GMI-253

DIRECTOR GENERAL BORDER ROADS

GENERAL MAINTENANCE INSTRUCTION NO. 253

ON OPERATION AND MAINTENANCE OF

SELF PROPELLED MEDIUM ROCK DRILL MAKE SANDVIK MODEL DC 122 R

INTRODUCTION:

(a)     Self Propelled Medium Rock Drill Make Sandvik model DC 122 R with on board Compressor fitted with CAT C2.2 Turbo charged Water cooled four cylinder diesel engine developing output 37kW @ 2800 rpm fully remote controlled, hydraulic and on a 4 wheel drive carrier.

(b)     This GMI gives the technical specification and know how on the operation, maintenance and repair procedure of Self Propelled Medium Rock Drill Make Sandvik model DC 122 R to ensure maximum performance and safe/satisfactory operation. Compliance with procedures given in this GMI will enable to get desired maximum service from the equipment.

(c)     Maintenance of Self Propelled Medium Rock Drill Make Sandvik model DC 122 R will lead to long life, trouble free operation and less frequent break downs and also to reduce maintenance cost. The periodic maintenance must be carried out according to the ‘Periodic Maintenance Schedule’ described in this GMI. Daily care, inspection and Period ic Maintenance are essential for preventing troubles and accidents to ensure satisfaction and safe operation for prolonging the operating life of the equipment. All information and instructions given in this GMI is based on the latest Operator’s manual and service booklet provided by the firm.

AIM:     The instructions are issued as guidelines for general, preventive maintenance schedule and lubrication of Self Propelled Medium Rock Drill Make Sandvik model DC 122 R manufactured by  M/s Sandvik Asia Pvt Ltd for regular attention to keep the equipment in good mechanical condition which must be strictly followed.

ACTION BY:

                       

a)	User unit:          To carryout periodic inspection and monitor regular/periodical maintenance as laid down in this instruction and record the tasks done in log book.
b)	Field Workshop :
	i)	To carryout and monitor maintenance schedule and oil changes as per periodical maintenance laid down in the maintenance instructions and to check the record of maintenance including lubrication.
	ii)	To advise the user unit in respect of any lapse noticed.
c)	Mobile Maintenance Team:    To ensure that proper maintenance is carried out and submit report accordingly to Task Force Commander and OC Wksp for their necessary action.

DETAILS:

         This instruction includes the following aspects:-

        

a)	Operating Procedure – Do’s and Don’ts.	Appendix ‘A’
b)	Periodic Maintenance schedule.	Appendix ‘B’
c)	Technical Specification..	Appendix ‘C’
d)	Oil filling capacity/periodicity for change and recommended lubricants for change.	Appendix ‘D’

           

                                                                                                (Deepak Kumar)

                                                                                                EE (E&M) NFSG

                                                                                                Joint Director (Tech)

                                                                                                For Dir Gen Border Roads

                                                                                                           

                                                                                                            Appendix ‘A’

OPERATING PROCEDURE - DO’s & DON’Ts

1.      Carry out maintenance and repair work only when the rig is not running. Make sure that the rig cannot be started unintentionally during maintenance work.

2.    Avoid using full percussion pressure. When the drill bit is not in contact with the rock, full percussion pressure strain the accumulator membranes and causes unnecessary wear of the flushing housing and cavitations in the percussion mechanism. Such idle drilling is especially dangerous when drilling upward and cleaning holes by pumping.

3.      Proper shank lubrication is necessary. Inadequate lubrication quickly causes serious damage to the rock drill. Inadequate lubrication causes the chuck and the shank to overheat and this leads to rapid wear of these component. Overheating of the shank also causes shank breakage.

4.      Wear hearing protections when the power pack is running.

5.     Before run ensure using a double nipple, connect the hoses of power pack to make a loop so that the lines of both pumps form their own closed circuits. Turn on the power pack, pull the levers of both control valves in to operating position, whereby oil starts flowing through the systems in free circulation. Allow the power pack to run for about 3 minutes, after which it is ready for the run.

6.      Connect the rock drill according to the hydraulic flow chart.

7.      Make sure that there is enough oil in the tank and control valve and levers are in neutral position.

8.   Never detach a pressure accumulator before verifying that the pressure has been released, before removing the accumulator from the rock drill.

