Sandvik DR540 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

DR540 SN 733771 2
SECTION 2 – Misc. Hardware 4
001423-000 CLAMPS,HOSE/HARNESS, MISC. 6
001132-000 PLUGS, JIC, MISC. 7
001135-000 PLUGS, BOSS, MISC. 8
001137-000 PLUGS, MPT, MISC. 9
001138-000 CAPS, JIC, MISC. 10
001595-000 CAPS, FPT, MISC. 11
001159-000 PIPE JOINT ASSEMBLIES 12
001742-000 FLANGE KIT ASSEMBLIES 14
002052-000 FLANGE KIT ASSEMBLIES 16
001825-000 CLAMPS, SINGLE,STAUFF, MISC. 20
001824-000 CLAMPS, TWIN, STAUFF, MISC. 22
001084-000 ELBOW, MPT/JIC, MISC. 24
001131-000 ELBOW, BOSS/JIC, MISC. 25
001944-000 ELBOW, SWIVEL, JIC/JIC, MISC. 26
001086-000 ADAPTERS, MPT/MPT, MISC. 27
001062-000 ADAPTERS, MPT/JIC, MISC. 28
001088-000 ADAPTERS, BOSS / JIC, MISC. 30
002235-000 TEE, SWIVEL, FJIC/JIC/JIC, MISC. 32
004036-000 TEE, FPT /JIC /JIC, MISC. 33
004461-000 TEE, FPT/FPT/FPT, MISC. 34
001082-000 ADAPTERS, FPT/JIC, MISC. 35
003328-000 ADAPTERS, FJIC/JIC, MISC. 36
010619-000 ADAPTERS, SWIVEL, FJIC/MJIC, MISC. 37
016898-000 CLAMPS, ELECTRICAL, MISC. 38
001161-000 TEE, MBOSS / MJIC / MJIC 39
001491-000 ELBOW, FPT/JIC, MISC. 40
010620-000 ADAPTER, SWIVEL, MBOSS / FJIC, MISC. 41
035179-000 CLAMP, RAIL MOUNTED, TWIN, MISC. 42
035165-000 CLAMP, RAIL MOUNTED, SINGLE, MISC. 44
035835-000 CLAMPS, SINGLE,STAUFF, MISC. 46
SECTION 3 – Undercarriage – Nameplates 48
BH00022610 UNDERCARRIAGE GROUP 50
BH00012341 CYLINDER ASSEMBLY, Hydraulic 56
BI00031818 CRAWLER ASSEMBLY, Complete 58
BH00019070 FINAL DRIVE/MOTOR ASSEMBLY 60
BH00012679 DRIVE, Final 62
BH00012645 CHAIN AND PAD ASSEMBLY 64
CX011518 GENERAL ARRANGEMENT GROUP 66
CX000058 STAND ASSEMBLY, Mast 68
CX001352 STEP ASSEMBLY, Service 70
CX011724 SWITCH ASSEMBLY, Tram pressure 72
CX011726 BRACKET ASSEMBLY, Filter/Regulator 74
CX012324 BATTERY BOX ASSEMBLY 76
CX015435 STEP ASSEMBLY, Auxiliary Maintenance Station 78
BH00010737 COVER ASSEMBLY, Valve 80
CX017309 COVER ASSEMBLY – Tram Valve Lockout 82
CX015852 HANDLE ASSEMBLY, Tram Valve Lockout 84
BH00010136 SKID PLATE INSTALLATION 86
BH00009824 FIRE SUPPRESSION DECK 88
BH00010076 LABEL KIT, Anodized 92
BH00010446 LADDER GROUP, Service, Air Cleaner 94
BI00022553 LADDER GROUP, Rear Access 96
BH00011467 LADDER GROUP, Rear Access 98
BI00022167 DECK GROUP 100
BI00022196 DECK ASSEMBLY 102
BI00022168 DECK ASSEMBLY 104
BH00005636 MARKETING DECALS 106
SECTION 4 & 5 – Engine – Compressor – Cooler 108
BH00017517 ENGINE & COMPRESSOR POWER GROUP – (A) 110
BH00011491 RECEIVER TANK ASSEMBLY 112
BH00012177 VALVE ASSEMBLY, Control, Air 128
CX000544 REGULATOR – 100-400 PSI 130
CX000545 REGULATOR, Inlet Signal Pressure 132
BH00012452 RADIATOR GROUP 134
CQ20100-27 COOLER ASSEMBLY 136
DR540 SN 733771
