Operator’s Manual

dc302r
Operator’s manual DC302R

2 (85) B 07059--2 en 0908 / PIR

DC302R Operator’s manual

PREFACE

Thank you for selecting a Sandvik drilling rig.

This manual describes the use of the DC302R drilling rig. Only people with the proper
training are allowed to operate this unit. In addition, the operator must read and
understand the contents of the operator’s manual and the safety instructions.
The manual gives you information on the design and operation of the drilling rig that is
essential for the correct use and maintenance of the rig. It also instructs you in
shift--specific service work. Regular maintenance procedures are explained in the
maintenance instructions.
For more complicated maintenance and repair work, we recommend that you contact the
nearest authorised service shop. Our maintenance staff have the skill and special tools
needed for more demanding work.
Correct operation and observance of the maintenance instructions help in reaching the
maximum degree of utilisation and a long service life for the drilling rig.
55055051-- B

B 07059--2 en 0908 / PIR 3 (85)

Operator’s manual DC302R

CONTENTS

1. DESCRIPTION OF THE RIG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.1. Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2. Recommended operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3. Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2. SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.1. General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.2. Main safety risks related to the use and maintenance of the rig . . . 13
2.3. Radio control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.4. Dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.4.1. Protection from dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.4.2. Dust collector system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.5. Location of the warning plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.6. Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.7. Symbol plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.8. Centre of gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.9. Inclination angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.9.1. When tramming and parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.9.2. When drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.10. Danger areas during tramming and drilling . . . . . . . . . . . . . . . . . . . . . . 22
2.10.1. When tramming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.10.2. When drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.11. Manner and operating conditions in which the rig
should not be used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.11.1. Risks to persons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.11.2. Risks to the rig and environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.12. Noise level and noise emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.13. Acceleration value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.14. Safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.15. Exhaust gases and dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.16. Location and use of fire extinguishers . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.17. Emergency stops and shutdown devices . . . . . . . . . . . . . . . . . . . . . . . 27
2.17.1. Emergency stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.17.2. Safety wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.17.3. Adjusting the safety wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.18. Automatic stop functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3. OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.1. Control devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.1.1. Instrument panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.1.2. Remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.1.3. Drilling gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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3.2. Operation in cold weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

3.3. Main switch and fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.3.1. Main switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.3.2. Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.4. Welding the rig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.5. Operation with the cable, in remote control mode . . . . . . . . . . . . . . . 42
3.5.1. Connecting the remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.6. Charging the remote control’s battery . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.7. Daily pre-- shift checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.8. Starting the diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.9. Daily checks while the engine is running . . . . . . . . . . . . . . . . . . . . . . . . 48
3.10. Stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.11. Equipment positions during tramming . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.12. Tramming and stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.13. Tramming to another drilling site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.14. Moving from one hole to another . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.15. Using the winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.16. Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.16.1. Releasing the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.17. Drilling instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.17.1. Principles of percussion drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.17.2. Drilling equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.17.3. Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.17.4. Positioning and support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.17.5. Boom control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.17.6. Drilling control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.17.7. Drilling parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.18. Overhead horizontal drilling forwards and bolting upwards . . . . . . 75
3.19. Turning the boom head to horizontal drilling position . . . . . . . . . . . . 76
3.20. Rotary actuator (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.20.1. Setting the rotary actuator’s zero point . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.21. Transporting the rig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.21.1. Tramming onto a transportation platform . . . . . . . . . . . . . . . . . . . . . . . . 79
3.22. Lifting methods and lifting points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.23. Storage instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4.1. Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4.2. Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.3. Hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

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Operator’s manual DC302R

1. DESCRIPTION OF THE RIG

1.1. Intended use
The DC302R is intended for 25, 28, or 32 mm (1”, 1 1/8”, or 1 1/4”) extension rod drilling.
It is especially suited for drilling operations at foundation constructions sites and road
construction sites, canal drilling, bolting, and other special drilling tasks.

1.2. Recommended operating conditions

D Ambient temperature . . . . . . . . . . . . . . . . . . --25_C ... +50_C
D Maximum allowed height from sea level . max. 3000 m
D In exceptional cases, please contact the Sandvik engineering department.

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DC302R Operator’s manual

1.3. Components
DRILLING MODULE
1. Rock drill
1 2. Feed
3 3. Boom
2

1. Rock drill
1. Low--pressure
3 2
accumulator
6 4
7 2. High--pressure
accumulator
3. Body cylinder
4. Rotation motor
5. Spacer
1 6. Gear housing
5 7. Flushing housing

2. Feed
1. Carriage
1
2. Feed motor
3. Suction head
2

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Operator’s manual DC302R

3. Boom

1. Boom lift cylinder

2. Boom knee cylinder
3 2
3. Feed extension cylinder
4. Feed swing cylinder
5. Feed tilt cylinder
6. Boom swing cylinder
4

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DC302R Operator’s manual

CARRIER MODULE
1. Control devices
2 1 2. Power pack
3 3. Receivers
4
4. Dust collector

1. Control devices

2 1. Tramming control lever

2. Boom control levers
1
3. Drilling control lever
3 4. Instrument panel

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Operator’s manual DC302R

2. Power pack

1. Diesel engine
1 2. Compressor
3. Hydraulic pumps

2
3. Receivers
1. Fuel tank
2 2. Hydraulic receiver
1

3
4
5
6

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DC302R Operator’s manual

4. Dust collector system

1. Suction head
2. Suction hose
2 3 3. Dust collector

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Operator’s manual DC302R

2. SAFETY INSTRUCTIONS

2.1. General safety instructions

Only people who have been given specialised operation and service
training are allowed to perform operation, service, and adjustment
procedures. Read the operating and maintenance instructions before
WARNING
using or servicing the equipment.

To avoid potential damage and injuries, carefully plan your work

beforehand. The operator must have full command of all the functions of
the rig before starting to use it.
WARNING

The operator must always use the required safety equipment, such as
safety helmets, protective overalls, protective footwear, hearing
protectors, eye protectors, and other required protective equipment.
WARNING

The rock drill must be kept clean of oil and dirt. Perform maintenance
work only when the rig is parked. Use proper, suitable tools for the work.
Replace or repair faulty tools and equipment. When performing
CAUTION
maintenance and repair work, make sure there are no unauthorised
persons in the working area.

If you must weld the rig, remove the alternator wires and open the main
. switch before welding. Take into consideration the fire and explosion
hazard created by welding. Make sure that the rig and its surroundings
WARNING are clean and fireproof.

The oiler and air receiver are pressure vessels, so they must not be
repaired without appropriate permission.

WARNING

Always keep a fire extinguisher to hand, and know how to use it. Inspect
and service the extinguisher at regular intervals and according to local
regulations.
CAUTION

During operation in confined spaces, the exhaust gases and dust must
be directed in such a way that they do not return to the working area and
create a hazard.
WARNING

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2.2. Main safety risks related to the use and maintenance of the rig

MAKE SURE THAT THERE ARE NO UNAUTHORISED PERSONS IN THE

WORKING AREA WHEN DRILLING OR TRAMMING.

