Sandvik DR560 Rotary Blasthole Drill Rig Index:

1. Introduction
2. Safety And Environmental Instructions
3. Machine Description
4. Periodic Maintenance
5. Maintenance Instructions
6. Lubricants and Capacities
7. Additional Instructions
8. Technical Specifications

1. Introduction
2. Safety And Environmental Instructions
3. Machine Description
4. Operating Instructions
5. Operator’s Maintenance Instructions
6. Additional Instructions
7. Troubleshooting
8. Technical Specifications

DR560 SN 733980 2
SECTION 1 – Maintenance Kits 4
SECTION 2 – Misc. Hardware 6
001423-000 CLAMPS, HOSE and HARNESS 7
001132-000 PLUGS, JIC, MISC. 8
001135-000 PLUGS, BOSS, MISC. 9
001137-000 PLUGS, MPT, MISC. 10
001138-000 CAPS, JIC, MISC. 11
001595-000 CAPS, FPT, MISC. 12
001159-000 PIPE JOINT ASSEMBLIES 14
001742-000 FLANGE KIT ASSEMBLIES 16
002052-000 FLANGE KIT ASSEMBLIES 18
001825-000 CLAMPS, SINGLE,STAUFF, MISC. 22
001824-000 CLAMPS, TWIN, STAUFF, MISC. 24
001084-000 ELBOW, MPT/JIC, MISC. 26
001131-000 ELBOW, BOSS/JIC, MISC. 27
001944-000 ELBOW, SWIVEL, JIC/JIC, MISC. 28
001086-000 ADAPTERS, MPT/MPT, MISC. 29
001062-000 ADAPTERS, MPT/JIC, MISC. 30
001088-000 ADAPTERS, BOSS / JIC, MISC. 32
002235-000 TEE, SWIVEL, FJIC/JIC/JIC, MISC. 34
004036-000 TEE, FPT /JIC /JIC, MISC. 35
004461-000 TEE, FPT/FPT/FPT, MISC. 36
001082-000 ADAPTERS, FPT/JIC, MISC. 37
003328-000 ADAPTERS, FJIC/JIC, MISC. 38
010619-000 ADAPTERS, SWIVEL, FJIC/MJIC, MISC. 39
016898-000 CLAMPS, ELECTRICAL, MISC. 40
001161-000 TEE, MBOSS / MJIC / MJIC 41
001491-000 ELBOW, FPT/JIC, MISC. 42
010620-000 ADAPTER, SWIVEL, MBOSS / FJIC, MISC. 43
035179-000 CLAMP, RAIL MOUNTED, TWIN, MISC. 44
035165-000 CLAMP, RAIL MOUNTED, SINGLE, MISC. 46
035835-000 CLAMPS, SINGLE,STAUFF, MISC. 48
SECTION 3 – Undercarriage – Nameplates 50
BH00022610 UNDERCARRIAGE GROUP 52
BH00012341 CYLINDER ASSEMBLY, Hydraulic 58
BI00031818 CRAWLER ASSEMBLY, Complete – (B) 60
BH00019070 FINAL DRIVE/MOTOR ASSEMBLY 62
BH00012679 DRIVE, Final 64
BH00012645 CHAIN AND PAD ASSEMBLY 66
BH00029348 FRAME ASSEMBLY – (A) 68
CX000058 STAND ASSEMBLY, Mast 72
CX001352 STEP ASSEMBLY, Service 74
CX005633 FRAME ASSEMBLY – (R18) 76
CX005671 BATTERY BOX ASSEMBLY 78
CX005670 BATTERY GROUP 80
CX011724 SWITCH ASSEMBLY, Tram pressure 82
CX015852 HANDLE ASSEMBLY, Tram Valve Lockout 84
BH00010737 COVER ASSEMBLY, Valve – (C) 86
BH00010167 PLATFORM GROUP, Tram – (D) 88
BH00010136 SKID PLATE INSTALLATION – (C) 90
BH00009824 FIRE SUPPRESSION DECK – (B) 92
BH00010076 LABEL KIT, Anodized 96
BH00010446 LADDER GROUP, Service, Air Cleaner 98
BH00009684 FIREWALL INSTALLATION 100
BH00010345 FIREWALL ASSEMBLY, Rear 102
BH00010412 DECK INSTALLATION, Service 104
BH00010411 SERVICE DECK ASSEMBLY 106