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TABLE OF CONTENTS Page
BH00007703 RADIATOR ASSEMBLY 138
BH00007704 OIL COOLER ASSEMBLY 140
BH00007705 AFTERCOOLER ASSEMBLY 142
CX002536 MOTOR ASSEMBLY, Hydraulic 144
BH00012724 ENGINE/COMPRESSOR/PUMP DRIVE GROUP 146
BH00011748 PUMP GROUP 148
CP002026 GEARBOX ASSEMBLY, Pump Drive 150
CP002037 PUMP, HYDRAULIC – 100cc 152
CP002130 PUMP, HYDRAULIC – 74cc, CW 156
BH00012414 COMPRESSOR GROUP 160
02250192-106 COMPRESSOR ASSEMBLY – 900 CFM 162
BH00009770 PANEL ASSEMBLY, Regulator – 500PSI 182
CX000544 REGULATOR – 100-400 PSI 130
CX000545 REGULATOR, Inlet Signal Pressure 132
BH00012486 ENGINE GROUP 184
CP002047 ENGINE, Cat C-15 Tier III 186
CQ41255 BRACKET ASSEMBLY 190
CX012322 HEAT SHIELD ASSEMBLY, Turbo, Tier III 192
BH00012972 FUEL TANK ASSEMBLY 194
CX011521 INLET GROUP, Air, Engine 196
CX011531 COOLER LINES GROUP, Engine 198
CX012444 HOSING, Compressor Oil 200
CX012480 HOSING, Radiator Hydraulic 202
CX012746 HOSING, Receiver Tank 204
CX014736 HOSING, Fuel Cooler 206
BH00024786 COMPRESSOR OIL HOSING 208
BI00022040 FIREWALL GROUP 210
BH00016060 AIR CLEANER INDICATOR ASSEMBLY 212
SECTION 6 – Air Hosing 214
CX012907 KIT, Air Supply 216
SECTION 7 – Hydraulics 218
BI00026500 HYDRAULIC GROUP, Base Frame 220
BI00025375 VALVE ASSEMBLY, Stacker, Setup 222
CP002746 VALVE ASSEMBLY, Setup 224
BI00025383 MANIFOLD ASSEMBLY, Feed 226
CP000053 MANIFOLD ASSEMBLY, Feed 228
BI00028762 VALVE ASSEMBLY, Tram 230
CP002747 VALVE ASSEMBLY, Feed/Tram 232
CP002748 VALVE ASSEMBLY, Rotation/Tram 234
BI00029027 PIPING ASSEMBLY, Hydraulic 236
BI00029255 DISCHARGE ASSEMBLY, Air – (D) 238
CX011533 FILTER ASSEMBLY,Hydraulic Return 240
BI00029459 HOSING GROUP, Base Frame 242
CX001670 FILTER ASSEMBLY, High Pressure 278
CX010504 TANK ASSEMBLY, Hydraulic – (8) 280
CX012400 SUCTION GROUP, Hydraulic 282
BH00010109 INSTALLATION, Mast Bulkhead 284
BH00013792 HOSING, Mast Bulkhead 286
BH00009694 VALVE GROUP, Tank Isolation 288
BH00022597 COMMON HYDRAULICS GROUP 290
CM77006A CYLINDER ASSEMBLY 292
CX077006 CYLINDER, HYDRAULIC 294
CP17417 PUMP ASSEMBLY, Fill, Oil, Manual 296
CX077603 CYLINDER ASSEMBLY, Hydraulic – 5 Bore X 47.16 Stroke 298
BH00016017 TEST CENTER GROUP 300
BH00012792 HOSE INSTALLATION, Fan Motor 302
CX009637 KIT, Hose, Top Drive 304
CX011159 KIT, ACCUMULATOR 306
CX011981 KIT, Hose, Water Pump 308
SECTION 8 – Cab-Air Conditioner-Seat 310
BH00022392 CAB INSTALLATION 312
BH00011233 CAB ASSEMBLY 314
BH00014543 SEAT ASSEMBLY 318
BH00011329 SEAT ASSEMBLY 320
BH00014390 STEP ASSEMBLY 322
CX004887 SEAT ASSEMBLY, Helper’s 324
CX002836 JUNCTION BOX, Cab 326
CX010742 KIT, Damper Cylinder 328

BAR ASSEMBLY, Exit 330