WARNING

Hazardous moving and rotating parts (boom, feed, and drilling

equipment). MAKE SURE THAT THERE ARE NO UNAUTHORISED
PERSONS IN THE DANGER AREA.
WARNING

Keep an eye on the movements of the rock drill when working close to
the drill. Watch out especially for the rotating drill rod.

WARNING

Hazardous boom movement. Secure the boom support before servicing

the hydraulic system.
WARNING

Insufficient rig stability. Never exceed the maximum inclination angles

Max. when parking, tramming, or drilling.

WARNING

Slipping, tripping, and falling hazard. Keep the stairs, steps, handrails,
handles, and working platform clean of oil, dirt, and ice.

WARNING

Danger of venting compressed air. The air can cause serious injury.
Allow the air to escape before opening the filling cap or the compressed
air connector.
WARNING

High-- pressure oil spray hazard. The high-- pressure oil might cause
serious personal injury. Allow the pressure to be released from the
hydraulic circuit before opening the plugs or connectors.
WARNING

When using the winch, always make sure that the winch drum has a
minimum of three (3) loops of cable. Merely locking the cable in the drum
is inadequate because the cable is subjected to tugging.
WARNING

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Operator’s manual DC302R

2.3. Radio control

The radio control system increases the usability of the DC302R drilling rig. The operator
of the rig must have sufficient knowledge before attempting to control the rig via the radio
control system.

Read the operating instructions carefully and ensure that you

understand everything.

WARNING

Keep the operating instructions safe and readily accessible.

WARNING

Make sure that there are no other transmitters in the same site operating
on the same frequency.

WARNING

Only personnel with adequate training are allowed to use the radio
control system.

WARNING

Before operating the rig, ensure that there is no--one in the danger area.

WARNING

In the event of a hazardous situation, switch off the rig and determine the
cause of the malfunction before operating the rig again.

WARNING

In the event of a hazardous situation, press the emergency stop button on

the transmitter.

WARNING

Switch the transmitter off when taking breaks as well.

WARNING

Do not leave the transmitter in a place where it could get into the wrong
hands.

WARNING

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2.4. Dust

Drilling creates dust, which may stay at the drilling site and its surroundings even when
you are not drilling.
Dust may be so fine that it cannot be seen. The fine unseen dust is very dangerous if
breathed by the operator.

Breathing dust will cause death or severe injury. Always wear approved
respirator.
DANGER

2.4.1. Protection from dust

-- Always use a respirator approved by the respirator manufacturer for the job you
are doing. Make sure that the respirator is in good condition.
-- Do not stay near suction head.
-- Do not stay near primary cyclone or dust collector.

2.4.2. Dust collector system

Make sure that the dust collector system functions well and effectively at all times. Make
sure that
-- The suction head is firmly against the ground when drilling.
-- The suction head and the suction head rubbers are in good condition.
-- The suction hoses are in good condition and tight.
-- The dust collector filters are in good condition. Use only original spare parts.
You should use the DustMizer --system, which keeps dusting at a more reduced level and
is available as optional equipment.
Using the correct drilling parameters and keeping the drilling equipment in good condition
reduces the amount of created dust.

Safe use of the machine requires skilled maintenance personnel trained

by Sandvik, and using only original spare parts. The daily and periodical
checks and maintenance must be carried out according to the
CAUTION
instructions.

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2.5. Location of the warning plates

3
1 2

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WARNING ! WARNING
DO NOT OPERATE THIS VEHICLE UNLESS YOU:
1. HAVE 2READ THE OPERATOR’S / SERVICE MANUAL.
2. UNDERSTAND AND OBSERVE ALL CAUTIONS AND
WARNINGS.
3. HAVE BEEN FULLY TRAINED. The rig is
DO NOT WORK UNDER THE BOOM WHEN DRILLING.
BEFORE TRAMMING TURN THE BOOM TO A TRAMMING
remote--
POSITION. controlled
BEFORE TRAMMING BE SURE THAT THE DUST
COLLECTOR FAN HAS STOPPED.
AFTER TRAMMING RAISE THE DRILL RIG ON THE
JACKS, LEVEL THE RIG BEFORE LEAVING THE
DRIVING PLATFORM.
EN ID = 550 266 71
NEVER OPERATE WITH LESS THAN THREE (3) ROPE
COILS REMAINING ON THE WINCH DRUM.
EN ID = 314 938 98 1
1

! WARNING ! WARNING
17_
40_
max 20˚ max 20˚ 25_ WARNING!
40_ DO NOT ENTER
Roll over hazard. MACHINE OPERATING
16_
Can cause severe
injury or death. DISTANCE!
Roll over hazard.
When tramming: Can cause severe
S keep boom in injury or death. EN ID= 232 247 08
tramming position When drilling:
S do not exceed S do not exceed 4
given gradient given gradient
angles angles.
EN ID = 233 045 08 EN ID =315 153 68

2 3

! WARNING WARNING

Hazardous moving Danger of getting

and rotating parts. tangled in the
drilling rod.
Can cause severe Can cause severe
injury. injury or death.
Do not enter working Do not install the
range with machine drilling rod into a
in operation. rotating shank or
rod.
EN ID = 207 329 38 EN ID = 550 317 32

5 5

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Operator’s manual DC302R

2.6. Type plate

55055051-- B

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2.7. Symbol plates

Main switch, carrier

Only lift the rig from these points.

Fuel tank / filling the tank

Fuses

To avoid temperature stress, let the motor idle

for three (3) minutes before stopping it.

Detach battery cables or open the main

switch before welding.

The winch drum should always have a

minimum of three (3) loops of cable.

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Operator’s manual DC302R

2.8. Centre of gravity

Centre of gravity when boom is in the tramming position.

1090

680

1140

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2.9. Inclination angles

Never exceed the maximum permitted inclination angles when parking,

drilling, or tramming.

WARNING

When tramming or drilling on a slippery surface, such as ice or plane

rock, the safe inclination angle is noticeably smaller than on holding
ground.
WARNING

2.9.1. When tramming and parking

If the terrain inclination is more than 20_, a winch must be used.

WARNING

During tramming, keep the boom in the tramming position.

WARNING

Do not exceed the specified maximum inclination angles.

20_ 20_

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2.9.2. When drilling

The figure indicates the maximum inclination angles into all directions when drilling is
performed in different boom positions.
17_

40_

25_

40_

16_

2.10. Danger areas during tramming and drilling

2.10.1. When tramming
3m

3m 3m
3m

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2.10.2. When drilling

max. boom extension

min. boom extension

2m 2m 2m

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Operator’s manual DC302R

2.11. Manner and operating conditions in which the rig should not be
used
2.11.1. Risks to persons

D Operator has inadequate training

D Unauthorised persons are in the working area
WARNING
D Safety systems are inadequate or out of order
D The area to be drilled is charged
D The rig is used for transporting people
D The rig is used for lifting

2.11.2. Risks to the rig and environment

D Risk of the embankment collapsing under the rig

CAUTION D Possibility of a loose boulder falling on the rig
D Icy or otherwise slippery drilling site
D Drilling under power lines with the danger of coming into contact
with a live power line
D Inadequate lighting

2.12. Noise level and noise emissions

Sound pressure level tests and volume measurements for the operator position have
been performed according to European Standard EN 791, Drill Rigs – Safety.
HL 300 rock drill
-- Operator position . . . . . . . . . . . . . . . . . . . . . LpA 102.5 dB (A)
ISO 11201--1995
-- Noise emission . . . . . . . . . . . . . . . . . . . . . . . LwA 122 dB (A)
ISO 4872--1978

2.13. Acceleration value

The acceleration value at the operator’s position has been measured in accordance with
European Standard EN 791, Drill Rigs – Safety. The acceleration value does not exceed
0.5 m/s2.

