460 Electrical Training Manual

DC ELECTRICAL TRAINING MANUAL DR460
Electrical Safety
Copyright © Sandvik Mining and Construction

ELECTRICAL SAFETY DR460
DC ELECTRICAL SAFETY
Safety first in the work place! Before starting the work process establish a JSA or risk assessment
regarding the work to be performed.
Equipment owners, technicians and operators shall determine the needs of the intended task prior
to commencing any work.
• Arrange proper tools for the job
• Utilize appropriate PPE personnel protective equipment for the task
• Read material that may be pertinent to the task
• Communicate with co-workers and/or operators of the equipment
• Lock out and tag out the main power supply to prevent accidental start up during the work pro-
cess
• Follow site specific safety protocol
• Remember the environment, prepare with necessary containment and disposal material
It is the responsibility of the individual operator/technician to read and understand the

machine specific operator, maintenance or service manual prior to operating a drill machine.
ELECTRICAL ACCIDENTS
Electrical accidents in the mining industry are caused by:
• failure to lock out/tag out electrical equipment and circuits
• unqualified people doing electrical work
• contact with overhead power lines
• improper installation and maintenance
ELECTROCUTION
Most circuits in any surface mine are of sufficient voltage to overcome your body’s resistance.
Therefore the miner must be able to recognize and avoid coming into contact with an electrical
source.
When a person is electrocuted, he/she becomes the path of least resistance for the electrical
source to ground and in effect becomes a part of the circuit.
Properly grounded equipment is the best way to prevent electrical shock. Another effective means
is insulation by means of rubber gloves and boots, rubber mats, insulated platforms and guards
around cables.
! DANGER
Handling electrical equipment with wet hands or while standing in water will cause electro-
cution. Handle all electrical equipment in a dry environment.
Copyright © Sandvik Mining and Construction 1

DR460 ELECTRICAL SAFETY
The killing factor in electrical shock is current. Current is measured in amps and is determined by
voltage. Ordinary household appliances require currents high enough to kill a person. Current nec-
essary to operate a 100 watt light bulb is (eight 8) to (ten 10) times the fatal amount.
• 1 milliampere (threshold of perception)
• 1 - 8 milliampere (sensation of shock)
• 8 - 15 milliampere (painful shock)
• 15 - 20 milliampere (loss of muscle control)
• 20 - 50 milliampere (breathing difficulties)
• 100 - 200 milliampere (ventricular fibrillation)
• over 200 milliampere (sever burns)
One milliampere (ma) is 1/1000 of an amp.
If a fellow worker becomes part of an elec-

trical circuit and cannot let go of the source,
DO NOT rush over and grab him/her.
You can become part of the electrical

shock as well.
Instead, disconnect the power to the cir-

cuit. If this is not possible, remove the per-
son from contact by using something
insulated to PUSH or PULL the person
away while protecting yourself.
In the event of accidental electrical contact call for help and apply the appropriate first aid mea-
sures.
Federal law requires that any repair, installation, or testing of electrical equipment be done by or
under the supervision of a qualified electrician.
All disconnecting devices must be tagged out of service prior to work being performed.
2 Copyright © Sandvik Mining and Construction

ELECTRICAL SAFETY DR460
Follow site specific lock out and tag out procedures recom-
mended by the mine site.
Do not attempt to operate the equipment until all lockout

devices are cleared by a shift supervisor(s).
All persons performing maintenance work shall have a

separate lock and signed tag connected to the multi
lock.
HIGH VOLTAGE AC or DC powered equipment should be de-energized prior to and during mainte-
nance work performed on the electrical systems.
Only electricians specifically trained to work with high voltage circuits should be permitted to per-
form electrical maintenance.
Appropriate ground fault management systems should be employed at the mine and made avail-
able to the specific machine.
Sandvik Mining and Construction mandates that each miner responsible to perform maintenance or
operating duties on a drill machine utilize the appropriate PPE personnel protective equipment
deemed necessary to perform the duties of the job or task assigned.

DC ELECTRICAL TRAINING MANUAL DR460
1. DC Electrical Systems
Copyright © Sandvik Mining and Construction

DC ELECTRIC TRAINING MANUAL DR460
1.1 ELECTRIC SYSTEMS

Easy access and simple installations make electronic controls a preferred component for DR460
cab design.
Electronic controls generate less noise and heat rejection than typical hydraulic components.
Reliable component selection is a must when designing electronic control systems. Hydraulic com-
ponents must comply with electrical components for optimum system control.
With electro/hydraulic controls operators do not need to use mechanical power during actuation.
Electronic controls are soft touch actuation.
1.2 Description
This section shall detail electrical and hydraulic system component locations on D75AU and DR460
products.
(AHJB)*
Junction boxes are mounted on the machine

deck, mast pedestal and mast assembly.
Cab electric panels and chair controls

are part of cab electronics.
(EJB)
(AJB)
(MJB)
(DCJB)
(OJB)
The engine junction box is positioned at the front pulley end of the engine. It houses main and alter-
nator circuit breakers, buss bars, shutdown relay, emergency stop and engine start components.
All junction boxes are sealed door type units and must remain closed during machine run modes.
Periodic maintenance must be performed to clean and inspect the electrical components and con-
nections.

DR460 DC ELECTRICAL TRAINING MANUAL
Engine junction box wire harness will

differ between Cummins and Caterpillar
applications. Electrical components
remain common.
DR460
EJB
Product wires are identified with dedicated numbering sequence for specific circuits. The number is
stamped every 1.5 inch (38 mm) throughout. Black, Blue and Green are the common wire colors.
Table 1: Wire Color Code
Color Function
Black DC Power
Grey DC Power
Blue Monitoring
Green Frame ground
Vendor components may have different colored wires that Sandvik connect to.
When applicable a compressor junction box* is positioned near the compressor. It typically houses
terminal boards and wire connections only.
This junction box is a sealed door type unit and must remain closed during machine run modes.
Periodic maintenance must be performed to clean and inspect the electrical connections.
When applicable a auxiliary heater junction box* (Arctic cold weather packages) is positioned near
the cooler assembly. It typically houses individual heater circuit breakers, terminal boards and wire
connections.
When servicing components with auxiliary heaters maintenance personnel shall turn the specific
circuit breaker to the off position.

