed then the function and connections must be checked.

Track frame / Rig frame - every 50th of engine hour

118

12 34

Figure: Track frame / Rig frame

Table: Track frame / Rig frame

Check point Control object Action1 Track frame / Rig frame Lubrication, Check wear condition

NoteIf central lubrication is installed then the function and connections must be checked.

Compressor and compressor filters - every 50th of engine hour

119

1

Figure: Compressor and compressor filters

Table: Compressor and compressor filters

Check point Control object Action- Receiver tank Oil / Air leakage

- Compressor air filter Check connection and couplings on inlet manifold

1 Oil filter Change oil filter after the first 50 hours

Engine cooler and oil cooler - every 50th engine hour

120

1

Figure: Engine cooler and oil cooler

Table: Radiator and cooler

Check point Control object Action1 Radiator Check coolant level and refill

2 Engine cooler and oil coolerCheck if radiator and cooler fins are clogged.Clean them with compressed air.

Hydraulic oil tank - every 50th engine hour

121

1

2

Figure: Hydraulic oil tank

Table: Radiator and cooler

Check point Control object Action

1

Hydraulic oil tank

Drain the water. The drill rig should have been standing still for one hour before water drain process

2Check hydraulic oil level and refill it.Do not mix different type of hydraulic oil.

Cabin - every 50th engine hour

122

1

2

Figure: Cabin

Table: Cabin

Check point Control object Action

Air conditioner / Heater Operating cabin indoor heating / cooling system

1 Air conditioner filter Clean or change the filter if requiredFire extinguisher Check or replace according to lawLever and joystick Check mounting condition and damageCabin frame and window Check damages or crackHorn and reverse warning signal Check functionalityWarning decals and plates Check lost or damages

2 Side step Check mounting, crack or damages

NoteThe variant of the fire extinguisher that is supplied depends on the different national regulations. It is therefore essential to follow the instructions printed on the fire extinguisher.The fire extinguishers supplied with the drill rig should be considered as “Delivery fire extinguishers”. If the fire extinguishers are not approved in accordance with provisions in force for the worksite then they must be replaced with approved ones. In which case, the manufacturer's instructions for maintenance must be followed.

Every 250th engine hour

123

1

2

Mast - every 250th engine hour

Figure: Mast

Table: Mast

Check point Control object Action

1 CradlesCheck mounting condition, damages and tightening torque. Plays 2 ~ 4mm. Replace sliding plates

2 Side rail Check wear condition3 Cylinder and bushes Check wear or damages

4 Support and break out tableCheck damages or crack. Check wear condition of chuck and replace if required.

5 Wires and pulley Check wear and damagesFeed cylinder Check mounting and damages

124

1

2

3

4

5

Break out table / Support - every 250th engine hour

Figure: Break out table / Support

Table: Mast

Check point Control object Action1 Bush, pins and cylinder Check wear and play.

2 Chuck Check wear condition and replace if required.

3 Bolts and nuts Check tightening condition, and retightening.

125

1

2

3

Boom - every 250th engine hour

Figure: Boom

Table: Boom

Check point Control object Action1 Mast and guide shell holder Check mounting conditions

2 Feed bracketCheck the play between sliding plates and bracket, 2 ~ 4 mm. Check mounting condition.

Bushes, pins and cylindersCheck play between bushes, pins and cylinders. Change bushes and pins if necessary. Less than 1mm is allowed.

126

1

2

Electrical system - every 250th engine hour

Figure: Electrical system

Table: Electrical system

Check point Control object Action1 Covers and cabinet Check sealing condition from water

- Electrical connections Open covers and check corrosion and tightening conditions

Track frame - every 250th engine hour

127

3 7

1

Figure: Track frame

Table: Track frame

Check point Control object Action1 Track motor Check mounting condition

3 Track shoe Check mounting and tightening bolts if necessary.

4 Sprocket Check wear, damage and corrosion5 Rollers Check mounting condition and wear

6 Track tension

Check the distance with flat bar. 25 ~ 50mm is recommended. Adjust track tension by supplying grease on grease port marked "6".

7 Roller Check mounting condition, oil leakage and wear

Dust collector - every 250th engine hour

128

145 6

58

Figure: Dust collector

Table: Dust collector

Check point Control object Action1 Fan motor Check air suction force.2 Pulse switch Check leakage and functionality

3 Air inlet connector Check air passage blockage, crack and wear

4 Dust collector filters Check wear, damage and corrosion.

5 Air hoses Check mounting condition, air leakage, wear, blockage and damages.

6 Hood Check air leakage and damages7 Pre-cleaner Check damages or air leakage8 Hoses and rubber mount Check wear and damages

Filters on engine, Clamps - every 250th engine hour

129

1

2

34

6

7

Figure: Filters on engine, Clamps

Table: Filters on engine, Clamps

Check point Control object Action

Engine oil Change engine oil according to engine maintenance instruction

Engine oil filter Change filterFuel filter Change filterFuel prefilter (water separator) Change filter

Battery Check electrolyte level. Replace it if required.