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2.14. Safety equipment

Check the emergency stops and safety equipment for proper

functioning and condition before the start of each shift and after
tramming.
WARNING

Fire extinguisher
Emergency stops
Pressure gauges
Indicators
Tramming and working lights
Tramming brake
Inclination gauges
Feed safety wire
Warning labels
Tramming alarm (reverse)
Warning buzzer
Beacon

2.15. Exhaust gases and dust

During operation in confined spaces, the exhaust gases and dust must
be directed in such a way that they do not return to the working area and
create a hazard.
WARNING

Never remove any elements of the engine’s exhaust system or any safety
covers and devices from the machine when it is operational.

WARNING

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2.16. Location and use of fire extinguishers

Extinguisher

Read the operation instructions on the side of the fire extinguisher. Make
sure that the extinguisher’s indicator gauge is not in the red zone. If the
indicator is in the red zone, the fire extinguisher must be serviced
WARNING immediately at an authorised service shop.

In the event of a fire

1. Stop the engine.
2. Remove the extinguisher from its holder.
3. Shake the extinguisher once or twice to mix its contents.
4. Pull the ring pin out and take the hose from its holder.
5. Assume a secure position and a good hold on the hose, and aim the nozzle toward
the flames.

6. Spray the extinguishing chemical by pressing the nozzle trigger. Stop spraying
when the flames are extinguished, in order to save as much of the contents as
possible in case the fire ignites again.
7. The extinguisher must be refilled at a service shop after each use.

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2.17. Emergency stops and shutdown devices

2.17.1. Emergency stops

Make sure that the emergency stops can be accessed at all times.

WARNING

Check the operation of the emergency stops daily.

WARNING

When one of the emergency stops is pressed, the engine stops and, along with this, all
functions cease. An indicator lamp lights up on the control panel. The engine can be
restarted only after the emergency stop has been released.

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2.17.2. Safety wire

The safety wire is located at the lower end of the feed. When the safety wire is pulled with
adequate force or the wire loosens, drilling operations stop and a red warning light on the
operating panel comes on. The engine still runs. The system is reset by pressing the
safety wire reset button. Check the operation of the stopping device daily.

Before resetting, check that the drilling control levers are not in
operating position.

WARNING

2.17.3. Adjusting the safety wire

1. During adjustment, the diesel engine must remain stopped.

2. Adjust the wire length from point A so that the edge of the attachment link is at mark
B on the switch lever.
3. Turn the power on with the ignition key, and test the switch by pulling the wire.
When the switch is activated, a red warning light on the operating panel comes on.
4. The switch is reset by pressing button C on the switch, and the indicator turns off
after the reset.

If the wire is not adjusted properly, the switch can be activated during
tramming or drilling.
CAUTION

C A

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2.18. Automatic stop functions

The engine is stopped automatically if:

-- The oil pressure sinks too low, and the indicator lamp lights on the instrument
panel.
-- The engine temperature rises too high, and the indicator lamp lights on the
instrument panel.
-- The compressor temperature rises above 115_C, and the indicator lamp lights on
the instrument panel.
Note that the engine oil pressure and charging indicator lamps are always illuminated
when the power is turned on but the engine is not running.

Engine oil Coolant Compressor

pressure temperature temperature

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3. OPERATING INSTRUCTIONS

3.1. Control devices

1. Instrument panel
2. Radio control
3. Drilling gauges

33 22

11

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3.1.1. Instrument panel

S16

H10

P1

S12

S15
S13

S2

H1 H2 H3 H4 S1

P1 Hour meter
S1 Ignition
S2 Dust collector and filter cleaning automatics selector switch
S12 Driving lights
S13 Drilling lights
S15 Anti--jamming selector switch
S16 Normal/edge anti--jamming selector switch
H1 Charging indicator (red)
H2 Engine oil pressure indicator (red)
H3 Engine oil temperature indicator (red)
H4 Compressor oil temperature indicator (red)
H10 Emergency stop indicator (red)

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3.1.2. Remote control

Never leave the remote control in the rain and avoid wetting it while
washing the machine. If the remote control is used in the rain or
otherwise wet conditions, keep it in its normal operating position (levers
CAUTION
upwards).

1 2

1. Code key (iON)

2. Emergency stop

Alarm
Power OFF
Power ON

Automatic winch
Left locked
tensioning

Oscillation open

Right locked Manual winch operation

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Water flushing Automatic hole aiming

OFF

Oscillation
Oscillation backwards,
forwards, rig tilts
rig tilts backwards
forwards

Threading close Threading open

Adjusting the feed Selecting the functions

pressure of the control levers

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Tramming and winch

Fast tramming

Slow tramming and winch

Forward
Right forward Left forward

Right forward, Left forward,

left backward right backward

No movements No movements

Right backward, Left backward,

left forward right forward
Right backward Left backward

Backward

Winch

Reel in, Reel out,

manual operation manual operation

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Jacks

Rear jacks down

Rear jacks up

Front jacks down

Left front jack down Right front jack down

Left front jack up Right front jack up

Front jacks up

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Boom and drilling control

Note! When the switch is in
this position, the drilling
functions too can be
operated.

PITO closed
Knee boom up

Rotation head clockwise Rotation head

anticlockwise

Boom turns to the left Boom turns to the right

PITO open
Knee boom down

Feed down
Base boom down

Lower end of feed Lower end of feed

forward backward

Lower end of feed left Lower end of feed right

Feed up
Base boom up

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Feed
Fast feed

Percussion + rotation Rattling

anticlockwise

Percussion + rotation
Rotation anticlockwise clockwise

Feed return
Fast feed return

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3.1.3. Drilling gauges

11 12 13 14

17 S50

16

18 45 46

S50 Anti--jamming pressure switch

11. Percussion pressure gauge
12. Rotation pressure gauge
13. Feed pressure gauge
14. Air pressure gauge
16. Feed and percussion ratio valve
17. Rotation flow--control valve
18. Threading synchronisation valve
45. Compressor temperature gauge
46. Hydraulic oil temperature gauge

3.2. Operation in cold weather

When the temperature is under 0_C, the passageways and handles of the rig must be kept
free of ice.
When starting a cold engine, refer to the instructions given in the section on starting a
diesel engine.
In cold weather, viscous hydraulic oil causes great flow resistance, so start the oil
circulation through all the components very carefully. Keep drill rotation on for a while
before starting percussion.
In very cold weather conditions, it is necessary to warm the engine oil before starting, by
using, e.g., a block heater.

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3.3. Main switch and fuses

3.3.1. Main switch

The main switch is located at the back of the rig.

3.3.2. Fuses

The main fuses (2 fuses, 25 A and 50 A) are located under the side panel.

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Operator’s manual DC302R

Additional fuses F1 -- F7 (7 pcs.) are located in the electric cabinet.