The power source for auxiliary heaters is sup-

plied from a diesel/generator with typical sup-
ply power of 110 or 220 vac.
CIRCUIT
BREAKERS
1.3 Operator Console
The DR460 chair swivels 340° to allow operator access to

left and rear side windows.
All electric for the cab chair is accessible from ground
level sealed panels.
Pushbuttons, joysticks, circuit cards wire terminations,

relays, potentiometers and resistors are housed on or
inside right or left side chair panels.,
Loosen latch screw and lift the access panel to view con-
trol relays, circuit boards and control terminals.

Left side console box houses up to 13 control

relays that activate with electrical input from
remote switches or frame mounted sensors.
Relay contacts may be manually over rode by
activating the blue tab as needed for trouble-
shooting. LEFT
CONSOLE
The chair control panels are sealed door units PANEL
and must remain closed during machine run
modes. Periodic maintenance must be per-
formed to clean and inspect the electrical com-
ponents and connections.

Right side console box houses up to 8

control relays that activate with electrical
input from remote switches or frame
mounted sensors.
Relay contacts may be manually over

rode by activating the blue tab as
needed for troubleshooting. RIGHT
CONSOLE
PANEL
Electrical circuit boards require adjustments when replacement units are installed. A volt meter is
required to accurately set the circuit boards too spec. Refer to electrical setting procedures.
When circuit board electrical power is at the desired calibration electrical adhesive should be
attached to the trim pot adjustment screws to protect the screws from unwanted motion during
machine operation.

1.4 Operator Console Power
Chair console power switch must be applied to

enable joystick power for running rotation pump.
Power on and off switches engage or disengage

control relay enabling DC power with engine oil
pressure present.
Reference electrical schematic 034666-001
During testing or adjusting it may be neces-

sary to momentary jump or bridge EPS
engine pressure switch contacts.
Remove jump wire after testing.
2.1 PUMP STROKER

The 900 series pump stroker is a precision designed hydraulic valve used on both drill/tram pumps
for tram, rotation and feed systems.

Minor adjustments for neutral centering ROTARY SERVO NULL TRIMMER

may be required on the machine. ASSEMBLY LOCKNUT
NULL
TRIMMER
Neutral centering adjustments are made SPRING
with minor increments to remove unwanted MANUAL STOP
rotary motion. Confirm zero electric input OVERRIDE LOCKNUT
and the pump control is in the neutral posi-
tion.
Remove solenoid A and B during the

neutral null adjustment procedure.
SPRING
With the 4.7mm (3/16 in) hex - allen wrench SOLENOID
STOP
SOLENOID
check the side to side play of the rotary A B
servo assembly.
DIN DIN
Any side to side play will hold the CONNECTOR A CONNECTOR B
rotary servo assembly off center and
hinder the neutral null adjustment. 900 SERIES ELECTROHYDRAULIC STROKER
The spring stop screw adjustment
can remove the side to side rotary
servo shaft play.
It is not recommended to service this device or make adjustments to the stroke limiting features on
the machine in the field.
Start the machine to perform final hydraulic checks and neutral the pump with the null adjustment.
2.2 Electrical - Flow Rotation System
Pump coil DIN connections shall be free of contaminants.
Coil resistance must be verified, expected 38 - 40 OHM temperature related.
Input from rotation joystick to Parker Denison driver

board designate output to pump coils.
Right side chair console supports rotation and tram

electrical components.
Verifying milliampere requires removal of driver board from

chair panel to access terminals.
Drill mode rotation system Parker Denison driver boar power

light illuminates.
Tram mode rotation driver board power light off.

034666-001 electrical schematic shows

driver board connections.
2.2.1 Checking And Setting Circuit Cards
Required tools:
• small flat blade screwdriver
• electric meter capable to measure OHMS and DC Volts.
• 7/16 (11mm) open end wrench
• large phillips (cross blade) screwdriver
• electrical contact adhesive

Refer to chair seat electrical 032599-002
Replacement driver boards are not pre-

set. This setting procedure will be
required when installing a new feed, rota-
tion or tram driver boards.
Milliamperes and components speeds will differ between the three systems.
Table 2 details driver board calibrations to factory spec. Altering rates will affect pump output and
component speed.
Table 2: Driver Board Set Points
FUNCTION MIN MAX
TRAM LEFT 50 mA 250 mA

TRAM RIGHT 50 mA 250 mA
ROTATION FORWARD 160 mA 300 mA

ROTATION REVERSE 160 mA 300 mA
FEED DOWN 130 mA 330 mA

FEED UP 130 mA 330 mA

2.2.2 Calibration Of Driver Boards With Meter ‘without Engine Running’
1. Place momentary jump wire across EPS engine pressure switch.
2. Apply drill/tram selector switch to drill mode.
3. Apply key switch to on position.
4. Apply seat console power switch on to illuminate green LED light.
5. Check dc voltage in, apply meter to terminal 1 + and terminal 3 -, expected 24 - 27 vdc.
6. Prepare to check dc voltage out apply meter to.
7. Apply joystick until LED illuminates.
8. Check milliampere, expected 160 mA, adjust threshold trim pot to obtain spec.
9. Continue joystick to full on position.
10. Check milliampere, expected 300 mA, adjust maxout trim pot to obtain spec.
11. Cycle rotation joystick rechecking output milliampere to set spec.
12. Apply seat console power off switch.
13. Apply key switch to off position.
14. Remove jump wire from engine pressure switch.
15. Remove test equipment.
Table 3: Rotation Pump Limits
CONTROL ADJUSTMENT MA
THRESHOLD 100
MAXOUT 400
Driver board set points and rotation pump limits vary due to differentials between coils and desired
pump output to meet the system requirements.
2.2.3 Calibration Of Driver Boards Without Meter ‘with Engine Running’
1. Apply drill/tram selector switch to drill mode.
2. Apply key switch to on position.