Belts on engine Check tension and adjustCheck damages and wear

1 Clamps Check air leakage and retighten

Hydraulic oil tank - every 250th engine hour

130

1

Figure: Hydraulic oil tank

Table: Hydraulic oil tank

Check point Control object Action1 Breather filter Change if clogged

Every 500th engine hour

131

1

Break out table / Support - every 500th engine hour

Figure: Break out table / Support

Table: Break out table / Support

Check point Control object Action1 Sliding plates Check wear and play. (less than 2mm)

Track frame - every 500th engine hour

132

1

1

Figure: Track frame

Table: Track frame

Check point Control object Action

1 Track frame Check mounting condition, cover and bolt tightening.

2 Roller Check mounting and bolt tightening.

3 Track motor Check tightening condition and bolt damages

Engine mounting - every 500th engine hour

133

23

Figure: Track frame

Table: Track frame

Check point Control object Action

1 Engine mounting Check rubber mount and tightening condition.

2 Engine frame Check damages and cracks.

3 Rubber coupling with pump Check crack and wearCheck mounting condition

4 Rubber coupling with compressor Check crack and wear

5 Compressor mounting Check rubber mount and tightening condition.

Compressor and compressor filter - every 500th engine hour

134

3

2

4

1

5

Figure: Receiver tank

Table: Receiver tank

Check point Control object Action1 Receiver tank Change compressor oil2 Compressor oil and filter Change oil and filter3 Safety valve Pressure test (D700, 28 bar)

Air filters for engine and compressors - every 500th engine hour

135

2

3

1

Figure: Air filters for engine and compressors

Table: Air filters for engine and compressors

Check point Control object Action1 Air filters Change air filters

NoteAir filters should be replaced regularly unless it will cause serious damages on engine and compressors.

Cabin - every 500th engine hour

136

1

Figure: Cabin

Table: Cabin

Check point Control object Action

1 Fire extinguisherCheck the local or the job site legibility of instruction and condition of extinguisher

2 Air conditioner filter Replace

Every 1000th engine hour

Mast - every 1000th engine hour

137

1

2

Figure: Mast

Table: Mast

Check point Control object Action1 Guides Check wear, damage and crack

Every 2000th engine hour

Dust collector filters - every 2000th engine hour

138

1

Figure: Mast

Table: Mast

Check point Control object Action1 Dust collector filters Change filters

Receiver tank - every 2000th engine hour

139

1

Figure: Receiver tank

Table: Receiver tank

Check point Control object Action1 Oil water separator Replace

Hydraulic tank suction filters - every 2000th engine hour

140

1

Figure: Hydraulic tank suction filters

Table: Hydraulic tank suction filters

Check point Control object Action1 Suction filters Change filters

Torque table

Bolt Strength Spec

8.8 10.9 12.9Norma

l Fine N.m kgf.m N.m kgf.m N.m kgf.m

● M4 x 0.7 2.8 0.3 4.1 0.4 4.8 0.5● M5 x 0.8 5.5 0.6 8.1 0.8 9.5 1.0● M6 x 1.0 9.5 1.0 14 1.4 16.5 1.7

141

1

● M8 x 1.0 24.5 2.5 36 3.7 43 4.4● M8 x 1.25 23 2.3 34 3.5 40 4.1

○ M10 x 1.0 52 5.3 76 7.8 89 9.1● M10 x 1.25 49 5.0 72 7.3 84 8.6

● M10 x 1.5 46 4.7 68 6.9 79 8.1● M12 x 1.25 87 8.9 125 12.5 150 15○ M12 x 1.5 83 8.5 122 12.5 145 15

● M12 x 1.75 79 8.1 117 12 135 14● M14 x 1.5 135 14 200 20 235 24

● M14 x 2.0 125 13 185 19 215 22● M16 x 1.5 205 21 300 30 360 37

● M16 x 2.0 195 20 280 28 330 34● M18 x 1.5 310 32 440 45 520 53○ M18 x 2.0 290 30 420 43 490 50

● M18 x 2.5 280 29 390 40 460 47● M20 x 1.5 430 44 620 63 720 73

● M20 x 2.5 390 40 560 57 650 66● M22 x 1.5 580 59 820 83 960 98

● M22 x 2.5 530 54 750 76 880 90○ M24 x 1.5 760 77 1,090 110 1,270 130● M24 x 2.0 730 74 1,040 105 1,220 125

● M24 x 3.0 670 68 960 98 1,120 115○ M27 x 1.5 1,110 115 1,580 160 1,850 190● M27 x 2.0 1,070 110 1,500 150 1,800 185