X2.1

NAARAS UROS
X3

ZERUST VC2-2

LUSTARELE

K9
U3
V200
V201
V202
V10
V11

F1
F2
F3
F4
F5
F6
F7
V4
V5
V8
V9

K3 K10 K12 K13

K1 K15

K2 K3.1 K8

X1:101-130, 153-165, 400

X1:1-15

1 2 3 4 5 6 7 8 9 10 11 12 13 15
+ + + + + + + + - - - - - - - -

+ + + + + + + + - - - - - - - - 153 154 155 156 157 158 159 160 161162 163 164 165 400

101 102103 104 105 106 107 108109110 111 112113 114 115 116 117 118 119120 121 122 123 124 125 126 127 128 129 130
X1
K217
MIINUS

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3.4. Welding the rig

Never repair the boom, boom components, or cylinders by welding.

CAUTION

The rig is equipped with electrical and electronic components that can
be damaged if the rig is welded. When welding the rig, comply with the
following instructions fully.
CAUTION

1. Stop the engine by turning the ignition key to the STOP position.
2. Open the main switch.
3. If the rig is equipped with TIM drilling instrumentation, disconnect the cables of the
operating panel, valve control unit, and sensors.
4. If the rig is equipped with a radio control system, disconnect the cables from the
radio receiver when welding near the receiver.
5. Attach the welding ground cable directly to the part to be welded. The cable must
be attached as close to the welding point as possible and such that the welding
current does not pass through bearings, hydraulic components,
electrical/electronic components, or the rig’s ground cable.
6. Check the grounding. Ensure that proper grounding is not prevented by, e.g., paint.
7. Follow the welding instructions.

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3.5. Operation with the cable, in remote control mode

The remote control is powered by the drilling rig’s electrical system when the cable is
connected.
In cold conditions, the use of the cable is recommended.

3.5.1. Connecting the remote control

1. Turn the power off by using the carrier’s ignition key.
2. Turn the remote control power off.
3. Remove the remote control’s battery.
4. Connect the connecting cable: Receiver – Remote control.
5. Turn the carrier power on.
6. Turn the remote control power on.

3.6. Charging the remote control’s battery

The charger is in the tool box.
A 230V charger is available for the rig.
The charging time is about 3 hours.
The charger features overcharge protection.
The recommended charging temperature is +10 ... +40qC.
It is recommended that the battery be charged daily.

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3.7. Daily pre--shift checks

Checks before starting the engine

Check the engine oil level (1).

The oil level must be between
the lower and upper markings.

Check the tightness and

condition of the V--belt (2).

Drain the water from the water

separator (3).
2

3 1

Check the hydraulic oil level.

3
34
45
56 Check the fuel level.
6

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Check the compressor oil level.

Check the tightness and

condition of the feed chain.

Lubricate the lower sprocket.

ROCK DRILL

Grease the shank with shank

lubrication grease:
2 grease nipples, 2 -- 3 presses
each after the shift, when the
rock drill is warm.

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Check the rock drill’s fastening

to the carriage visually (bolts 1,
2, and 3).

2 1

1 Check the fastening of the rock

3 drill’s flushing housing visually
(bolts 1, 2, 3, and 4).

4 2

Check the reading of the diesel

engine hour meter.

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Check the diesel engine and

compressor suction hoses and
their connections.

Check the oil level of shank

lubrication unit (1) (optional).

2 Drain accumulated water from the

shank lubrication unit (2) (optional).

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3.8. Starting the diesel engine

Always before starting, you must check that there are no unauthorised
persons within the danger area and that the control devices are not
switched to the operating position.
WARNING

Check that the emergency stop buttons are up and check that safety wire
is not activated.

WARNING

Starting a cold engine

1. Turn the main contact switch to the ON position.
2. Turn the ignition key to position (1).
3. Turn the remote control power on (S25.1). The red light (H10) has to go off after
c. 3 seconds. Remote control green light (H20) goes on. Engine does not start if
communication to remote control does not work, use cable if necessary.

H10

Pre--heating

S25.1 H20 Starting

4. Turn the ignition key for 6 seconds to pre--heating position and start the engine by
turning the ignition key to the starting position. As soon as the engine starts,
release the ignition key and make sure that the charging and oil pressure indicator
lamps are not illuminated.
5. In extremely cold conditions (below –15_C), the ball valve of the air outlet can be
kept open during starting in order to reduce the load on the starter motor.

However, in order to ensure compressor oil circulation, the valve must be

closed right after the engine has started.
CAUTION

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Operator’s manual DC302R

Do not attempt starting for longer than 30 seconds at a time. Let the
starter motor cool off for one (1) minute before restarting.
CAUTION

6. Additional starter batteries are recommended if you intend to start the equipment
at a temperature of under –18_C.

Engine running speed can be controlled with the hand throttle. The rig is also equipped
with rotation speed automatics that change the running speed of the diesel engine
according to whether there is pressure in the rock drill’s percussion line or not.
The engine cannot be started by towing.

CAUTION

3.9. Daily checks while the engine is running

Checks while the engine is running

Check the operation of the

lights (1).

1 Engine oil pressure (2).

Engine temperature (3).

Compressor temperature (4).

2 3 4

Check the operation of the

gauges.

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Check the operation of the

emergency stops, safety wire,
and alarm.

Check the service indicator of

the compressor intake air filter.

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Check the condition of the dust

collector filters.

Check the condition of the dust

collector system’s hoses and
hose connections.

Check that there are no oil

leaks in the rig.

Check for possible rock drill oil

leaks during drilling.

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The greatest risks related to diesel engine exhaust fumes are caused by
nitrogen oxides and carbon monoxide. DO NOT USE THE RIG IN
ENCLOSED SPACES WITHOUT ADEQUATE VENTILATION.
WARNING

Do not leave the rig idling unattended.

CAUTION

3.10. Stopping the engine

Stop the engine by turning the ignition key to position 0. Also, there is a lever on the engine
for mechanical stopping. If necessary, it can be used as an emergency stopping device.
In a hazardous situation, the engine can also be stopped using the
emergency stops.
CAUTION

Never turn the main switch off while the engine is running. This might
harm the charging generator and the voltage regulator.
CAUTION

Before the engine stops, let it idle for three (3) minutes so that the
temperature stress has time to even out.
CAUTION

3.11. Equipment positions during tramming

1. The boom is in the lower position and on the transportation support.
2. The feed is in the rear position and on the transportation support.
3. The dust collector is turned inward.
4. The grinding unit is turned inward.
5. The jacks are up.
6. The remote control is in its holder.
2 1

4
3 5 5

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3.12. Tramming

Never tram the rig when the dust collector is running.

CAUTION

Fast tramming

Slow tramming and winch

D Tramming is controlled by using the right tramming control lever.

D The rig starts moving when tramming control lever is pushed slowly forward. To
reach the maximum speed, push the lever forward as far as it will go. When you
want to reverse, pull the lever toward you.
D If you want to turn right when tramming forward, push the tramming control lever
to the right.
The rig has two tramming speeds. The speed can be changed during tramming. When
the speed is changed, the torque of the tramming motors changes, too.