BH00005636 MARKETING DECALS 108
038400-001 NAMEPLATES – English 110
038396-001 KIT, Nameplate – Frame – English (G) 112
038398-001 NAMEPLATES, FEED BUNDLE, ENGLISH – (B) 116
038399-001 KIT, Nameplate – Cab And Boom – English (E) 124
BH00011467 LADDER GROUP, Rear Access 130
SECTION 4 & 5 – Engine, Compressor, Gearbox 132
BH00009353 TANK ASSEMBLY, Fuel – (J) 134
DR560 SN 733980
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TABLE OF CONTENTS Page
CX005692 MANIFOLD ASSEMBLY, Engine Oil Remote 140
CX005650 INLET GROUP, Air, Engine 142
CX005767 COOLER LINES GROUP, Engine – (9) 150
BH00012403 COMPRESSOR/ENGINE/DRIVELINE GROUP – (D) 152
BH00011604 ENGINE ASSEMBLY – 860HP (C) 154
CP000281 ENGINE ASSEMBLY – QSK-23 158
CX005412 COMPRESSOR ASSEMBLY, Air Conditioner 160
CX010292 KIT, Dipstick 162
BH00011734 PUMP GROUP – (B) 164
CP002026 GEARBOX ASSEMBLY, Pump Drive 166
CP002037 PUMP, HYDRAULIC – 100cc 168
CP002129 PUMP, HYDRAULIC – 100cc 172
BH00011743 COMPRESSOR GROUP – (D) 176
02250192-107 COMPRESSOR ASSEMBLY – 1150 CFM 180
BH00009770 PANEL ASSEMBLY, Regulator – 500PSI 200
CX000544 REGULATOR – 100-400 PSI 202
CX000545 REGULATOR, Inlet Signal Pressure 204
BJ00015859 RECEIVER TANK ASSEMBLY – (A) 206
BH00012177 VALVE ASSEMBLY, Control Air – (C) 222
CX000544 REGULATOR – 100-400 PSI 202
CX000545 REGULATOR, Inlet Signal Pressure 204
CX011718 THERMAL BLANKET ASSEMBLY, Muffler, Cummins 224
BH00009634 INDICATOR GROUP, Air Cleaner 226
CX005406 MUFFLER GROUP 228
BH00012337 COOLER GROUP – (J) 230
CP000279 RADIATOR ASSEMBLY – (3) 242
BH00015930 RADIATOR 244
BH00015931 AFTERCOOLER ASSEMBLY 246
CP000280 OIL COOLER ASSEMBLY – (R5) 248
BH00015933 COOLER ASSEMBLY, Oil 250
BH00015934 COOLER ASSEMBLY, Oil 252
CP000812 MOTOR ASSEMBLY, Hydraulic 254
CP000813 MOTOR ASSEMBLY, Hydraulic 256
CX001670 FILTER ASSEMBLY, High Pressure 258
CX012746 HOSING, Receiver Tank – (1) 260
BH00024786 COMPRESSOR OIL HOSING 262
CX004769 Fuel Prime Pump Kit 264
CX013664 HOSING, Fuel Line 266
BH00009704 ISOLATION GROUP, Rubber Sheet 268
SECTION 6 – Air Hosing 270
CX012907 KIT, Air Supply – (B) 272
SECTION 7 – Hydraulics 274
BH00025393 BASE FRAME HYDRAULIC GROUP 276
BH00010060 ANCHOR GROUP, Whipsock – (D) 278
BH00010005 ANCHOR ASSEMBLY, Whipsock 280
BI00025375 VALVE ASSEMBLY, Stacker, Setup 282
CP002746 VALVE ASSEMBLY, Setup 284
BH00025316 MANIFOLD ASSEMBLY, Feed – (A) 286
CP000053 MANIFOLD ASSEMBLY, Feed 288
BI00027682 TANK ASSEMBLY, Hydraulic – (B) 290
BI00028762 VALVE ASSEMBLY, Tram 292
CP002747 VALVE ASSEMBLY, Feed/Tram 294
CP002748 VALVE ASSEMBLY, Rotation/Tram 296
BI00029459 HOSING GROUP, Base Frame 298
BI00029625 PIPING ASSEMBLY, Frame – (C) 334
BI00029255 DISCHARGE ASSEMBLY, Air – (D) 338