9.      Never heat an accumulator to temperature over 100⁰C.

10.   Do not disassemble a pressurized accumulator (if an accumulator cannot be depressurized, it must be disposed of properly).

11.    Do not try to depressurize an accumulator using false methods e.g. drilling a hole through diaphragm.

12.  Do not use any other methods, than described in the manual, to depressurize or disassemble an accumulator.

13.    Do not drill a hole through the diaphragm or any other part of an accumulator.

14.    Before resetting, check that the rod handling and drilling joysticks are not in the operating position.

15.    Do not go under an unsupported rig. Do not disconnect hydraulic hoses or valves unless you are certain that the system has no static load. Remove all static loads always before starting repair work by a mechanical support or by driving a cylinder to its extreme position.

16.     Do not add cold coolant to a hot engine. Doing so could damage the cylinder head.

17.     Do not fill the filter with fuel prior to installation.

18.     Adjust engine’s idle speed to 1500 rpm with the adjusting screw.

19.     Do not mix different type of oils.

20.     Run the engine at the low idling (at least 3 minutes) to cool the engine slowly and then stop the engine.

21.    Insufficient machine stability can cause unexpected machine movement which could result in death or severe injury. Never exceed the specified maximum inclination angles when parking or operating the machine.

22.    Compressed air jets can cause serious injury. Allow the pressure to be released from the hydraulic circuit before opening the plugs or connectors.

23.  Rock drill pressure accumulators are field with Nitrogen N₂ gas. Before removing the pressure accumulators from the rock drill, release the accumulator pressure by opening the filling valve.

24.    Check the emergency stops and safety equipments like Fire extinguisher, Pressure gauges, Indicators, Tramming and working lights, Parking brake, Tramming brake, Inclination gauges and Warning labels for proper functioning and condition before the start of each shift and after tramming.

25.    Make sure that the dust collector system well and effectively at all times. Make sure that the suction head is firmly against the ground during drilling and suction rubbers/hoses are in good conditions/tight. Also ensure dust collector filters are in good conditions.

26.    The engine is stopped automatically, if (a) the oil pressure sinks to low, and the indicator lamp lights on the instrument panel (b) compressor temperature rises above 115⁰C, and the indicator lamp lights on the instrument panel (c) the engine coolant temperature rises too high, and the indicator lamp lights on the instrument panel.

27.     Do not start the engine by towing.

28.     Before stopping the engine, allow it to idle for three minutes to equalize thermal stresses.

29.     In danger situations the engine can also be stopped with one of the emergency stop buttons.

30.     Never exceed maximum allowed inclination angles (when drilling or tramming).

31.    When using the winch, always make sure that the winch drum has a minimum of three loops of cable. Merely locking the cable in the drum is inadequate because the cable is subjected to tugging.

32.     If the inclination of the drilling site is greater than 10 degrees, secure the rig by attaching a winch cable to a firm location on the uphill side. If the terrain inclination is more than 20 degrees, a winch must be used.

33.     Make sure that all control levers are in the middle position before you start the power pack.

34.    Ensure that rock drill lubrication is working. Faults arise in the rock drill very quickly if shank lubrication does not operate correctly. Proper shank lubrication is also necessary.

35.     The engine is equipped with a suction fan. Clean the radiator by blowing air from the fan side.

36.     If the oil level in the tramming gear rises, the shaft seal of the hydraulic motor is probably damaged.

37.     When the shank lubrication is working properly it is normal, that the drill steel is oily up to about 25 cm (1 ft) from the rock drill. Make sure that air comes out through the shank lubrication exhaust hole (on the feed side of the front cover).

                                                                                                                           

 Appendix ‘B’

PERIODIC MAINTENANCE SCHEDULE

                                                             