D Keep the oscillation valve open (in the middle position) while tramming so that the
wheels can move freely. This improves manoeuvrability.
D Use fast tramming when the tramming conditions are good.
D Use slow tramming speed on difficult terrain so that the torque of the tramming
motors is high and the movements of the rig are slow.
D When tramming on uneven terrain, use oscillation to keep the rig as level as
possible.
D If there is an obstacle under the wheels of just one side, use oscillation to ensure
the stability of the rig and make sure that the rig does not fall abruptly from the
obstacle.

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3.13. Tramming to another drilling site

1. Secure the equipment in tramming position; refer to the section ‘Equipment
positions during tramming’.
2. Check before starting the engine that the tramming control lever is centred.
3. Start the engine.
4. Drive with utmost care to the next drilling site.

3.14. Moving from one hole to another

1. Lower the boom onto the transportation support.
2. Stop the dust collector and the cleaning automatics by turning the operating panel
selector switch (S2) to position 0.
3. Lift the jacks up.
4. Tram to the next hole.

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3.15. Using the winch

Tipping hazard. Can cause severe injury or death. Never exceed

maximum allowed inclination angles (when drilling or tramming).

WARNING

When using the winch, always make sure that the winch drum has a
minimum of three (3) loops of cable. Merely locking the cable in the drum
is inadequate because the cable is subjected to tugging.
WARNING

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.

WARNING

>10_

If the terrain’s inclination is more than 20_, a winch must be used.

WARNING

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Automatic winch
tensioning

Manual winch operation

Winch

Reel in, Reel out,

manual operation manual operation

Select automatic winch tensioning or manual operation with remote control’s selector
switch (S18).
The winch is operated with the left control lever of the remote control.
Monitor the condition of the cable. Replace the cable if the strands are frayed; refer to
instructions C 87100.
Always keep a slight tension in the cable when tramming. This ensures that the cable does
not sag. This will prevent sudden tugs and the breaking of the cable. Make sure you reel
the cable evenly onto the drum. A tangled cable breaks easily.

To ensure proper operation of the winch brake, the cable must be reeled
onto the drum anticlockwise, as seen from the direction of the hydraulic
motor. If the cable is reeled in the wrong way, the winch brake will not
WARNING function. The rig will then not be kept in place by the winch.

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3.16. Towing

Always exercise great caution when towing.

WARNING

Make sure that the brakes of the towing vehicle are in proper condition
and that they are efficient enough to stop both vehicles in all situations.

WARNING

Do not try to start the rig by towing.

CAUTION

3.16.1. Releasing the brakes

If the rig needs towing, the tramming motors must be set to neutral. Make sure that the
rig is not able to move by itself on a slanted surface.

When the tramming motors are set to neutral, there are no brakes
available for the rig.

WARNING

The rig must be attached to the towing vehicle before the brakes are
released.

WARNING

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At the end of the motor there is a plug (G) under which there is a piston with a tapped hole
(M16) for a pull--out screw (1). Place a strong washer (2) between the motor cover and
the pull--out screw to act as a mating surface. The brake is released by turning the pull--out
screw clockwise. Approximately one full rotation of the pull--out screw is enough to release
the brake.
Note that these procedures must be performed for both tramming motors.
After the brakes are released, the towing must be performed using a stiff towing bar.
Tramming speed during towing should not exceed 3 km/h.
The tramming motor brakes must be engaged before detachment of the
rig from the towing rig.

WARNING

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3.17. Drilling instructions

3.17.1. Principles of percussion drilling

PERCUSSION

FEED
ROTATION

Percussion drilling has four main functions:

D Percussion, which makes the drill

bit penetrate the rock
D Feed, which keeps the drill bit in
FLUSHING tight contact with the rock
D Rotation, which turns the drill bit to
a new position before the next
percussion
D Flushing, which removes the
cuttings and cools the drilling
equipment

The percussion energy created by the rock

drill piston is transferred to the rock through
the drilling equipment.

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Percussion

The percussion power is generated by the

percussion force, the percussion
frequency, and the drill bit’s penetration.
The percussion power is conveyed to the
rock through the drilling equipment.
Percussion power can be directly
controlled by using percussion pressure.

One basic issue in drilling is the ability to

transfer energy. Only a maximum of a
certain amount of kinetic energy can be
transferred using drilling equipment of a
certain size. When the equipment’s ability
to transfer energy is exceeded, equipment
damage increases rapidly.

The percussion power used depends on

the quality of the rock to be drilled. If the
rock is soft, a lower percussion pressure
can be used. If the rock is hard, a higher
percussion pressure is used.

Setting the percussion pressure always

involves a compromise between
penetration rate and equipment durability.

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Feed

The purpose of the feed is to keep the

shank tightly connected to the rock drill and
the drill bit tightly connected to the rock.

When the percussion pressure is

increased, the feed pressure must also be
increased. The correct feed power
depends on the percussion pressure, rock
conditions, hole depth, and the size and
type of the drilling equipment.

Broken rock should be drilled using low

percussion pressure and low feed
pressure.

The correct feed pressure can be

determined by observing and listening.
OBSERVE the following things:
-- The constant progressive
movement of the rock drill (the
drill carriage should not shake)
-- Constant rotation of the rock drill
(constant rpm)
-- Tight shank connection (the
connection cannot
overheat/bend/turn blue/smoke)
-- Constant penetration
LISTEN to the following things:
-- Constant drilling sound (no
rattling or shaking sounds)

Excessive feed power does not increase

penetration – it only increases drill bit wear
and causes irregularity in the drilled holes,
and it bends the rod, causing unusually
high rotation pressures.

Inadequate feed power leads to the drill bit

not staying in contact with the drilled rock.
This causes the percussion energy to be
reflected back to the drilling equipment,
causing damage to the equipment, the rock
drill, and the drill carriage.

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Rotation

The main purpose of rotation is to turn the

drill bit to a new position after each
percussion. The correct rotation speed
depends on the form and diameter of the
drill bit, hole depth, rock conditions, and the
other main operations involved in drilling.

Inadequate rotation speed causes energy

loss (the cuttings are ground too finely) and
leads to poor penetration.

Excessive rotation speed causes rapid

wear of the drill bit because the rock gets
broken by the rotation, not by the
percussion. Excessive rotation speed also
leads to the tightening of threaded
connections, which causes problems for
the opening of those threads.

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Flushing

The purpose of flushing is to remove the

cuttings from the drill shaft and to cool the
drill equipment. The flushing air is carried
to the bottom of the hole through the rod
hole and the holes in the drill bit. The
mixture of flushing air and cuttings is
guided out through the hole, through the
space between the rod and the wall of the
hole.

Poor flushing leads to low penetration

(cuttings are ground at the bottom of the
hole), to short drilling equipment service life
(the risk of rod jamming is increased), and
to rapid wear of the drill bit.

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3.17.2. Drilling equipment

Shank

Impact energy and rotation torque of rock

drill is transferred to drilling equipment
through shank.

Coupling sleeve

Coupling sleeves connect extension rods

to one another.

Extension rods

Both ends of an extension rod have

identical threads. Rod length is usually
10--12 ft. (300 -- 360 cm).

MF rods

MF rods have a male thread in one end

and a female thread in the other. Rod
lengths are the same as for extension
rods.

Drill tubes

Tube equipment have threads as in MF

rods. Drill tubes have large--diameter
flushing holes. Guide tubes are used in
difficult drilling conditions.