CX015832 BAR ARRANGEMENT, Disable 332
BH00014295 MOUNT ASSEMBLY, Fire Extinguisher, Cab 334
CX008050 GUARD GROUP, Cab Window 336
CX010742 KIT, Damper Cylinder 328
BH00024147 CONTROL PANEL, ENGINE 338
CX002951 CONSOLE, Cab 342
BH00024146 CONSOLE WIRING GROUP 344
BH00013855 KIT, Glass, Standard 348
CX003290 WIPER/WASHER GROUP, Window, Cab 350
BH00010693 ELECTRICAL GROUP, Cab 352
BH00011316 REMOTE STATION ASSEMBLY, Pendant 358
CX002950 SUPPORT ASSEMBLY, Monitor 360
BH00011314 STOP ASSEMBLY, Emergency – (C) 361
BH00016399 RADIO GROUP 362
BH00016558 ANGLEBLASTER GROUP 364
CP002206 BRACKET, Mounting, Display 366
BH00013910 AIR CONDITIONER GROUP – (B) 368
BH00013912 AIR CONDITIONER ASSEMBLY 370
BH00023379 HVAC ASSEMBLY 7kW 6kW, 24VDC 372
BH00023386 PRESSURIZER BLOWER 376
1000431279 HVAC ELECTRICAL PANEL LAYOUT 378
BH00017959 ELECTRICAL GROUP, Air Conditioner 380
BH00022600 BOOM GROUP, Cab – (A) 382
BH00011543 ACCUMULATOR, Piston – 5000psi 384
BH00022512 CYLINDER, HYDRAULIC 386
BH00013854 KIT, Glass, XIR 388
BH00010150 GUARD/LIGHT ASSEMBLY 390
BH00010154 RESERVOIR ASSEMBLY, Washer 392
BH00009660 ALTERATION, Seat Cover & Belt 394
BH00009713 INSTAL., RADIO 396
BH00009586 BLINDS GROUP, Perforated 398
SECTION 9 – Mast-Feed System 402
CX000450 PLATE ASSEMBLY, Mast Connection 404
CX017455 BOOM GROUP, Mast – (2) 406
CQ41123 JOINT ASSEMBLY 408
CX002332 PIN ASSEMBLY, Expander – 3.99 X 14.57 Lg 410
CX002333 PIN ASSEMBLY, Expander – 3.49 X 14.02 Lg 412
CX002334 PIN ASSEMBLY, Expander – 2.99 X 9.37 Lg 414
CX002335 PIN ASSEMBLY, Expander – 2.99 X 10.25 Lg 416
CX002402 KNUCKLE ASSEMBLY, Boom, Mast 418
CX002519 HINGE ASSEMBLY, Boom 420
CX004200 HINGE ASSEMBLY – 22.5 Arms 422
CX010804 CYLINDER ASSEMBLY, Mast Swing 424
CX010904 CYLINDER ASSEMBLY, Boom Swing 426
CX010905 CYLINDER ASSEMBLY, Boom Lift 428
CX010906 CYLINDER ASSEMBLY, Mast Dump 430
CX017440 BOOM ASSEMBLY, Mast 432
BH00012736 MAST ASSEMBLY 434
CM65106A BOOM ASSEMBLY, Jib 438
CP19900-AR2 GUIDE ARRANGEMENT, Cable Chain 440
BH00012236 CHAIN ASSEMBLY, Cable 442
CX007165 MOUNT ASSEMBLY, Cable Chain 444
CQ66107 BLOCK ASSEMBLY, Carrier 446
CQ66402-1 HEAD HOUSING ASSEMBLY, Mast 448
CX007821 E-stop Assembly 452
CX009269 BRACKET, Mounting, Proximity Switch 454
CX009874 KIT, ACCUMULATOR 456
CX004070 FOOT ASSEMBLY, Mast 458
CX001596 CYLINDER ASSEMBLY 460
CX012743 ROUTING GROUP, Mast Hose Knuckle 462
BH00009043 CYLINDER ASSEMBLY, Hydraulic – Feed w/Depth Sensor 466
SECTION 10 – Rotary System 468
BH00017061 TOP DRIVE 6240-A-TJBO W/CUSHION 470
BH00014203 CUSHION SUB ASSEMBLY 472
CX011030 TOP DRIVE ASSEMBLY 474
CX002896 MOTOR ASSEMBLY, Hydraulic 476
BH00019718 SWIVEL ASSEMBLY 478
DR540 SN 733771