Maintenance work	Service intervals in hours							Remarks
GENERAL MAINTENANCE	Daily	50	250	500	1000	1500	3000
Clean the rig.		*	*	*	*	*	*
Test the fire extinguisher and refilling.							*
Check suction hoses and there connections of engine and compressor.	*
Check the operation of the gauges.	*
Check for possible oil leaks during drilling.	*
BOOM
Grease all the greasing points.	*	*	*	*	*	*	*
Check the cradle and feed clearance. .i.e. 0.50 mm)		*	*	*	*	*	*
Check the welding of boom and cradle.				*	*	*	*
Check the mountings of hydraulic cylinders.				*	*	*	*
Check the tightening  torque of the cylinder taper pin bolts.				*	*	*	*
FEED
Check the tightness and condition of the feed chain.	*
Lubricate all the greasing points.	*	*	*	*	*	*	*
Check rock drill carriage/feed rail clearance.		*	*	*	*	*	*
Check the clearances of the sprocket wheel bearings.				*	*	*	*
Check condition of the retaining centralizer jaws.			*	*	*	*	*
HYDRAULIC ROCK DRILL
Check shank lubrication oil level and top up if necessary and its function (There should be 30 to 50 drops/min during drilling). Adjust/clean if necessary.	*
Check the condition of the chuck.	*
Check condition of flushing  pipe.	*
Check the mounting of rock drill.	*
Check condition of accumulator valves and pressures.		*	*	*	*	*	*
Check the tightness of the pressure accumulator bolts.		*	*	*	*	*	*
Check the tightness of the front cover bolts.		*	*	*	*	*	*
Check the tightness of the rear cover bolts.		*	*	*	*	*	*

Maintenance work	Service intervals in hours							Remarks
DUST COLLECTOR SYSTEM	Daily	50	250	500	1000	1500	3000
Lubricate the grease nipples of the cut-off cylinder and the butterfly valve.		*	*	*	*	*	*
Check suction head rubbers.			*	*	*	*	*
Check the operation of the cut-off cylinder and the butterfly valve.			*	*	*	*	*
Check the condition of the impact plate.			*	*	*	*	*
CARRIER
Lubricate the greasing points.		*	*	*	*	*	*
Check the condition and mounting of winch rope.		*	*	*	*	*	*
Check the electrolyte and connections in the batteries.		*	*	*	*	*	*
Check the operation of brakes.			*	*	*	*	*
Check the winch oil level from plug.			*	*	*	*	*
Check the welding seams.				*	*	*	*
Change the Final Drive Oil					*		*
Change of Winch Oil.						*	*
DIESEL ENGINE
Check the engine oil level.	*
Check the engine coolant level.	*
Check the tightness and condition of the V-belt.	*
Drain water from water collector.	*
Check air intake lines and connections.		*	*	*	*	*	*
Clean the cooler/radiator core.		*	*	*	*	*	*
Change the engine oil.			*	*	*	*	*
Change the oil filter.			*	*	*	*	*
Check the engine grounding.			*	*	*	*	*
Change the air filter.				*	*	*	*
Check the Water Pump for Leaks.				*	*	*	*
Change the safety filter element.						*	*
Check the Valve Clearance.					*		*
Check the Tightness of the Cylinder Head Bolts.					*		*
Check the engine vibration dampers.						*	*
Check the injector nozzles.						*	*
Clean the crankcase breather.						*	*

Maintenance work	Service intervals in hours							Remarks
	Daily	50	250	500	1000	1500	3000
Change the engine coolant and replace the engine thermostat.						*	*
Check the water pump, the starter motor and the alternator.						*	*
FUEL SYSTEM
Check the fuel level.	*
Drain fuel tank water trap.		*	*	*	*	*	*
Change the fuel filter (pre-filter).			*	*	*	*	*
Change the fuel filter/water  separator.			*	*	*	*	*
Change the fuel tank breather.				*	*	*	*
Clean fuel tank.					*		*
HYDRAULIC SYSTEM
Check the hydraulic oil level.	*
Replace the hydraulics return filters.				*	*	*	*
Change the hydraulic oil.					*		*
Clean Hyd oil receiver.					*		*
Replace the hydraulic oil receiver breather.				*	*	*	*
PNEUMATIC SYSTEM
Check the compressor oil level.	*
Check the compressor air intake lines and connections.		*	*	*	*	*	*
Check the compressor belt tension .(i.e. 7.5 mm)		*	*	*	*	*	*
Change the air filter.				*	*	*	*
Change the compressor oil.				*	*	*	*
Change the compressor oil filter.				*	*	*	*
Check the shut down temperature switch.				*	*	*	*
Clean the oil regeneration line strainer and orifice.					*		*
Change the safety filter element.						*	*
Change the oil separator element.						*	*
Clean the compressor oil receiver.					*		*