● M27 x 3.0 1,000 100 1,400 140 1,650 170○ M30 x 1.5 1,540 155 2,190 225 2,560 260● M30 x 2.0 1,490 150 2,120 215 2,480 255

● M30 x 3.5 1,350 140 1,900 195 2,250 230○ M33 x 1.5 2,050 210 2,920 300 3,420 350● M33 x 2.0 2,000 205 2,800 285 3,300 335

● M33 x 3.5 1,850 190 2,600 265 3,000 305○ M36 x 1.5 2,680 275 3,820 390 4,470 455● M36 x 3.0 2,500 255 3,500 355 4,100 420

● M36 x 4.0 2,350 240 3,300 335 3,900 400○ M39 x 1.5 3,430 350 4,890 500 5,720 585● M39 x 3.0 3,200 325 4,600 470 5,300 540

● M39 x 4.0 3,000 305 4,300 440 5,100 520

9. OptionsWater Injection

There are many conditions where water injection are required. Water injection tank and controller can be mounted on the machine as option.

The followings are conditions where water injection is recommended.

Soft rock (clay) drillingThe clay or dust remained on the bottom of hammer is acted as spring, and it cause inefficient drilling performance.

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To remove dusts from drilled hole efficiently, water or water with foam with air will helpful to evacuate dust.

Hole stabilization from collapseThe soft and brittle rock may be collapsed by vibrating force, and this hole collapse will bring time consumption. Injected water with air steam will hardening the wall to endure the force during the drilling.

Dust reductionSmall dusts which escaped from dust collector suction may harmful for human and environment. To reduce dust, water injection would be useful.

Reduce friction between hole and pipeWater / water and foam may reduce the friction between drilled hole and pipe.

Figure: Water injection switch.

A Water injection ON B OFF C Water injection tank heater ON

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AB

C

Symbol Description

Water Injection

Water tank heater

Figure: Water injection with air stream. Figure: Water tank.

IMPORTANT!Do not use salted or mineral water. It will cause corrosion or damages on hammer and piping.

The impurities contains on the injection water will cause damages on hammer. Using purified water is recommended.

When hammer is exposed salted water or dirty water is injected, dismantle the hammer immediately, and check the components whether it is damaged. Then, clean and dry the hammer components and pipe. After drying and assemble all components, spray anti rust fluid on the components where salted or dirty water effected.

Table: Water injection quantity.

Hammer Size Approximate Injection rate of water

3 " (in) 1 - 3 liter (0.25 ~ 0.65 gal) per minutes

4 " (in) 3 - 7 liter (0.65 ~ 1.55 gal) per minutes

5 " (in) 5 - 8 liter (1.10 ~ 1.75 gal) per minutes

6 " (in) 7 - 10 liter (1.55 ~ 2.20 gal) per minutes

8 " (in) 8 - 15 liter (1.75 ~ 3.30 gal) per minutes

Note : The actual water injection should be determined according to rock characteristic, air pressure and air output volume.

Too much air injection will bring bad penetration of drilling by hammer.

Foam InjectionFoam can be used in DTH drilling to improve flushing performance. Mixed foam with water will lifting up the dust out of hole and it also helps to stable and seal the hole wall.

Selection of foam is important for minimize corrosion or damages on hammer.

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CAUTION!Foam may contains toxic chemical to human or environment.

Foam mixing recommendationIt may different according to foam supplier. Normally, 0.5 ~ 2 percent of foam mixture ratio is recommended.

MaintenanceWater and foam injection will be helpful for dust reduction, hole cleaning and hardening the drilled hole wall, however it can cause the hammer to corrode if it is not properly maintained. Refer to following procedure to avoid hammer corrosion and damages

• Ensure that the water being used is free from solids contamination. Also, salted water or mineral water which may cause chemical reaction with steel or blockage of pipe will not be allowed.

• Any time a hammer is not operated for one or more hours, stop water injection and operate hammer with lubricant only for 5 minutes. It will clean and coat the internal parts of hammer and pipe to minimize corrosion.

• For water injection application, it is recommended injecting more lubricant with air. The lubricants should be increased around 2 time more than normal operation.

10. Trouble shootingEngine

Cause Main cause Remedy

Engine coolant temperature is too high.