3. Apply engine to high idle speed.
4. Apply seat console power switch on to illuminate green LED light.
5. Apply rotation joystick on for slow forward motion.
6. Adjust min A for optimum slow rotation speed such as a threading speed.
7. Apply rotation joystick full on.
8. Adjust max A for optimum fast forward rotation speed according to bit specifications or ground
conditions.
9. Apply rotation joystick on for slow reverse motion.
10. Adjust min B for optimum slow rotation speed such as a threading speed.
11. Apply rotation joystick full on.
12. Adjust max B for optimum fast reverse rotation speed. This parameter is not as critical as for-
ward.
This method may be suited to optimize pump for specific operating conditions.
Do not overextend machine specific rotation speed.
2.3 ELECTRICAL - PRESSURE ROTATION SYSTEM

Valve coil DIN connections shall be free of contaminants.
Coil resistance must be verified.
Input from rotation amplifier board and operator potentiometer.
Right side chair console supports rotation electrical components.
Refer to 034666-001 electrical sche-

matic.
2.3.1 Checking And Setting Circuit Cards
Required tools:
• small flat blade screwdriver

• electric meter capable to measure OHMS and DC Volts.
• 7/16 (11mm) open end wrench
• large phillips (cross blade) screwdriver
• electrical contact adhesive
Refer to chair seat electrical 032599-002
Replacement circuit cards are not preset.

This setting procedure will be required
when installing a new feed or rotation
pressure amplifier board.
2.3.2 Calibration Of Amplifier Board With Meter
Apply drill/tram selector switch to drill mode.
Apply key switch to on position.
Apply seat console power switch on to illuminate green LED light.

Rotate operator rotation potentiometer ccw.
1. Check dc voltage in, apply meter to VS and G terminals, expected 24 - 27 vdc
2. Prepare to check dc voltage out, apply meter to pwm A and G.
3. Apply potentiometer cw until RPA rotation amplifier board LED illuminates.
4. Check dc voltage, expected 6 - 8 vdc - 200 mA, adjust low trim pot to obtain spec.
5. Apply rotation potentiometer cw to stop.
6. Check dc voltage, expected 21 - 24 vdc - 700 mA, adjust HI A trim pot to obtain spec.
7. Cycle rotation potentiometer ccw and cw rechecking output voltage to set spec
8. Apply sealant to trim pot threads.
9. Apply seat console power off switch.
10. Apply key switch to off position.
11. Remove test equipment.
Rotation pressure amplifier board controls RPV rotation pressure valve according to operator
potentiometer values. RPV also referenced as VPO1 valve is connected to rotation pump V port.

Rotation pressure valve RPV - VPO1 are same unit

connected to rotation pump VA port.
Input power from rotation pressure amplifier regu-

lates rotation pump forward direction pressure from
zero to 4200 psi accordingly.
Reference hydraulic schematic 034875-001
2.4 REMOTE TRAM STATION

DR460 machines are equipped with a remote tram station allowing operators two means of moving
the drill machine across mine terrain.
• Seated tram controls as previously stated
• Stand up console on the front console panel

Selecting the console tram position, switches power from

the chair joystick controls to the stand tram joystick con-
trols.
The stand joystick controls with circuit cards

require calibration. Spare part joystick circuit cards
are not preset. This setting procedure will be
required when installing a new tram joystick or cir-
cuit card.
During testing or adjusting it may be neces-

sary to momentary jump or bridge EPS engine
pressure switch contacts.
Remove jump wire after testing.
The two calibration settings are threshold and maxout.
• threshold = to the on time voltage required to move a feature
• maxout = to the maximum voltage desired for the specific function
THRESHOLD
TRIM POT
MAXOUT
TRIM POT

2.4.1 Remote Tram Controls: Setting Left And Right Tram Functions
Actuate the remote tram selector switch to the standing mode.
1. Turn key switch to the on position.
2. Silence the DMS alarm after 30 seconds.
3. Connect electric meter + positive and - terminals, expecting 24 - 27.5 vdc.
4. Connect electric meter + positive red lead on A terminal.
5. Connect electric meter - negative black lead on - negative or ground terminal.
6. Actuate the joystick slightly toward the A side, listen for the second microswitch contact. A red
led will illuminate on the circuit card.
7. Check the power output on the meter. Threshold power output should be 6 to 8 volts. Adjust-
ments may be made by turning the threshold potentiometer.
8. Actuate the joystick full stroke toward the A side.
9. Check the output power on the meter. Maxout power output should be 21 volts. Adjustments
may be made by turning the maxout potentiometer
10. After initial setting it may be necessary to recheck threshold and maxout electrical power out-
puts.
11. Apply electrical adhesive to potentiometer set screws to eliminate possible calibration changes
due to machine vibrations.
12. Remove electric test equipment from terminals.
13. Turn key switch to the off position. Remove bypass wire installed on the EPS switch prior to
electrical tests.
It is required that both left and right joystick controls threshold and maxout power limits are similar.
The threshold and maxout power is driving the right and left Parker Denison pump coils. As previ-
ously stated the load must be confirmed so that the control power can move the function.
If there is a difference of output power the hydraulic pump flows will be affected. This translates to
incorrect steering in the tram mode.
2.4.2 Tram/Drill Switching
A series of relays inside right chair panels enable switching between tram and drill features.
• CR control relay enables current flow between wires B8 and B9 enabling seated joystick drill
and accessory control features
• DR drill relay enables seated drill joystick control for rotation and feed

• SET set relay enables seated tram joystick control
• CTR console tram relay disables seated tram and enables standing tram
• TR1 and TR2 tram relays enable full power to feed and rotation amplifier boards enabling full
output power to both VPO1 hydraulic valves resulting in full pump pressure
• GSR 1 and GSR2 ground switching relays switch ground from pump coils to allow standing and
seated tram modes
• PSCR pump signal control relay switch power for pump coils to allow standing and seated tram
modes
• MSW mode switch on right side chair panel enables or disables relays for switching between
drill and tram modes

2.5 Solenoids
Electrohydraulic valves inside mast pedestal range between feed, rotation, tram and accessory
systems.
034665-001
Note!
Coil resistance and o-ring seals may hinder valve actuation and system pressures.
RIGHT BRAKE
There are up to six solenoid valves posi- MODE CONTROL

tioned on the gearbox mounting flange or LEFT BRAKE
mast pedestal.
Each solenoid valve has a dedicated

system.