General Maintenance Instructions :-

i)	Park the rig on a steady and level surface.
ii)	Ensure that the rig cannot move by itself. Lift the rig on to the jacks, or use a safety brake and tire wedges.
iii)	Always stop the rig before commencing maintenance procedure. Prevent accidental starting of the rig by turning the main switch off or removing the ignition key.
iv)	Wash the rig before maintenance do not use solvents that contain aromatic or chlorinated hydrocarbons. Using mineral-oil-based fuel, such as gasoline, diesel, or petroleum, as detergent is also forbidden! These substances can cause deterioration, cracking, or softening of rubber and plastic parts.
v)	Clean the area around the filling cap thoroughly before adding fuel or oil.
vi)	When replacing the filters or changing oils, ensure that the oil added is pure. A high particle content in the oil (e.g., the filter becomes clogged rapidly) can indicate some kind of fault. Find out the reason for this situation before more serious damages is done.
vii)	Reinstall protective rails and covers after maintenance.
viii)	Ensure that the hoses and cables cannot get entangled or tightened during use of the rig.

Daily Maintenance:-

               

i)	Check for possible oil leaks.
ii)	Check the hoses and hose connections.
iii)	Check that the end of the flushing pipe is intact.
iv)	Check the tightness and condition of the feed chain.
v)	Check the tightness and condition of bolts and nuts. If a self locking not has loosened, it must be replaced. If a normal bolted joint loosens repeatedly, use a self-locking not or chemical locking agent.
vI)	Check and ensure one level daily using the dipstick, the oil level must be between the upper and lower markings on the dipstick.
vii)	Check the coolant level daily the coolant level should be between the marks in the expansion tank.
viii)	Check the tightness of v belt the deflection of the belt should be 10-15 mm.
ix)	Service air indicator must be checked daily by pressing the button on the top (The filter cartridge must be replaced whenever the service indicator shows red or according to maintenance schedule, whichever comes first).
x)	Check oil level in the hydraulic receiver with the sight glass. The oil level should be in the middle of the sight glass.
xi)	Check amount of fuel from the fuel sight glass.

Weekly Maintenance:-

               

i)	Check the accumulator filling valves and their cover plugs, and the tightness of the accumulator fastening bolts.
ii)	Check accumulator pressures.
iii)	Check the condition of the chuck, rotation bushing and rotation bushing bearing.
iv)	Check the tightness of the front and rear cover bolts.
v)	Wash the feed & boom.
vi)	Tighten all bolt and nuts of boom.

Monthly Maintenance:-

i)	Check the sprocket wheel bearings.
ii)	Measure all sliding clearances and adjust if necessary.
iii)	Wash inside of shank lubricator.