Drill bits

Button bit is the most common drill bit

type. Its advantages are good penetration
rate, durability, and easy resharpening.
Various types of button bits are available
for different drilling conditions.

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Example of the use of different drilling equipment. Guide tube and special bit is used when
straight holes are required and the drilling conditions are difficult.

Shank Shank Shank

Coupling sleeve

MF rod MF rod
Extension rod

Coupling sleeve

Guide tube
MF rod

Extension rod

Drill bit

Drill bit Drill bit

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3.17.3. Safety precautions

Note all safety precautions.

CAUTION

Always check the drilling site visually before starting the power pack and
beginning to drill.

WARNING

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

WARNING

Before moving the boom or starting to drill, make sure that there are no
unauthorised persons in the drilling area.

WARNING

Be careful of the rotating drill rod.

WARNING

Never mount a rod on the rock drill / shank when drill rotation is on.

WARNING

When checking rig operations, pay special attention to:

D Operation of the emergency stop buttons

D Operation of the boom and feed movements
D Operation of the rock drill percussion, feed, and rotation
D Condition of the hoses and connections

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3.17.4. Positioning and support

When drilling occurs on a slope, the feed must be on the downhill side.
Begin positioning and supporting the rig by running the front jacks down, so that the rig
is straight laterally.
Lower the rear jacks, so that the rig is straight.

1. Start the dust collector and the filter cleaning automatics by turning the operating
panel selector switch (S2) to position 1.
2. Switch the anti--jamming automatics on by turning the operating panel selector
switch (S15) to position 1, and select normal or edge anti--jamming with the switch
(S16).
3. Check that the remote control selector switch (S8) is in position 1 (boom control).

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3.17.5. Boom control

Before the boom is moved from the transportation support, the rig must
be supported by the jacks.

WARNING

1. Check that the remote control selector switch (S8) is in the boom control position.
2. Push the control lever (S6) forward (base boom down) and push the control lever
(S4) forward (knee boom up).
3. If the boom needs to be turned, tilt the control lever (S4) to the right or to the left.
4. Find the correct drilling direction by tilting the control lever (S6) to the right or to
the left (feed tilt and swing).

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3.17.6. Drilling control

1. Start the dust collector and the filter cleaning automatics by turning the selector
switch (S2) on the operating panel to position 1.
2. Switch the anti--jamming automatics on by turning the selector switch (S15) on the
operating panel to position 1, and select normal or edge anti--jamming with the
switch (S16).
3. Turn the remote control selector switch (S8) to drilling control position.
4. Tilt the control lever (S7) two positions to the left. and then push it forward.
When the control lever is tilted to the left, rotation starts first and then percussion. When
the lever is pushed forward, feed starts.
Use the feed adjustment when beginning to drill a hole. When the anti--jamming
automatics are on, feed switches automatically to low pressure for 3 -- 5 seconds when
you are beginning to drill a hole.

Do not attempt to increase feed pressure during the collaring load relief.

CAUTION

Hold the tip of the feed device in contact with the rock during drilling. This is to avoid
unnecessary shaking as well as rapid wear to the centraliser, drilling equipment, and rock
drill. Also, the penetration rate decreases if the feed is not in contact with the rock.
When percussion is engaged, the rpm cylinder affects the throttle levers and the running
speed of the motor increases.
Flushing starts automatically when percussion is started. At the same time, the cleaning
automatics of the dust collector filters are switched off (controlled by the flushing pressure
switch).

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5. If necessary, adjust the feed pressure and the anti--jamming automatics.

11 12 13 14

17 S50

16

18 45 46
S50 Anti--jamming pressure switch
11. Percussion pressure gauge
12. Rotation pressure gauge
13. Feed pressure gauge
14. Air pressure gauge
16. Feed and percussion ratio valve
17. Rotation flow--control valve
18. Threading synchronisation valve
45. Compressor temperature gauge
46. Hydraulic oil temperature gauge

-- Close the pressure switch (S50) adjustment knob of the anti--jamming automatics
by turning it clockwise. Now the anti--jamming automatics’ adjustment is so tight
that the anti--jamming action does not operate.
-- Adjust the feed by turning the remote control adjustment knob (R1) clockwise or
anticlockwise. Pay special attention to the rotation pressure gauge (12) and the
rotation of the drill rod, and to the sound and vibration of the rock drill. The feed
pressure is determined by the rock drill, the hole size, and the type of rock being
drilled. In drilling solid rock, normal feed pressure is usually achieved when the
rotation pressure is 30 -- 50 bar.
-- Check the rotation pressure from the pressure gauge (12). Open the adjustment
knob of the anti--jamming automatics’ pressure switch (S50) so that its scale’s
pressure reading is 20 -- 30 bar higher than the rotation pressure reading.
Monitor the operation of the anti--jamming automatics, opening or tightening the pressure
switch adjustment knob of the anti--jamming automatics as needed. If drilling using
anti--jamming is not successful, switch off the anti--jamming automatics (disengage
drilling first) and carefully run through the rock fracture using subtle feed.
When the oil is cold, the anti--jamming automatics operate more sensitively.

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The feed and the anti--jamming automatics must usually be readjusted

when hole size or rock type changes!
CAUTION

If, despite this, the drill rod gets jammed, detach the rod from the fracture by using rotation,
feed, and percussion.
Continue drilling as usual, but adjust the anti--jamming automatics as soon as possible
because the adjustments are clearly not correct. If necessary, adjust also the
anti--jamming time relays; refer to separate instructions C 73156.

6. Adjust the rotation speed.

The rotation speed is primarily determined by the hole size. In addition, the model of the
bit and the type of rock drilled must be taken into account in adjustment of the rotation
speed. Adjust the rotation speed during drilling with the flow--control valve as follows:

Bit diameter Rotation speed

mm in. 1/min
38 1 1/2 150 - 220
51 2 120 - 180
64 2 1/2 100 - 160

When drilling with a button bit, use a rotation speed approx. 30 -- 50 1/min lower than that
used with piece bits.
When drilling soft rock, use a higher rotation speed than that used with hard rock.
Optimal rotation speed is achieved by observing the drilling and by trying various
adjustment values.
Pay attention to the following things:
-- Bit wear
-- Button breakdowns
-- Rotation pressure
-- Smoothness of rotation
-- Roughness of cuttings and the efficiency of their removal

In general, the rotation speed must be readjusted when hole size or rock
type changes!
CAUTION

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7. Monitor the gauge readings during drilling, especially those of the oil temperature
meter and the pressure gauges for flushing and rotation. Deviations in oil
temperature and flushing pressure are signs of a malfunction (clogged drill bit, dirty
radiator, etc.). Note that a clogged drill bit usually manifests itself as an increase
in flushing pressure.

8. When the rock drill has travelled the entire feed length or the desired hole depth
has been reached, return the control lever (S7) to its middle position; this stops the
percussion, rotation, and feed. Run the rock drill back to the upper end of the feed
by tilting the control lever to the back while simultaneously pushing the fast feed
push button on control lever (S7).
The cleaning automatics of the dust collector filters are engaged automatically when the
percussion is disengaged.