The 002006 series solenoid valves use oring and

back up rings to seal between the three working
sections P/A/T ports.
A repair kit includes o-ring and backup seals.
Coil power is a factor in proper control of this

valve. Deutch connectors may be unlocked to
allow easy access to the terminals.
Confirm polarity Positive to + negative to -
Coil resistance:
33 to 45 OHM P
Testing and adjusting the electrical system must be performed with reliable test equipment.
Stacker valves located on the machine frame as base stacker and in the mast as mast stacker are
electric controlled. Each valve work section has two coils for directional flow control.
Mast stacker shown:
Depending on coil the valves sections may be config-

ured for proportional or on off operating.
When applicable supply voltage is calibrated at

the operator control circuit card. Coil power is a
factor in proper control of this valve. Each coil
Deutsch connector may be unlocked to allow easy
access to the terminals.
Troubleshooting base and mast stacker valve is a

matter of differentiating between operator control,
electrical input, coil or hydraulic solenoid, pilot
pressure, actuator malfunctions.
Deutsch connector kit part number 019244-112 is a must for repairing Sandvik wire assemblies.

A simple test may be administered with the

base and mast stacker valves.
Unplug affected valve Deutsch con-

nector from coil. BRASS PLATE
BETWEEN PINS
Brass plate between contact pins is a man-
ual override to shift the hydraulic spool.
If hydraulic system is correct applying

light tension to brass plate will shift
hydraulic spool to transmit fluid motion
to the actuator.

3.1 MONITORING
Three features allow operators or technician access to vital machine operating parameters.
• Engine message center

• DMS drill monitor system
• EDC electronic depth counter
3.2 Message Center
Engine parameters are visible on a message center display during normal run mode.
• Engine speed
• Engine oil pressure
• Fuel level
• Engine water temperature
GEM software runs on a CANtrak display with five soft keys providing a flexible and intuitive Human
- Machine Interface (HMI).
The five soft keys access a graphical menu structure that uses standard and easily understood
icons to indicate the keys current function.
This allows the operator to select the required engine data and display it in the following formats.
• Analogue gauge
• Digital values
• Multi gauge

• Historical trend graphs

• Current or stored alarm messages
Table 4: Soft Keys & Display
DESCRIPTION DISPLAY
KEY 1: TRI-DISPLAY, REPEAT

PRESS CYCLE THROUGH VAR-
IOUS MODES
KEY 2: QUAD DISPLAY,

REPEAT PRESSES CYCLE THE
DISPLAY AROUND THREE DIF-
FERENT DISPLAY OPTIONS
KEY 3: UNI-DISPLAY, SHOWING

DATA HISTORY REPEAT
PRESSES CYCLE DISPLAY
THROUGH AVAILABLE PARAM-
ETERS
KEY 4: ACTIVE ALARM DIS-

PLAY, HOLDING KEY BRINGS
UP ACTIVE ALARMS
KEY 5: CONTRAST AND LIGHT-

ING ADJUSTMENT, OR IF HELD
FOR 3 SECOND BRINGS UP
CONFIGURATION MENU
3.2.1 3412e - C27 Fault Codes
Cat fault codes register as text on message center.

FLASH SHUT SCH

DESCRIPTION SER
CODE DOWN SER
71 CYLINDER 1 FAULT X
13 FUEL TEMPERATURE X
14 INJECTION ACTUATION X
PRESSURE CONTROL
VALVE OPEN CIRCUIT
PRESSURE CONTROL
VALVE SHORT TO
GROUND
17 BATTERY VOLTAGE X
21 ANALOG SUPPLY OPEN/ X

SHORT TO GROUND
21 ANALOG SUPPLY SHORT X

TO + BATTERY
21 DIGITAL SUPPLY SHORT X

TO + BATTERY
21 DIGITAL SUPPLY SHORT X

TO GROUND
PRESSURE SIGNAL OPEN/
SHORT TO + BATTERY
PRESSURE SIGNAL
SHORT TO GROUND
42 ATMOSPHERIC SPRES- X
SURE SENSOR CALIBRA-
TION
42 SPEED/TIMING SENSOR X
CALIBRATION
42 BOOST PRESSURE SEN- X

SOR CALIBRATION
24 OIL PRESSURE SIGNAL X

OPEN/SHORT + BATTERY
24 OIL PRESSURE SIGNAL X

SHORT TO GROUND

FLASH SHUT SCH

DESCRIPTION SER
CODE DOWN SER
25 BOOST PRESSURE SIG- X

NAL ABOVE NORMAL

NAL OPEN SHORT TO +
BATTERY

NAL SHORT TO GROUND
38 INTAKE MANIFOLD TEMP X

SENSOR OPEN CIRCUIT
38 INTAKE MANIFOLD TEMP X

SENSOR SHORT CIRCUIT
26 ATMOSPHERIC PRES- X
SURE SIGNAL OPEN/
SHORT + BATTERY
26 ATMOSPHERIC PRES- X
SURE SIGNAL SHORT TO
GROUND
27 COOLANT TEMP SIGNAL X

OPEN/SHORT TO + BAT-
TERY
27 COOLANT TEMP SIGNAL X

SHORT TO GROUND
37 FUEL TEMPERATURE SIG- X

NAL OPEN/SHORT TO +
BATTERY
37 FUEL TEMPERATURE SIG- X

NAL SHORT TO GROUND
OIL TEMP SIGNAL OPEN/ X

SHORT TO + BATTERY
OIL TEMP SIGNAL SHORT X

TO GROUND
34 LOSS OF PRIMARY X
SPEED/TIMING SIGNAL
34 PRIMARY SPEED/TIMING X
SIGNAL OPEN/SHORT TO
+ BATTERY
34 PRIMARY SPEED/TIME- X
ING SIGNAL ABNORMAL
34 LOSS OF SECONDARY X
SPEED/TIMING SIGNAL
34 SECONDARY SPEED/ X
TIMIMG SIGNAL OPEN/
SHORT TO + BATTERY
34 SECONDARY SPEED/TIM- X
ING SENSOR SHORT TO
GROUND
37 FUEL PRESSURE SIGNAL X