TECHNICAL SPECIFICATION

Description	:	Self propelled Medium Rock Drill Make Sandvik model DC 122 R.
POWERPACK
Engine Type.	:	CAT C 2.2 Turbocharged water cooled four cylinder diesel engine, Hyd pumps and on-board Compressor.
Engine output.	:	37 kw @ 2800 rpm.
Transmission Type.	:	Direct /Polygroove belt.
Hydraulic pumps.	:	Three gear pumps.
Screw Compressor type.	:	Enduro 3.
Air flushing capacity/output.	:	1.2 m3/minute.
Flushing Air pressure.	:	4 to 8 bar.
Maximum operating pressure.	:	8 bar.
Air Cleaner.	:	2 Pcs.
Fuel tank.	:	75 litres.
Average fuel consumption.	:	4 to 6 ltrs/hour.
Maximum operating altitude.	:	3000 meters.
Fuel saving system.	:	Standard.
HYDRAULIC ROCK DRILL
Rock Drill Type.	:	HEX I, Hydraulic.
Drill rod diameters.	:	HEX 19 x 108 mm, HEX 22 x 108 mm & HEX 25 x 108 mm.
Operating Pressure.	:	100 to 160 bar.
Pressure rate.	:	82 Hz.
Percussion output power.	:	5.5 kW.
Maximum rotation torque.	:	100 Nm/120 bar.
Shank lubrication.	:	Air / oil mist.
Flushing.	:	Air.
Shank lubrication oil consumption.	:	50 to 100 gm per hour.
Shank lubrication air consumption.	:	200 to 400 ltr per minute.
Shank lubrication air pressure.	:	6 to 8 bar.
Weight.	:	46 kg.
FEED
Chain feed type.	:	CF 100 x 32 / HEX I, incl. One set of Jaws.
Length of feed.	:	4540 mm.
Rock drill travel.	:	3300 mm.
Maximum length of starter rod.	:	3200 mm hexagonal or 10 feet, R23 MF.
Hole depth with starter rod.	:	2800 mm. (9’ 2”)
Maximum length of two rods.	:	6400 mm. (21 feet)
Hole depth with second rod.	:	6000 mm. (19’ 8”)
Feed / pull out force.	:	3.7 kN.
Front Centralizer.	:	Manual.
Travelling Centralizer.	:	Manual.
Feed Extension Travel.	:	600 mm (2’)
Feed Swing.	:	+/- 470
Feed tilt.	:	1100
Weight without steels.	:	155 kg.
BOOM
Boom Type.	:	DB 120, articulated.
Boom Length.	:	3800 mm (3.8 m.)
Boom Swing.	:	+/- 430
Drilling coverage on flat.	:	10 m2
Collaring height.	:	+2.2 m / -4.0 m.
Horizontal Holes.	:	Sideways, forwards.
HYDRAULIC SYSTEM
Hydraulic system type.	:	Open centre, pilot control.
Filtration rate.	:	10 micron abs.
Cooling capacity.	:	Up to +500C ambient.
Hydraulic oil tank.	:	45 litres.
Shank lubrication device.	:	WL 30.
CONTROL SYSTEM
Tramrock TA 132 E / 120.	:	Remote Controlled
Antijamming system.	:	Controlled by I/O-module and software.
Voltage.	:	24V DC.
Boom and Drilling control.	:	Radio Remote.
Driving and Jack control.	:	Radio Remote.
DUST COLLECTOR
Dust Collector Type.	:	DC 120, Hydraulic.
Suction hose.	:	75 m.
Capacity/Vacuum.	:	5 m3/min at 855 mm vacuum H2O.
Filter elements/material.	:	6 pcs/fiber.
Total filter surface.	:	4.8 m2
Hydraulic motor output.	:	3 kW.
Hydraulic motor maximum pressure.	:	125 bar.
Hydraulic motor speed.	:	5800 rpm.
Weight.	:	90 kg.
Total height.	:	1324 mm.
CARRIER
Carrier Type.	:	Rubber tyred, 4-wheel drive.
Ground clearance.	:	300 mm.
Tramming force.	:	20 kN.
Tramming speed.	:	3.6 km/hour
No. of Hydraulic Jacks.	:	4.
No. of working lights	:	4.
Others
Total weight.	:	2850 kg.
Total width.	:	1.8 m (1800 mm.)
Total height.	:	2.1 m (2100 mm.)
Total length.	:	4.6 m (4600 mm.)
Hole diameter.	:	22 to 45 mm.
Production capacity.	:	300 to 540 m3 / 8 hour.

Jaws For Drill Steels

Drill steel type	Drill steel diameter	Recommended hole diameter
Hexagonal steels.	19 mm.	22 to 27 mm.
Hexagonal steels.	22 mm.	28 to 45 mm.
Hexagonal steels.	25 mm.	35 to 45 mm.
MF rods.	R23.	33 to 45 mm.
Shank adapter/shank rod.	R23.	33 to 45 mm.
Shank rod Alpha 250.	25 mm.	35 to 45 mm.

Appendix ‘D’

OIL FILLING CAPACITIES AND PERIODICITY FOR CHANGE

Item	Quantity	50 Hrs	250 Hrs	500 Hrs	1000 Hrs	1500 Hrs	3000 Hrs
Engine Oil.	8.20 litres		*	*	*	*	*
Hydraulic Oil.	45 litres				*		*
Compressor Oil.	6 litres			*	*	*	*
Final Drive Oil (4 pcs).	0.70 litres			*	*	*	*
Winch Oil.	0.70 litres						*
Engine cooling system.	10 litres						*