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TABLE OF CONTENTS Page
BH00022185 HOUSING, Top Drive 480
CQ66403 MOUNTING PLATE ASSEMBY, Top Drive 482
SECTION 11 – Carousel – Breakout 484
BH00022442 Carousel Assembly – 6 X 20 FT (C) 486
CM78809 CYLINDER ASSEMBLY, Clamp – 2.75 ID 2.9 Stroke 498
CM78810 CYLINDER, HYDRAULIC – 2.5 ID 6.12 Stroke 499
CM78811 CYLINDER, HYDRAULIC – 2.5 ID 4.5 Stroke 500
CP85811 GEAR BOX ASSEMBLY – 25.42:1 502
CX000265 MAST REST ASSEMBLY, Carousel 504
CX002555 SHAFT 506
CX005177 MOUNT ASSEMBLY, Valve – 10 Section 508
CX010787 Pin Assembly, Bottom Feed Cylinder 510
CX009800 BREAKOUT ASSEMBLY, Triple Jaw 512
CM47050 Centralizer Cylinder 514
CX002549 Cylinder, 5.00DIA x 3.08 stroke, TJBO 516
CX072450 CYLINDER 518
CX013723 Jaw Assy, Tong Die 520
BH00007926 PIPE INSERT KIT, Carousel – 3.5 Inch (B) 522
SECTION 13 – Winch 524
040006-603 WINCH ASSEMBLY – PL1 526
BH00009612 WINCH COMPONENTS 527
SECTION 14 – Dust & Water Control 528
BH00010232 WATER TANK GROUP 530
BH00010227 TANK ASSEMBLY, Water 532
CX010673 SENSOR ASSEMBLY, Water Level 534
CX005760 DIVERTER 536
CX011403 WATER PUMP/DRIVE GROUP 538
CP18322-1 PUMP ASSEMBLY, Water 540
SECTION 16 – Air Lubricator 542
CX000211 INJECTION ASSEMBLY, Oil 544
SECTION 17 – Accessories – Tools 546
CX011419 TOOLS, Maintenance and Repair 548
CX011364 TOOLS, Breakout, Cushion Sub 550
CX011420 LOCK PIN ASSEMBLY, Mast 552
SECTION 18 – Drilling Tools 554
CP41029-2 WRENCH ASSEMBLY, Breakout 556
CP41029-200C CHAIN ASSEMBLY 557
SECTION 19 – Special Equipment – Options 558
BH00010603 INSTALL, Lincoln Auto Lube 560
BH00009818 WATER FILL ASSEMBLY 562
006113-023 LUBRICATION GROUP 564
006113-000 LUBRICATION INJECTORS 566
006113-068 PUMP ASSEMBLY, Basic 572
037987-003 KIT, Clamp 578
CX007201-1 KIT, Hosing, Grease Pump 580
CX009986 KIT, Cab Boom Auto Grease Line 582
CX010314 KIT, Carousel Auto Grease Line 590
CX010167 KIT, Track Auto Grease Line 606
CX009985 KIT, Mast Boom Auto Grease Line 614
CX014286 BEACON GROUP 624
BI00022062 SERVICE CENTER GROUP 626
BH00015856 KIT, Hose, Service Center 628
BH00011725 CAMERA MOUNTING GROUP – (D) 632
SECTION 20 – Electrical 638
BH00022242 ELECTRICAL GROUP 640
BH00012592 BOX, Mast Valve Junction 644
BH00024190 FAN CONTROL BOX ASSEMBLY 646
BH00024197 FAN CONTROL WIRING GROUP 650
BH00012167 BOX, Mast Sensor Junction 652
CX015628 GENERAL LAYOUT TRAM VALVE LOCKOUT 654
BH00011545 EMERGENCY STOP GROUP – (C) 656
BH00011314 STOP ASSEMBLY, Emergency – (C) 361

1. Introduction
2. Safety and Environmental Instructions
3. Lubricants and Capacities
4. Recommended Tools
5. Undercarriage
6. Air Compression Systems
7. Hydraulic Systems
8. Mast and Boom
9. Winch
10. Dust Suppression