CX008843 FILTER ASSEMBLY, Hydraulic Oil Return – (R7) 340
BG00933189 FILTER ASSEMBLY, HYDRAULIC RETURN – 4-bolt lid holddown 342
CX001670 FILTER ASSEMBLY, High Pressure 258
CX009492 HOSE ASSEMBLY, Suction 344
CX009493 Fitting Kit – Suction 346
CP18313-2A THREAD GREASING GROUP – (C) 348
BH00010109 INSTALLATION, Mast Bulkhead 350
BH00013792 HOSING, Mast Bulkhead 352
BH00009694 VALVE GROUP, Tank Isolation 354
BH00022598 HYDRAULICS GROUP, Common – (B) 356
CX077603 CYLINDER ASSEMBLY, Hydraulic – 5 Bore X 47.16 Stroke 358
BH00009698 MINIMESS TEST GROUP 360
BH00010599 FAN TO MOTOR HOSE GROUP 362

MAST HYDRAULIC GROUP – (A) 364
BI00025376 VALVE ASSEMBLY, Stacker, Mast – (C) 380
CP002745 VALVE ASSEMBLY, Drilling Valve 382
BI00028310 MANIFOLD ASSEMBLY, Sequence, Pipe Arm 384
CP000054 MANIFOLD VALVE, Sequence 386
CM77006A CYLINDER ASSEMBLY 388
CX077006 CYLINDER, HYDRAULIC 390
CP000037 MANIFOLD ASSEMBLY, Triple Jaw 392
BI00029751 MAST HOSING GROUP – (D) 394
CX013749 HYDRAULIC OIL MANUAL FILL 422
CP17417 PUMP ASSEMBLY, Fill, Oil, Manual 424
CX009637 KIT, Hose, Top Drive 426
CX011159 KIT, ACCUMULATOR 428
CX011981 KIT, Hose, Water Pump – (R4) 430
SECTION 8 – Cab-Air Conditioner-Seat 432
BG00914014 CAB ASSEMBLY – (A) 434
BH00011233 CAB ASSEMBLY 436
BH00014543 SEAT ASSEMBLY 440
BH00011329 SEAT ASSEMBLY 442
BH00014390 STEP ASSEMBLY 444
CX004887 SEAT ASSEMBLY, Helper’s 446
BH00023708 JUNCTION BOX, Cab – (B) 448
CX010742 KIT, Damper Cylinder 450
BH00009629 LIGHT ASSEMBLY, Cab 451
CX015222 BAR ASSEMBLY, Exit 452
CX015832 BAR ARRANGEMENT, Disable 454
BH00014295 MOUNT ASSEMBLY, Fire Extinguisher, Cab 456
CX008050 GUARD GROUP, Cab Window – (6) 458
CX010742 KIT, Damper Cylinder 450
BG00909579 Cab Control Panel – (A) 460
CX002951 CONSOLE, Cab – (R13) 466
BG00909593 CONSOLE WIRING GROUP – (A) 468
BH00013855 KIT, Glass, Standard – (B) 472
CX003290 WIPER/WASHER GROUP, Window, Cab 474
BG00910868 CAB ELECTRICAL GROUP – (A) 476
BH00011316 REMOTE STATION ASSEMBLY, Pendant 480
CX002950 SUPPORT ASSEMBLY, Monitor – (R4) 482
BH00011314 STOP ASSEMBLY, Emergency – (D) 484
BH00016399 RADIO GROUP 486
BH00016558 ANGLEBLASTER GROUP – (D) 488
CP002206 BRACKET, Mounting, Display 490
BV00006264 AIR CONDITIONER GROUP – (A) 492
BH00013912 AIR CONDITIONER ASSEMBLY 496
BH00023379 HVAC ASSEMBLY – 7kW 6kW, 24VDC 498
BH00023386 PRESSURIZER BLOWER 502
1000431279 HVAC ELECTRICAL PANEL LAYOUT 504
BV00005930 ELECTRICAL GROUP – Bergstrom (A) 506
BH00026547 KIT, Air Conditioner Hose 508
BH00022600 BOOM GROUP, Cab – (A) 510
BH00011543 ACCUMULATOR, Piston – 5000psi 512
BH00022512 CYLINDER, HYDRAULIC 514
BH00013854 KIT, Glass, XIR 516
BH00010150 GUARD/LIGHT ASSEMBLY 518
BH00010154 RESERVOIR ASSEMBLY, Washer 520