RECOMMENDED LUBRICANTS FOR CHANGE

S/ No	Item	Kind of fluid	Classifica-tion (SAE)	Ambient tempera-ture in oC	Grade		Periodicity for change
a)	Diesel Engine.	Engine oil.	SAE 0W-20	-40 to +10	API CJ-4 multigrade oil. API CI-4 multigrade oil that meets Caterpillar ECF-1-a or ECF-2 specifications . API CH4 multigrade oil that meets Caterpillar ECF-1-a or ECF-2 specifications. API CG-4 multigrade oil that meets Caterpillar ECF-1-a or ECF-2 specifications.		Initial oil and oil filter element change at 250 Hrs and thereafter ever 250 hrs. Note: Indian Oil Servo 15W40 an API Cl-4 or any equivalent grade engine oil manufactured by any other company can be used in place of CAT 15W 40.
			SAE 0W-30	-40 to +30
			SAE  0W-40	-40 to +40
			SAE  5W-30	-30 to +30
			SAE  5W-40	-30 to +40
			SAE  10W-30	-20 to +40
			SAE 15W-40	-15 to +50
b)	Compressor.	Mineral-based engine oil.	SAE 5W-20	-20 to +35	Mineral-based engine oil or synthetic compressor oil can be use in the compressor.		Initial oil change at 500 Hrs. If the operating temperature is continuously over 90ºC, the oil change interval for mineral-based oils is 250 engine hours (500 engine hours for synthetic compr oils).
			SAE 10W	-10 to +30
			SAE  20W-20	0 to +40
			SAE 10-30	-5 to +60
		Synthetic compressor oil.	ISO VG 32 (40º C)	-30 to+40			If the operating temperature is continuously over 100ºC (ambient temperature over 40ºC) or below -20ºC (In arctic conditions), synthetic compr oil must be used.
			ISO VG 46 (40º C)	-20 to+60
c)	Transmission. (Winch)	Transmis- sion oil.	API GL-5, SAE 80W-90 or synthetic SAE 75W-90		Mineral based oil or synthetic oil.		At every 3000 hrs.
d)	Transmission (Tramming gear)	Transmis- sion oil.	ISO VG 100	-35 to+60	Mineral based oil or synthetic oil.		Initial oil change at 500 Hrs & thereafter every 500 hrs.
			ISO VG 220	-25 to+80	Mineral based oil or synthetic oil.
e)	Lubrication grease.	Grease.	Alvania EP Grease 2 (SHELL) Mobilux EP 2 (MOBIL) Energrease LS-EP2 (BP) Beacon EP 2 (ESSO) Gulfcrown Grease EP 2 (GULF) Speeroll AP 2 (CASTROL) Marfax All Purpose (TEXACO)
f)	Engine coolant.	Coolant.	Cat ELC 100%	-37			Caterpillar Extended life coolant is a red ethylene glycol based fluid. Only this same Cat ELC fluid or distilled water can be added to the cooling system.
			Cat ELC 80% + 20% ELC concentra-te added	-38 to -52
g)	Shank Lubricator	Rock drill oil.	Torcula 100 (Shell)	+12 to+55	Lubricant	Ambient Tempera-ture in oC
			Torcula 32 (Shell)	-10 to +38	Energol RD-E 46 (BP)	-10to+38
			Tellus oil R10 (Shell)	-30 to +18	Energol RD 50S (BP)	-32 to+58
			Gulfstone 100 (Gulf)	+12 to+55	Rock Drill LubeX 68 (Texaco)	+18to+55
			Gulfstone 46 (Gulf)	-5 to +35	Rock Drill Lube X32 (Texaco)	-10to +38
			Merit       15 (Gulf)	-25 to +18	RD oil 100 (Castrol)	+12to+55
			Energol RD-E l00 (BP)	+12 to+55	Hyspin   VG 10 (Castrol)	-30to +18
h)	Hydraulic system.	Engine oil in the Hyd system.	SAE  5W-20	+25 to+42			Only use in high-quality oils. Following oils and fluids are suitable for Hydraulic systems. (a) Shell Rimula R3 (engine oil) (b) Shell Tellus S (hydraulic oil.)
			SAE 5W-30	+28 to+45
			SAE 10W-30	+28 to+50
			SAE 10W-40	+38 to+60
			SAE 10W	+18 to+30
			SAE 20W-20	+32 to+45
			SAE 30	+38to+52

Note:

(a)        Never mix two different brands of oil in any system of the machine.

(b)        Do not mix one brand of Coolant/Antifreeze with a different brand.

(c)    50 Hrs, 250 Hrs and 500 Hrs maintenance are also to be carried out at the time of 1000 Hrs maintenance.

                                                                        ________