The dust collector filters must be replaced immediately if drilling dust

appears from the dust collector outlet (between the cover and the frame).
CAUTION

Never tram the rig when the dust collector is running. Stop the dust
collector by turning the selector switch (S2) to position 0.
CAUTION

Adding drill rods

Never mount a rod on the rock drill / shank when drill rotation is on.

WARNING

1. When the extension sleeve comes close to the PITO centraliser jaws, open the
jaws enough to fit the sleeve between them.
2. You can ease off the feed when the lower edge of the extension sleeve is at the
level of the PITO centraliser’s upper edge.
3. When the extension sleeve is between the PITO centraliser jaws, stop feed first,
then percussion and rotation.
Open the threading as follows:
-- Run the drill bit against the bottom of the hole.
-- Switch feed off.
-- If the threading does not open, repeat feed and hammering.

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4. Stop rotation and, with fast feed, reverse the rock drill up enough to add the next
rod. Do not run the rock drill against the limiters with fast feed.
5. Position the next drill rod, and start thread tightening with the push button (S9).
6. Open the PITO centraliser jaws, and lift the rod string slightly upward.
7. Continue drilling. When the extension sleeve has passed the PITO centraliser
jaws, close the jaws.

Stopping drilling

1. When the desired hole depth is almost reached, ease off feed.
2. Stop feed first, then percussion and rotation.
3. Hammer the rod string against the bottom of the hole until the threads open up.
4. Lift the rod string until the extension sleeve is between the PITO centraliser jaws.
You can use fast feed.
5. Close the PITO centraliser jaws, and thread the joint open.

Be careful when using detachable sleeve equipment!

WARNING

6. Move the drill rod to the rod bracket.

7. With fast feed, run the rock drill close to the extension sleeve and thread the rock
drill to the extension sleeve.
8. Do not lift the drill bit through the suction head seal rubber, as the drill bit wears
the seal rubber down quickly.
9. Lift the feed carefully so that the hole does not collapse.
10. Use the alignment control levers (S4 and S6). Lift the feed up with the feed
extension cylinder to get the boom’s supporting point as low as possible.
11. Run the feed almost to the correct angle without lowering the stinger to the ground
(the feed angle changes slightly when the feed is pushed to the ground). Always
lower the feed to the ground with the feed extension cylinder to ensure sufficient
weight for the stinger.
If you change the position of the boom while the stinger is in the ground, always run two
opposite movements simultaneously (for example, boom lift cylinder and knee boom
cylinder, or feed side tilt cylinder and boom swing cylinder) to avoid unnecessary stress
on the structures and to ensure that the stinger stays put when drilling begins.

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3.17.7. Drilling parameters

The level and ratio of percussion pressure, feed power, and rotation speed vary according
to the rock type being drilled and the hole size. Drilling parameters must be adjusted
whenever the drilling conditions change. The following tables present the standard drilling
pressure as well as typical parameter adjustment errors and their consequences. Use the
tables to correct adjustment errors.

Rock drill Flushing Percussion Rotation Feed

HL 300
Drilling 5 -- 7 bar 130 -- 150 bar 30 -- 50 bar 60 -- 90 bar

ERROR CONSEQUENCE

Percussion -- Feed power requirement increases.

pressure too high -- Service life of rock drill and drilling equipment
CUSSION

decreases.
-- Hydraulic oil overheats.
-- Risk of the rod getting stuck increases.
PERC

Percussion -- Penetration rate decreases (in drilling soft stone, the

pressure too low best penetration performance and drilling equipment
life is achieved with a percussion pressure lower than
that used when drilling hard rock).

Rotation speed too -- The outer edge of the drill bit wears down too quickly
high (‘risk of anti--tapered bit’).
-- Drilling cuttings are fine--grained.
TATION

-- The components of the rock drill and rotation

mechanism wear down.
ROTA

Rotation pressure -- The drill rod rotates irregularly..

too low -- The penetration rate decreases.
-- The drill rod and the rotation mechanism are under
greater stress than is normal.

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ERROR CONSEQUENCE

Feed force too high -- Rotation falters (presents as uneven rotation

pressure).
-- Rotation moment increases (presents as an increase
in rotation pressure), causing overstrain on the drilling
equipment and the rock drill rotation mechanism.
NOTE! Increased rotation pressure may also be
caused by a bent drill rod or other abnormal rotation
resistance.
-- The drill rod bends, the centralisers and chuck wear
down, and the risk of the piston hitting the rod shank
at an angle is increased.
-- The sound of the rock drill changes.
FEED

NOTE! INCREASING FEED EXCESSIVELY DOES

NOT INCREASE THE PENETRATION RATE.
F

Feed force too low -- The rock drill jumps and shakes (clinking sound).
-- Excessive wear occurs to the front end of the chuck
and the drill rod collar.
-- The rock drill’s jointing surfaces wear down
(shortened service interval).
-- The penetration rate decreases. The rock drill is not
in the correct position when the piston strikes; this
means that only a small proportion of the percussion
power is conveyed to the rock.
-- The service life of the drilling equipment decreases
(equipment exhibits high tensile stress).

Flushing pressure -- The risk of the rod getting stuck increases.

too low -- The drill bit wears down quickly.
FLUSHING

-- Shank lubrication operates poorly.

-- The penetration rate decreases.
-- Drilling cuttings are fine--grained.

Flushing pressure -- The drill bit wears down needlessly.

too high -- The diesel engine of the rig is stressed needlessly.

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3.18. Overhead horizontal drilling forwards and bolting upwards

The DC302R rig must not be used for drilling forwards or bolting
upwards, unless the base boom is lifted to its upright position.

WARNING

If the base boom is tilted backwards, the overcentre valve of the lift cylinder can open as
a result of feed force and boom weight. This will allow the boom to fall backwards causing
a hazardous situation.

Base boom

Lift cylinder

Danger area

90˚

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3.19. Turning the boom head to horizontal drilling position

Turning of the boom head must always be carried out by two persons.
1. Run the boom out, turn the feed so that it is vertical, and lift the feed slightly off the
ground.
2. Remove the rod, and run the rock drill to the lower end of the feed.
3. Open the four bolts (1) at the corners of the flanges at the middle of the boom head.
Do not open the other two flange nuts (part 2 in the figure below), as
otherwise the boom head will fall and possibly cause injury.

WARNING

4. Tilt the feed left (swing).

5. Run the rock drill upward carefully just below the middle section of the feed.
6. Take hold of the lower end of the feed, and lift it so that the boom head turns; the
boom head can be turned 90_ or 180_. Tighten the flange bolts.
7. It is recommended that horizontal drilling be carried out parallel to the rig’s
tramming direction and forwards with the feed rotated 180_ from the normal
vertical drilling position.
If the flushing hose is in the way during drilling with the back of the rig downward, turn the
flushing housing 90_, disconnect the hose from the bulkhead plate, and re--route it to run
along the side of the rig.
When the feed is in horizontal orientation, make sure that there are no
rods in the rod bracket.

WARNING

1
2
Warning!
Do not open
these.

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3.20. Rotary actuator (optional)

With the hydraulic rotary actuator, the feed can be turned horizontally ±180_.