OPEN SHORT TO + BAT-
TERY
37 FUEL PRESSURE SIGNAL X

SHORT TO GROUND
53 INTERNAL ECM FAULT X

If an engine misfires and a loss of power occurs a fault code should be displayed on the operators
panel. This situation may require machine shutdown and diagnostic tools to be attached to the
ECM for analysis.
Engines are factory programed to shutdown under common Caterpillar switch parameters.
• high coolant temperature approximate range
• water temp regulator fully open
• low oil pressure is dependent on engine idle speed, the approximate range is 32 psi @ 1200
rpm and 43 psi @ 2000 rpm.
• engine oil temperature should not exceed
3412E - C27 TIER III SERIES
Table 5: Caterpillar
Switch Switch Switch Switch

1. cylinder head 2. customer connec- 3. injection actuation 4. oil temperature sen-
grounding stud tor with Sandvik pressure control sor
wires valve
5. oil pressure sensor 6. atmospheric pres- 7. secondary speed/ 8. fuel temperature

sure sensor timing sensor sensor
9. primary speed/tim- 10. coolant tempera- 11. tc probe connector 12. electronic control
ing sensor ture sensor module (ECM)
13. coolant flow switch 14. injection actuation 15. turbocharger outlet 16. __________
connector pressure sensor pressure sensor

3.2.2 Event Codes
Events refer to engine operating conditions such as low oil pressure or high coolant temperature.
Logged events usually indicate a mechanical problem instead of electronic system problem.
FLASH DESCRIPTION OF CODE

CODE
21 HIGH INJECTOR ACTUATION PRES-
SURE
35 ENGINE OVERSPEED WARNING
37 LOW FUEL PRESSURE WARNING
46 LOW OIL PRESSURE WARNING
46 LOW OIL PRESSURE SHUTDOWN
61 HIGH ENGINE TEMPERATURE WARN-

ING
61 HIGH ENGINE TEMPERATURE SHUT-

DOWN
62 LOW ENGINE COOLANT WANING
Additional reference materials:
Caterpillar operation and maintenance manual SEBU6960-003 and SEBU6960-04.

Caterpillar Electronic Troubleshooting Guide SENR 1012 and Troubleshooting manual SENR 1073
for industrial engines.
3.3 CUMMINS QSK19 SERIES CELECT ELECTRONIC CONTROLS

All fault codes recorded will either be
• active (fault code is presently active on engine) or
• inactive (fault code was active at some time, but is not presently active).
3.3.1 Cummins Fault Codes

Fault codes register as text on message center.
Reference material Quantum wiring diagram bulletin no. 3666133-02, Operator and
maintenance manual QSK19 series engine bulletin no. 3666120-02 (publication
020235-000)

FAULT
DESCRIPTION EFFECT
CODE
111 ELECTRONIC CONTROL MODULE - MEM- RED LIGHT

ORY FAILED
115 ENGINE SPEED SENSOR - BOTH SIGNALS RED LIGHT

LOST SHUTDOWN
122 BOOST PRESSURE SENSOR - COMPO- AMBER LIGHT

NENT SHORT HIGH (> 4.72 VDC)
123 BOOST PRESSURE SENSOR - COMPO- AMBER LIGHT

NENT SHORT LOW (< 0.33 VDC)
135 OIL PRESSURE SENSOR - COMPONENT AMBER LIGHT

SHORT HIGH (> 4.88 VDC)
141 OIL PRESSURE SENSOR - COMPONENT AMBER LIGHT

SHORT LOW (< 0.31 VDC)
143 OIL PRESSURE SENSOR - DATA BELOW ENGINE PRO-

NORMAL RANGE TECTION
144 ENGINE COOLANT TEMP SENSOR - COM- AMBER LIGHT

PONENT SHORT HIGH (. 4.95 VDC)
145 ENGINE COOLANT TEMP SENSOR - COM- AMBER LIGHT

PONENT SHORT LOW (< 0.21 VDC)
151 ENGINE COOLANT TEMP SENSOR - DATA ENGINE PRO-

ABOVE NORMAL (212° f 100° c) TECTION
153 iNTAKE MANIFOLD TEMP SENSOR - COM- AMBER LIGHT

PONENT SHORT HIGH (> 4.88 VDC)
154 INTAKE MANIFOLD TEMP SENSOR - COM- AMBER LIGHT

155 INTAKE MANIFOLD TEMP SENSOR - DATA ENGINE PRO-

ABOVE NORMAL (220° f 104° c) TECTION
221 AMBIENT AIR PRESSURE SENSOR - COM- AMBER LIGHT

PONENT SHORT HIGH (> 4.78 VDC)
222 AMBIENT AIR PRESSURE SENSOR - COM- AMBER LIGHT

234 ENGINE SPEED - DATA ABOVE NORMAL RED LIGHT
254 FUEL SHUT OFF VALVE - COMPONENT RED LIGHT

SHORT LOW (< 17 VDC)
261 FUEL TEMPERATURE SENSOR - DATA ENGINE PRO-

ABOVE NORMAL (> 160° f 71° c) TECTION
263 FUEL TEMPERATURE SENSOR COMPO- AMBER LIGHT

265 FUEL TEMPERATURE SENSOR COMPO- AMBER LIGHT

343 ELECTRONIC CONTROL MODULE - INTER- AMBER LIGHT

NAL COMMUNICATOR ERROR
346 ELECTRONIC CONTROL MODULE - AMBER LIGHT

POWER ERROR
415 OIL PRESSURE SENSOR - DATA INDI- ENGINE PRO-

CATES VERY LOW OIL PRESSURE TECTION
441 BATTERY VOLTAGE UNSWITCHED - DATA AMBER LIGHT

BELOW NORMAL (12VDC)
442 BATTERY VOLTAGE UNSWITCHED - DATA AMBER LIGHT

ABOVE NORMAL (38 VDC)