Lack of coolant √ Refill or replace coolant

Blocked radiator fins √ Clean radiator

Leak from reservoir tank cap √ Tighten cap

Blockage of coolant line √ Check the inner side of radiator and clean it√ Check coolant piping and clean it

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Malfunction of sensor or temperature gauge √ Repair or replace

Lack of fan motor efficiency, or failure

√ Check blow condition from fan and hydraulic motor

Engine can not be started.(Engine is not cranked)

Emergency stop system is activated. √ Check and disable emergency condition

Master switch is off √ Turn on master switch

Disconnected electric line √ Check electric connections

Empty batteries √ Check and recharge batteries

Ignition switch failure √ Repair or replace

Engine can not be started.(Engine is cranked)

Lack of fuel √ Refill fuel

Mixed air into fuel √ Exhaust air on fuel line

Fuel injection pump or nozzle failure

√ Contact official engine service dealer. Change failed parts

Blockage of fuel line or filters √ Replace fuel filters and cleaning fuel line

Fuel leakage from piping and hoses √ Check and repair the fuel line

Battery charging lamp is "ON"

Lack of alternator efficiency √ Check the tension of alternator

Alternator failure √ Check and change alternator

Sudden engine stop during operation

Lack of engine oil √ Check the pressure of engine oil and refill it

High coolant temperature √ Check radiator and coolant condition

High compressor oil temperature

√ Check compressor oil condition√ Check oil fan condition

Cause Main cause Remedy

Engine RPM can not be adjusted

Electric connection failure(CAT Engine)

√ Check electric connection between rpm adjuster and engine

Cable connection failure(Cummins Engine)

√ Check cable (wire) connection between rpm adjuster and engine

Abnormal exhaust gas from muffler

Dark color√ Turbo charger is polluted. Clean turbo

charger.

√ Air filter is blocked. Clean or replace air filters.

White color

√ Engine oil can be burned. Check remained engine oil level, and repair piston rings.

√ Air may be mixed with fuel. Check and exhaust air in fuel.

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Traveling

Cause Main cause Remedy

Machine won’t travel.Traveling is difficult.

Excessive track tension √ Adjust tension

Pilot line blockage √ Check pilot line pressure. Clean pilot line and replace filter

Failed track motor √ Repair or replace

Control lever or valve failure √ Repair or replace

Insufficient hydraulic pressure from relief valve √ Adjust hydraulic pressure

Main pump failure √ Repair or replace

Machine slips on a slop with parking position

Break valve failure √ Check spool and valve

Too much load on the machine √ Remove heavy object on the machine

Track shoe gets out of it's place

Loosen track tension √ Adjust tensionWorn out idler, roller, or sprocket √ Replace parts

Worn out or broken track shoe √ Replace track shoe assembly

Air compressorCause Main cause Remedy

Compressor oil is come out with air

Too much compressor oil in receiver tank √ Check and adjust oil level

Oil separator filter damage √ Replace oil separator

Air regulator failure √ Check air regulator and set the pressure correctly.

Compressor temperature is too high

Too much compressor oil in receiver tank √ Check and adjust oil level

Oil cooler fin blockage by dust √ Clean oil cooler

Bypass valve (Thermo start valve failure) √ Check compressor oil bypass valve

No air flow from drifter, or air pressure is too low

Compressor switch is off √ Check and turn on compressor switch

Air filter blockage √ Clean or replace compressor air filter

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Unload valve setting problem √ Adjust or reset unload valve pressure

Dust collectorCause Main cause Remedy

Air suction fan is not rotate

Dust collector motor failure √ Check and replace

Hydraulic line cut or blockage √ Check hydraulic lines to motor

Electric line disconnection √ Check electric cable

Air suction force is too low

Air suction hose blockage √ Check and clean air suction hoses

Dust collector filter blockage √ Clean or replace

Hydraulic motor failure or hydraulic setting problem √ Repair or replace

Air pulse on dust collector is not functioned

Air tank drain cock is opened √ Close air drain cock

Low pressure setting from air regulator √ Adjust or reset the air regulator

Pulse timer or electric line failure √ Check or replace

Oil coolerCause Main cause Remedy

Hydraulic oil temperature is too hot

Blocked oil cooler by dust √ Clean oil cooler

Low cooling motor efficiency

√ Check hydraulic condition to motor√ Repair or replace motor

Low hydraulic oil level √ Fill hydraulic oil in tank

Temperature gauge or sensor failure √ Repair or replace

Hydraulic cylindersCause Main cause Remedy

Hydraulic cylinder is not operated or moves slow

Damaged seals √ Replace internal seals

Hydraulic setting problem √ Check hydraulic pressure and flow, and adjust

Control lever or valve failure √ Repair or replace

Electric solenoid valve failure

√ Check electric signals√ Replace solenoid valve

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Notes

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EVERDIGM Corp.Sales Office: Room #1203, Woolim Lion's Valley , 680,Ⅱ

Gasan-Dong, Geumcheon-Gu, Seoul, Korea 153-803Tel: +82-2-801-0800 / Fax: +82-2-801-0899

Head Office: 332-3, Janggwan-ri, Jincheon-eub, Jincheon-gun,& Factory Chungcheongbuk-do, Korea 365-802

Tel: +82-43-530-3300 / Fax: +82-43-530-3318

www.everdigm.com