BH00009660 ALTERATION, Seat Cover & Belt 522
BH00009713 INSTAL., RADIO 524
BH00009586 BLINDS GROUP, Perforated 526
SECTION 9 – Mast-Feed System 530
CX000450 PLATE ASSEMBLY, Mast Connection 532
CX017455 BOOM GROUP, Mast – (2) 534
CQ41123 JOINT ASSEMBLY 536
CX002332 PIN ASSEMBLY, Expander – 3.99 X 14.57 Lg 538
CX002333 PIN ASSEMBLY, Expander – 3.49 X 14.02 Lg 540
CX002334 PIN ASSEMBLY, Expander – 2.99 X 9.37 Lg 542
CX002335 PIN ASSEMBLY, Expander – 2.99 X 10.25 Lg 544
CX002402 KNUCKLE ASSEMBLY, Boom, Mast 546
CX002519 HINGE ASSEMBLY, Boom 548
CX004200 HINGE ASSEMBLY – 22.5 Arms 550
CX010804 CYLINDER ASSEMBLY, Mast Swing 552
DR560 SN 733980
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TABLE OF CONTENTS Page
CX010904 CYLINDER ASSEMBLY, Boom Swing 554
CX010905 CYLINDER ASSEMBLY, Boom Lift 556
CX010906 CYLINDER ASSEMBLY, Mast Dump 558
CX017440 BOOM ASSEMBLY, Mast 560
BH00012736 MAST ASSEMBLY – (H) 562
CM65106A BOOM ASSEMBLY, Jib 566
CP19900-AR2 GUIDE ARRANGEMENT, Cable Chain – (13) 568
BH00012236 CHAIN ASSEMBLY, Cable 570
CX007165 MOUNT ASSEMBLY, Cable Chain 572
CQ66107 BLOCK ASSEMBLY, Carrier 574
CQ66402-1 HEAD HOUSING ASSEMBLY, Mast 576
CX007821 E-stop Assembly 580
CX009269 BRACKET, Mounting, Proximity Switch 582
CX009874 KIT, ACCUMULATOR 584
CX004070 FOOT ASSEMBLY, Mast 586
CX001596 CYLINDER ASSEMBLY 588
CX012743 ROUTING GROUP, Mast Hose Knuckle 590
BH00009043 CYLINDER ASSEMBLY, Hydraulic – Feed w/Depth Sensor 594
SECTION 10 – Rotary System 596
BH00016965 TOP DRIVE W/Cushion & Saver Subs – 6240A- TJBO 598
BH00014203 CUSHION SUB ASSEMBLY 600
CX011030 TOP DRIVE ASSEMBLY 602
CX002896 MOTOR ASSEMBLY, Hydraulic 604
BH00019718 SWIVEL ASSEMBLY 606
BH00022185 HOUSING, Top Drive 608
CQ66403 MOUNTING PLATE ASSEMBY, Top Drive – (R7) 610
SECTION 11 – Carousel – Breakout 612
BH00022442 Carousel Assembly – 6 X 20 FT (C) 614
CM78809 CYLINDER ASSEMBLY, Clamp – 2.75 ID 2.9 Stroke 626
CM78810 CYLINDER, HYDRAULIC – 2.5 ID 6.12 Stroke 627
CM78811 CYLINDER, HYDRAULIC – 2.5 ID 4.5 Stroke 628
CP85811 GEAR BOX ASSEMBLY – 25.42:1 630
CX000265 MAST REST ASSEMBLY, Carousel 632
CX002555 SHAFT 634
CX005177 MOUNT ASSEMBLY, Valve – 10 Section 636
CX010787 Pin Assembly, Bottom Feed Cylinder 638
CX009800 BREAKOUT ASSEMBLY, Triple Jaw 640
CM47050 Centralizer Cylinder 642
CX002549 Cylinder, 5.00DIA x 3.08 stroke, TJBO 644
CX072450 CYLINDER 646
CX013723 Jaw Assy, Tong Die 648
BH00007925 KIT, Carousel Insert – 4 inch pipe 650
SECTION 13 – Winch 652
040006-603 WINCH ASSEMBLY – PL1 654
BH00009612 WINCH COMPONENTS 655
SECTION 14 – Dust & Water Control 656
CQ18422-300A TANK ASSEMBLY, Water – (R9) 658
CX010671 KIT, Hose, Water Level – 3/4 ID 660
CX010673 SENSOR ASSEMBLY, Water Level 662