FAULT
DESCRIPTION EFFECT
CODE
451 FUEL PRESSURE SENSOR - COMPONENT RED LIGHT

SHORT HIGH (> 4.78 VDC)
452 FUEL PRESSURE SENSOR - COMPONENT RED LIGHT

SHORT LOW (< 0.15 VDC)
554 FUEL PRESSURE SENSOR - IN RANGE AMBER LIGHT

FAILURE (< 0.50 / > 1.83 VDC)
555 HIGH BLOW BY PRESSURE ENGINE PRO-

(> 14.5 IN H2O) TECTION
719 BLOW BY PRESSURE SENSOR - COMPO- AMBER LIGHT

729 BLOW BY PRESSURE SENSOR - COMPO- AMBER LIGHT

There are engine electronic fuel system fault codes and engine protection system fault codes.
Active fault codes may be read using the check engine (amber) and diagnostic light (red) on the
drill console. Inactive fault codes may be read with a laptop only.
To check for active fault codes:
• Turn the key switch to the off position.
• Move the diagnostic switch to the on position.
• Turn the key switch to the on position.
• If active fault codes are available the check engine light will begin flashing a three digit code
with one second pauses between digits.
The lights will remain off during normal engine operation.
• Red light on while engine is running, stop the engine in a safe manner as soon as possible. This
fault may be engine disabling.
• Amber light on the engine can still be run but may loose some system features which may result
in a power loss condition. The failure must be repaired as soon as convenient.
Cummins engine protection system monitors the QSK series engines for:
• High coolant temperature
• Low coolant level (optional)
• Low coolant pressure
• High fuel temperature
• High intake manifold temperature
• Low/very low oil pressure

• High blow by pressure
QSK Cummins Engine Sensors (Left C D

Side) B
A Coolant Temperature Sensor A

B Oil Pressure Sensor
C Intake Manifold Temperature Sensor
D Intake Manifold Pressure Sensor
E
E Engine Speed Sensor
F Ambient Air Pressure Sensor
G Engine Control Module
G
F
Some external components will be at different locations for different engine models.
QSK Cummins Engine Sensors

(Right Side)
H Coolant Pressure Sensor

I Starter motor
I H
Troubleshooting the engine requires a skilled engine technician familiar with electronic fuel sys-
tems.
Three lights positioned on the machine operator panel will enable active fault codes to be seen
when they occur. The sequence of flashes represents the system diagnostic message.

The first sequence of flashes represents the first digit of the diagnostic code. There will be a 1 sec-
ond pause between flashes. Codes are in a three digit numeric sequence.
Diagnostic retrieving may be performed using the toggle switch labeled increment/decrement.

4.1 DRILL MONITOR SYSTEM

Maintenance monitoring is achieved with a printed circuit board referenced as DMS. External
switches are used to monitor filters, fluids, levels, pressure and temperatures.
4.2 DIP Switch Positions

A DIP switch is a set of manual electric switches that are packaged in a group in a standard
dual inline package (DIP).
This type of switch is designed to be used on a printed circuit board along with other elec-
tronic components and is commonly used to customize the behavior of an electronic device
for specific reasons.
DIP switches are an alternative to jumper blocks. Their main advantages are that they are
quicker to change and no moving parts.
ON *
OPEN
INPUT SENSOR SELECTOR SWITCH
ON FOR NORMAL OPEN SENSORS
OPEN FOR NORMAL CLOSED SENSORS
DIP switch positions have to correspond with physical switch rating.

When DIP switches differ from the physical switch rating, alarms or shutdown conditions can occur.
Engine coolant flow ECF and compressor oil pressure COP are normal open sensors however in a
dynamic run mode they are closed.
The ECF and COP, DIP switch positions must be in the open position as a closed switch for normal
run conditions.
Compressor interstage temperature CIT, DIP switch position 12 * is used on high pressure two
stage air compressors only.
Make the DIP switch position down or open for high pressure compressor applications.
Make the DIP switch position up or on for low pressure compressor applications.
Power to the DMS is initiated from the key switch KS and LEVEL 1
the main relay MR as standard to DMS terminals 1, 20 and
21. A green power light indicates 24 vdc power to the moni-
tor circuit board.
Applied power through the DMS maintains for 30 seconds

or until monitored pressures close the normal open pres-
sure switches.
LEVEL 2
If the machine is not started with pressures met the
DMS will time out after 30 seconds. Power through
terminal 20 and 21 will open, the engine will stop and/
or will not start.
LEVEL 3
DMS terminal 21 engages a shutdown relay SDR that communicates to the engine control module
ECM. The SDR coil must be energized to run. The SDR contacts enable a ground contact to the
ECM through the relay terminals.
If the SDR is not energized fuel cannot get to the injectors, the engine starter will turn the engine
flywheel but no fuel will be available.
The monitor offers three levels of monitored protection.
• Level one is referencing maintenance indicating amber light
• Level two is referencing immediate maintenance indicating amber light and alarm
• Level three is referencing shutdown condition indicating red light, alarm and engine shutdown
The DMS circuit board retains memory as long as the green power light is illuminated. When the
key is turned off the DMS green power light is off and the DMS memory resets.

4.2.1 Prelube Starter - DMS
When customer options include a prelube starter system power to the DMS is initiated after the pre-
lube cycle occurs. A self latching relay (SR) enables power to the DMS after the lube cycle is fin-
ished.
The DMS power light will illuminate after the prelube time cycle completes. Continue to hold
the bypass switch after the start cycle until engine runs smooth at low idle.
SR start relay influences DMS input

power due to prelube starter circuit run SR SR
time
Timer set - 7 to 10 seconds run then 3

second delay prior to start
BPS SPB PTR SMS
Pressure switch - 0.9 - 0.14 bar (14 to 20
psi) engine oil pressure
+ -
SR
DMS

5.1 ELECTRONIC DEPTH COUNTER

The EDC electronic depth counter is a monitoring device that enables a drill operator the capability
to preset drilling parameters, change programs and select drilling modes during the drill cycle.
Reference depth counter 016544-000
00.00
EDC
New and replacement EDC monitors require specific programing parameters to suit the model of
Sandvik rotary drill equipment.
Program parameters are priority to Sandvik engineering and specific machine models.
When the EDC monitor is removed from the mounting cover the terminal strip is exposed.