±180_

3.20.1. Setting the rotary actuator’s zero point

1. Remove the rod, and run the rock drill to the lower end of the feed. Run the feed
extension cylinder to the minimum length.
2. Run the boom out, and turn the feed as shown in the figure.
3. Keep the tip of the feed as close to the ground as possible.
4. Loosen the rotary actuator’s cover bolts, 24 pcs. (1), about 5 mm.
5. Pull the cover (2) in the direction indicated by the arrow, against the bolts.
6. Rotate the tip of the feed by hand in the desired direction until the required zero
point is reached. Do not let the feed rotate after that point has been reached.
7. Tighten the 24 bolts (1) crosswise. The tightening torque is 148 Nm.

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When the bolts (1) are loose, the feed can rotate by itself. Ensure that
unintended rotation of the feed is prevented at all times.

WARNING

Check the tightness of the rotary actuator bolts every 500 operating
hours.
CAUTION

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3.21. Transporting the rig

3.21.1. Tramming onto a transportation platform

Before tramming onto a transportation platform, the boom, feed, dust

collector, remote control, and grinding unit must be placed in their
transport positions. Never exceed the maximum allowed inclination
WARNING angle.

Max. 20_

D When you are tramming the rig onto a transport platform and off it, use access
ramps. Loading must always be performed on level ground.
D Always use low speed and observe great caution when tramming the rig from the
ramps to the transport platform.
D Lower the rear jacks before transport.
D Use straps or chains to fasten the rig so that it cannot move during transport.

Always take into consideration the maximum height and width of the
transport vehicle.
CAUTION

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3.22. Lifting methods and lifting points

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Always follow the appropriate legislation and safety regulations

concerning lifting safety in the location where lifting will take place.

WARNING

Take into consideration the rig’s total weight, indicated in the technical
specifications.

WARNING

D Use only a lifting device of the appropriate type and with sufficient lifting capacity.
The rig or its components may not be lifted using any devices other than those
designed for lifting purposes. Do not use, for instance, a loader for lifting.
D You must know the weight of the load, and the capacity of the lifting device, as
specified by the manufacturer, is not to be exceeded.
D Lifting routes must be planned so that loads are not lifted over people or locations
where there might be people.
D Check that the lifting device is in good condition.
D The lifting wires and chains must be checked regularly. Damaged wires and chains
must be marked clearly and removed from use immediately.
D The rig may be lifted only from the locations marked with a hook symbol.

D Make sure that the load is properly fastened and balanced. To check fastening and
balance, lift the load up only a few centimetres initially. Do not continue lifting until
you are certain that the fastening and balance are good.
D Never twist the wires and chains around the lifting hook. Lifting wires and chains
must be fastened according to the manufacturer’s instructions.

NOT LIKE THIS LIKE THIS

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3.23. Storage instructions

Surroundings

D The storage temperature should be between 0 and +35_C, and the rig must be
protected from sun and rain.
D Humidity should be below 90%.

_C F
30 86
20 68
10 50
0 32
max. 90%

Rig
D Wash the rig thoroughly if it will be stored immediately after use or if it has been
transported from overseas (use a pressure--cleaning unit or steam).
D Grease all the lubrication points.
D Purge the pressure accumulators and place warning labels on the rig. The
pressure accumulators must be refilled before initiating use again.
D Spread protective grease on the cylinder piston rods.
D Change all lubricants and fluids, which may have deteriorated in use.
D Protect the electric devices with anti--corrosive agent to prevent contact faults.

Spray protective grease, order number 867 430 49, into the following locations:
-- terminal strips
-- battery terminals

Spread protective grease, order number 867 429 89, into the following locations:
-- multi--terminal strips
-- the terminals of the solenoid valve connection caps, pressure switches, etc. Fill the
connection caps with grease.

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4. TROUBLESHOOTING
4.1. Engine
FAULT POSSIBLE REASON / PROCEDURES

1. The starter motor 1. The emergency stop button is pressed down. Release
does not crank the the button.
engine. 2. Power is not switched on at the main switch. Switch
power ON.
3. The battery has discharged. Detach and charge.
4. Break in the circuit. Check, and repair if necessary.
5. The main fuse has blown. Replace the fuse.
6. Faulty starter motor. Check, and repair if necessary.
7. Faulty starter motor relay. Replace the relay.

2. The engine starts 1. The automatic stop function has stopped the engine.
poorly or not at all. Inspect to find the reason and repair, or let it cool off
before attempting to restart.
2. Pre--heating time too short. Pre--heat longer.
3. Fuel has run out. Refuel.
4. Fuel filter clogged. Check, and repair if necessary.
5. Wrong fuel. Switch fuel.
6. Fault in the transfer pump, spray pump, or nozzles.
Check, and repair if necessary.

3. The engine 1. Engine overloads. Find out the reason and repair.
overheats. 2. Fan belt broken or slipping. Replace or tighten belt.
3. Radiator clogged. Clean radiator.

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4.2. Compressor
FAULT POSSIBLE REASON / PROCEDURES

1. Air supply is 1. Compressor belt broken or slipping. Replace or tighten

insufficient belts.
2. Clogged suction air filter. Clean or replace the filter.
3. Clogged oil separator. Replace oil separator.
4. Pressure release valve open. Check the valve.
5. Output valve closed. Check for jamming.
6. Air consumption too high. Check air--consuming devices
(e.g., the blow--off valve and drill--steel retainer), and
inspect for leaks.
7. Compressor screws worn down.
8. The blow--out valve of the dust collector filters is faulty.

2. The compressor has 1. Insufficient oil level. Check the oil, and add more if
overheated. needed.
2. Radiator clogged. Clean the radiator.
3. Wrong oil in the compressor. Switch oil (refer to oil
recommendations).
4. Compressor screws worn down.
5. Faulty thermostat.

3. Oil consumption is 1. Oil return pipe and its filter and/or orifice clogged. Open
too high. and clean.
2. Oil separator cartridge damaged or loose. Check, and
repair if necessary.
3. Oil separator cartridges clogged. Change the oil
separator cartridges.
4. Wrong oil in the compressor. Switch oil (refer to oil
recommendations).

4. System pressure 1. Control valve not operational. Check, and repair if

rises above the necessary.
predetermined 2. The intake valve does not close. Check intake valve,
threshold. and repair or replace if necessary.
3. The shaft seal of the air end is leaking. Replace the
shaft seal.

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4.3. Hydraulic circuit

FAULT POSSIBLE REASON / PROCEDURES

1. Pump output is 1. Pressure relief valve incorrectly adjusted, or internal

insufficient or there leak in the valve. Adjust and check.
is not enough 2. Leak in the hoses. Check, and repair if necessary.
pressure.
3. Clog in the hoses. Check, and repair if necessary.
4. Gearing from motor to pump broken. Check, and repair
if necessary.
5. Pump damaged. Repair or replace pump.
6. Motor rotation speed too low. Adjust rotation speed.
7. Faulty rock drill. Check, and repair if necessary.

2. Hydraulic oil 1. Insufficient oil level. Check the oil, and add more if
overheats. needed.
2. Radiator clogged. Clean the radiator.
3. Thermostat valve damaged. Check, and repair if
necessary.
4. Incorrect hydraulic oil. Switch hydraulic oil (refer to oil
recommendations).
5. Motor rotation speed too high. Adjust rotation speed.
6. Fan V--belt broken or slipping. Replace or tighten belt.

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