CX005760 DIVERTER 664
CX011981 KIT, Hose, Water Pump – (R4) 430
SECTION 16 – Air Lubricator 666
CX000211 INJECTION ASSEMBLY, Oil – (B) 668
SECTION 17 – Accessories – Tools 670
CX011419 TOOLS, Maintenance and Repair 672
CX011364 TOOLS, Breakout, Cushion Sub 674
CX011420 LOCK PIN ASSEMBLY, Mast 676
SECTION 18 – Drilling Tools 678
CP41029-2 WRENCH ASSEMBLY, Breakout 680
CP41029-200C CHAIN ASSEMBLY 681
SECTION 19 – Special Equipment – Options

WATER FILL ASSEMBLY 686
006113-023 LUBRICATION GROUP 688
006113-000 LUBRICATION INJECTORS 690
006113-065 PUMP AND CONTAINER ASSEMBLY, Grease 696
006113-068 PUMP ASSEMBLY, Basic 698
037987-003 KIT, Clamp 704
CX007201-1 KIT, Hosing, Grease Pump 706
CX009986 KIT, Cab Boom Auto Grease Line 708
CX010314 KIT, Carousel Auto Grease Line 716
CX010167 KIT, Track Auto Grease Line 732
CX009985 KIT, Mast Boom Auto Grease Line 740
CX011536 GPS SYSTEM 750
CX011483 RECEIVER MOUNTING 752
CX011486 SENSOR, Mast Angle 754
CX011542 SENSOR, Mast Tilt 755
CX011544 TILT SENSOR INSTALLATION 756
CX011548 GPS MOUNTING GROUP – (6) 758
CX002950 SUPPORT ASSEMBLY, Monitor – (R4) 482
CX014286 BEACON GROUP 760
BH00009919 WASH GROUP, Rig 762
BH00016003 REEL, Hose – 3/4 ID X 75 Ft 766
BH00009917 WATER PUMP ASSEMBLY 768
BH00013511 VALVE ASSEMBLY, Solenoid 770
BH00010210 SERVICE CENTER GROUP 772
BH00013908 KIT, Hose, Service Center 774
BH00011725 CAMERA MOUNTING GROUP – (D) 778
BG01157409 OIL SAMPLING GROUP – (A) 784
SECTION 20 – Electrical 790
BG00920928 ELECTRICAL GROUP 792
BH00012592 BOX, Mast Valve Junction – (C) 796
BH00024190 FAN CONTROL BOX ASSEMBLY – (C) 798
BH00024197 FAN CONTROL WIRING GROUP – (C) 802
BH00012167 BOX, Mast Sensor Junction 804
BH00011545 EMERGENCY STOP GROUP – (E) 806
BH00011314 STOP ASSEMBLY, Emergency – (D) 484
BH00017609 LIGHTING GROUP, Chassis 810
BH00011595 CABLE GROUP, Battery 814
CX015628 GENERAL LAYOUT TRAM VALVE LOCKOUT 818
BH00022732 BOARDING LIGHT, Cab 820
BV00005764 REMOTE CONTROL PANEL – (C) 822
BV00005761 POCKET GATEWAY MODULE ASSEMBLY – Preprogrammed 830
BH00016791 SWITCH INSTALLATION, Inclinometer Proximity 832
BH00027868 GROUND STRAP INSTALLATION GROUP 834
BH00011316 REMOTE STATION ASSEMBLY, Pendant 480
BH00012122 INTERLOCK GROUP, Engine Start 836
BH00011545 EMERGENCY STOP GROUP – (E) 806
BH00011314 STOP ASSEMBLY, Emergency – (D) 484
BH00009869 ISLOLATION BOX GROUP, Starter/Battery 838
BH00009703 BOX, STARTER / BATTERY Isolation 842
BH00013528 WIRING GROUP, Water Injection 844

1. Introduction
2. Safety And Environmental Instructions
3. Lubricants and Capacities
4. RECOMMENDED TOOLS
5. Undercarriage
6. AIR COMPRESSOR & COOLER
7. HYDRAULIC SYSTEMS
8. MAST AND BOOM
9. WINCH
10. DUST SUPPRESSION