Before servicing, turn off all power. The key

switch power off will suffice and remove the
key from the switch to prevent accidental
power on.
Access to the EDC monitor terminal

strip is on the rear panel. Power in,
ground, and signal wires are secured to
pin terminals that enable the counter to
function properly.
5.2 VC Voltage Converter
Voltage spec as low as 18 and high as 50 VDC. Orange wire input is @ 24 - 27.5 VDC with 15 amp
automotive fuse. Key switch input power 24 VDC is connected on the EDC at terminals 25 and 28.
Regulated voltage output is @13.8 VDC output. Red wire is 13.4 VDC no fuse. Input regulated 12
VDC power is connected on EDC terminal 15.
Both black wires are common ground (24 vdc) (12 vdc) and must be connected to ground due to
high currents developed in this unit. Converters are mounted inside the cab front panel with the
heat sink fins vertical for maximum heat dissipation.
Input and output connections are marked on the converter side plate.
5.3 ENC Encoder
The encoder signals range between 0 to 5 VDC variable due to shaft speed. Maximum input to the
encoder should not exceed 135 ma. A oscilloscope is required to see the square wave signals 0 - 5
volt range.

CIRCUIT BOARD
Encoder signals are transmitted
through a 4 wire shielded cable
assembly. Testing the signal inputs SHAFT
may be performed on the EDC termi-
nals 11 white wire, or 12 green wire.
D D - RED WIRE 12 VDC POWER IN

F F - BLACK WIRE GROUND
A A - WHITE WIRE 0 - 5 VDC
B B - GREEN WIRE 0 - 5 VDC
The gear ratio, sprocket sizes are factory set. Encoder sprocket mounting requires free
movement of the taperloc bushing onto the encoder shaft. Sprocket alignment and chain
tension held @ 3/8 (9.5 mm) are the only maintenance.
5.4 PHL Preset Hole Depth Light

A typical 24 volt light senses input power only when the EDC preset hole depth counter measure-
ment is reached. The counter may be manually programed for various hole depths.
5.5 HWP Holding Wrench Proximity Switch
A shock mounted proximity switch positioned on the side of the holding wrench (deck wrench) is
used to stop the counter is used with multipass drilling applications. This proximity switch may be
omitted with single pass drill applications.
Brown (I) power in, Black (S) output signal and Blue (G) common ground wires for the switch will
work as a normal open contact - closing contacts when sensing metal. The proximity switch has a
red LED that should illuminate when the brown and black wires become common.
Cut excess wire to an appropriate length and secure wire ends with sealed Deutsch electrical con-
nectors.
5.6 RHU Rotary Head Up Proximity Switch/Limit Switch
The rotary head up proximity switch is mounted onto a fixed plate that supports the specific metal
sensing switch.
Metal sensing occurs when the rotary head is up near the switch with the starter drill pipe con-
nected to the rotary head indicating that drill pipe is out of the blasthole.
There are four variations for this switch position.

• proximity switch center mast @ carrier sprocket position.
• proximity switch top center of feed rail

• micro switch top left side mast chord position.
• magnetic switch top left side mast chord position.
proximity switch center mast @ carrier

sprocket position shown:
Switch position may need alteration accord-

ing to drill string length.
RHU SWITCH
General purpose proximity switches

BR
Proximity switches use Brown (I) power in,
Black (S) output signal and Blue (G) com-
mon ground wires for the switch will work as BLK
a normal closed contact - opening contacts
when sensing metal. The proximity switch
has a red or amber LED that should illumi-
nate when the brown and black wires
become common.
BL
Cut excess wire to an appropriate length and
BR
secure wire ends with sealed Deutsch electrical
connectors.
BLK
Position insolated wire with at least 4 inches
(10 cm) and tie strap the wire to the proxim-
ity switch body. This action removes stress
from the wire and housing bore.
BL
5.6.1 PS pressure switch and CR control relay
As part of the pipe in the hole warning system one pressure switch (013051-007) is ported into the
machine leveling - hydraulic system.
The pressure switch is in the hydraulic cabinet with a pressure hose from the lower stacker inlet
section. A preset pressure value of (H) equals 900 psi (60 bar) and is adjustable on a as needed
basis.

(I)
CR
7 2
PS (I)
B
1 3
R
8 6
(H)
PIPE IN THE HOLE WARNING
The normal open switch continues a circuit to a control relay typically positioned under the EDC dis-
play panel. (I) equals input voltage measured at 24 - 27.5 VDC.
Control relay socket base 002099-001 DIODE
2 1 8 7
The PITH control relay enables audible and visual
warning only when the leveling jack or mast raise cyl-
inders are used.
A diode connects pin 2 to pin 7 so magnetic field

can dissipate to earth when the coil deener-
gizes. Failure of the 013613-002 diode may lead
to memory failures and erratic depth count. 3 5
4 6
5.7 Operation And Maintenance
Maintain a dust and water free environment for the EDC major electronic components. Compo-
nents inside the cab are protected as best as possible with a cover.
Common used keypad functions:
Position 6 Bit position
Position 7 Distance from bottom 50.00

Position 8 Accumulated depth
Position 9 Penetration rate
Position 1 Preset hole depth

5.7.1 Calibrating Preset Hole Depth
1. Press program button the red LED will blink on/off for 10 seconds in this mode. If no program
change occurs the preset hole depth program will remain unchanged.
2. Press the preset hole depth button then press the corresponding number sequence required for
the drilling application. A display reading of 50.00 will be the depth that the preset hole depth
light illuminates.
3. Press the enter button when the correct hole depth factors are on the EDC display.
4. The new preset hole depth calibration will illuminate the preset hole depth light during the drill-
ing application. The drilling cycle will not be stopped.
5.7.1 Calibrating The Preset Warning Depth
1. Press program button the red LED will blink on/off for 10 seconds in this mode. If no program
change occurs the preset warning depth will remain unchanged
2. Press the preset warning depth button, then press the corresponding number sequence fol-
lowed by the setup button. A negative number should be displayed.
3. Press the enter button when the correct negative factor are on the EDC display.
4. This display reading is required for the pipe in the hole warning indication. A calibrated display
reading of -.030 will be the point at which the pipe in the hole warning disables the buzzer and
warning light during leveling jack and mast raise operations.
NOTE!
• The preset warning depth calibration should not have to be reset during daily drilling activity.
• The preset warning depth calibration may need to be reset when a new length of drill string is
added to the machine. Top sub, bit sub and drill pipe length and rotary head proximity switch
location affect the preset warning depth feature.
5.7.2 Bit Position
1. Lower the feed and place the drill bit on the ground to be drilled.
2. Press reset button, the press bit position button.
3. The bit position reading will be 00.00
4. Commence drilling to the required depth or until the calibrated preset hole depth light illumi-
nates.
The bit position feature is to assist the drill operator for accurate hole depths according to the spe-
cific drill bench.

5.7.3 Accumulated Depth
1. Press the reset button, then press the accumulated depth button at the beginning of each shift
or at drill bit change intervals etc. The display will read a 00.00 value.
The accumulated depth feature is to record drill related activities as needed.
5.7.4 Programming A New Counter
The EDC has to be programed for a specific machine for either metric or english display readings.
The unit has to be run through 19 set up modes to be calibrated for a specific model of machine.
Position the 6 DIP switches as shown

1. = off, down
2. = on, up DIP
3. = off, down
4. = on, up
5. = off, down
6. = off, down
SET UP MODE ONLY
ADD MOMENTARY JUMP WIRE
ON (PIN 1 ENB) AND (PIN 16 GND)
Prior to mounting the EDC into the cover frame perform the following procedure.
5.7.5 Set Up Parameters
1. Add a momentary jump wire to pin 1 and pin 16 in order to enter the set up mode to calibrate
the unit and distance inputs.
2. Press the set up button, then press enter button. The number 01 will appear on the display.
3. Press enter again, this is the first program able set up mode.
Set up light illuminated
01
4. Continue to press enter, through the number 19, noting or changing the parameters as needed.

NOTE!
When changing a parameter in a specific set up mode select the appropriate number then push the
enter key. The new number will be saved and the next program set up mode will appear on the dis-
play.
5.7.6 EDC Codes
The 19 machine specific codes are engineering protected for machine specific data and english or
metric specifications.
Sandvik service may render machine specific codes on a as needed basis according to the
machine serial number, when requested by an authorized Sandvik servicing dealer.
Use the following table with pencil to note the set up parameters for a specific model and serial
number machine.
Table 6: EDC CODES
5. Remove the momentary jump wire from pin 1 and 16 at the completion of set up. This prevents
accidental set up mode changes during machine operation.
5.8 SERVICE and REPAIR LITERATURE

The table below references service materials found in Sandvik rotary drill Service and Repair man-
uals for high pressure and low pressure DC electrical systems. When component adjustments,
overhaul or repairs are needed it is advisable to use service procedures.
Machine specific service procedures are supplied to original equipment purchasers.
Not all service procedures will be made available to end users for a specific machine. Only those
procedures that apply to said machine will be available in end users manual.
This section may be updated as new procedures are written.
Table 7: Service Procedures
DESCRIPTION P/N
Hupp Air Conditioner/Heater 002712-051

Table 7: Service Procedures
DESCRIPTION P/N
Engine ETS HP Application 003171-000
Engine ETS LP Application 004318-000
Centralized Lubrication 006113-000
Tachometer Installation Caterpillar 006269-000
Engine ETR LP Application 006814-00
Engine ETR HP Application 006814-002
Tachometer Installation Cummins 007672-000
Air Conditioner - Sigma 008692-000
Voltage Converter 011017-000
Centralized Lubrication 011060-000
Lubricator 011362-000
Controller Adjustment 014441-000
Engine ETR HP Application 015351-000
Amplifier Board Adjustment 015509-000
Drill Monitor System 015702-000
Solenoid Service 017503-000
Auto Level CPU 018009-000
Automatic Leveling 018083-000
Sigma Air Conditioner/Heater 018146-000
Engine Perkins 3.152 Genset 019105-001
Engine Perkins 4.236 Genset 019105-002
Auto Level Schematic 019699-000
DMS Dip Switch Chart 021531-001

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DC ELECTRICAL TRAINING MANUAL DR460

Copyright © Sandvik Mining and Construction

• Arrange proper tools for the job

• Utilize appropriate PPE personnel protective equipment for the task

• Read material that may be pertinent to the task

• Communicate with co-workers and/or operators of the equipment

It is the responsibility of the individual operator/technician to read and understand the

Copyright © Sandvik Mining and Construction 1

One milliampere (ma) is 1/1000 of an amp.

If a fellow worker becomes part of an elec-

You can become part of the electrical

Instead, disconnect the power to the cir-

2 Copyright © Sandvik Mining and Construction

Do not attempt to operate the equipment until all lockout

All persons performing maintenance work shall have a

Copyright © Sandvik Mining and Construction 3

Copyright © Sandvik Mining and Construction

1.1 ELECTRIC SYSTEMS

Junction boxes are mounted on the machine

Cab electric panels and chair controls

Copyright © Sandvik Mining and Construction 1

Engine junction box wire harness will

Table 1: Wire Color Code

Green Frame ground

2 Copyright © Sandvik Mining and Construction

The power source for auxiliary heaters is sup-

1.3 Operator Console

The DR460 chair swivels 340° to allow operator access to

Pushbuttons, joysticks, circuit cards wire terminations,

Copyright © Sandvik Mining and Construction 3

Left side console box houses up to 13 control

4 Copyright © Sandvik Mining and Construction

Right side console box houses up to 8

Relay contacts may be manually over

Copyright © Sandvik Mining and Construction 5

1.4 Operator Console Power

Chair console power switch must be applied to

Power on and off switches engage or disengage

Reference electrical schematic 034666-001

During testing or adjusting it may be neces-

Remove jump wire after testing.

2.1 PUMP STROKER

6 Copyright © Sandvik Mining and Construction

Minor adjustments for neutral centering ROTARY SERVO NULL TRIMMER

Remove solenoid A and B during the

2.2 Electrical - Flow Rotation System

Pump coil DIN connections shall be free of contaminants.

Coil resistance must be verified, expected 38 - 40 OHM temperature related.

Input from rotation joystick to Parker Denison driver

Right side chair console supports rotation and tram

Verifying milliampere requires removal of driver board from

Drill mode rotation system Parker Denison driver boar power

Tram mode rotation driver board power light off.

Copyright © Sandvik Mining and Construction 7

034666-001 electrical schematic shows

2.2.1 Checking And Setting Circuit Cards

• small flat blade screwdriver

• electric meter capable to measure OHMS and DC Volts.

• 7/16 (11mm) open end wrench