Original instructions

SAFETY BULLETIN 1 (11)

ID B000280
READ AND UNDERSTAND FIRST, THEN ACT Rev. 1
2023-05-01

1. Topic: MAST RAISE AND BUSHING REPLACMENT

2. Exposed product(s) / Model: DR416i for Serial No 733790, 734047 and 734132
Part(s):
The Owner of machinery has a liability to inform and when necessary to train according to the content of this Bulletin all the
personnel (like operators, maintenance personnel) whom this Bulletin concerns.
3. Possible occurrence of Transport Maintenance
topic: Operation Spare parts
Tramming Other:
4. Sales area: EU Canada
Others USA
Australia

5. Supplementary safety information including new hazard(s) identified, how to avoid the hazard(s)
and the potential consequences of not avoiding the hazard:

WARNING
FALLING PARTS HAZARD!

Thoroughly inspect mast raise pins and bushings.

Inspections and repair must be performed by qualified
persons only and in accordance with the manual and
maintenance program. If any cracks are found, stop all
operation of the machine.

Sandvik Mining and Rock Technology has learned that on the DR416i mast raise pins and bushings have
incorrect tolerance and must be replaced. Long term use of old pin will create grooves or gouging of pins.

6. Actions to be taken immediately:

Copyright © Sandvik Mining and Construction USA LLC

13500 NW County Road 235
Alachua, FL 32615 USA
www.sandvik.com
This document shall be incorporated in the "information of use" documentation and kept there for the life of the product.
Unless otherwise specified, Sandvik accepts no responsibility for changes, labor or replacements incurred from this bulletin.
 Original instructions

SAFETY BULLETIN 2 (11)

ID B000280
READ AND UNDERSTAND FIRST, THEN ACT Rev. 1
2023-05-01

Sandvik recommends the following:

Replace the mast raise and upper pedestal bushings.
a. Remove Original pin BJ00004594 and replace with BG01764652 pin. Before installing new pins, remove
old bushing BH00028039 and replace with new bushing BG01764594.
b. Remove Original pin BH00024046 and replace with BG01764656 pin. Before installing the new pins,
remove old bushing BH00028040 and replace with new bushing BG01764614.

7. List of Appendices:
NA
8. List of tools, parts and safety labels required for corrective measures:

Copyright © Sandvik Mining and Construction USA LLC

13500 NW County Road 235
Alachua, FL 32615 USA
www.sandvik.com
This document shall be incorporated in the "information of use" documentation and kept there for the life of the product.
Unless otherwise specified, Sandvik accepts no responsibility for changes, labor or replacements incurred from this bulletin.
 Original instructions

SAFETY BULLETIN 3 (11)

ID B000280
READ AND UNDERSTAND FIRST, THEN ACT Rev. 1
2023-05-01

Complete a Job Risk Assessment (JRA) before starting this procedure:

Before beginning these procedures, take time to observe any safety hazards in the area or on the machine.
Check the condition of the required tools, parts, and personal protection equipment (PPE) that may be
required or any factors that may indicate an unsafe condition.

Report and correct any unsafe condition before starting

this procedure!

NOTICE

Table 1: Safety First!

• Always perform Job Risk Assessment (JRA)

• Always wear proper PPE

• Always Lock Out/Tag Out Machine

• Clean the area where work is to be done

• Use appropriately rated lifting slings

• Tighten all bolts, nuts, and fittings to factory

specifications

Table 2: Minimum PPE Requirements

• Steel toe boots • Gloves • Hard hat

• Safety glasses • Safety shield • Hearing protection

Copyright © Sandvik Mining and Construction USA LLC

13500 NW County Road 235
Alachua, FL 32615 USA
www.sandvik.com
This document shall be incorporated in the "information of use" documentation and kept there for the life of the product.
Unless otherwise specified, Sandvik accepts no responsibility for changes, labor or replacements incurred from this bulletin.
 Original instructions

SAFETY BULLETIN 4 (11)

ID B000280
READ AND UNDERSTAND FIRST, THEN ACT Rev. 1
2023-05-01

Tools needed:
200-ton overhead crane or two 100-ton cranes.
Instructions to be followed:
Replace Mast Raising pins and bushings. You will need to remove mast. Follow the procedure below for
mast removal.
Note: Perform a risk assessment with the assembly crew and crane operator prior to lifting the mast
structure. Establish crane operators and ground guides that will communicate during the lift and
install process.
1. Attach lifting device to mast at lifting points as shown.

The lifting points are marked with a lifting hook decal

2. Attach crane or cranes to lifting devices on the mast.

3. Install sand lines or guidelines to each end of the mast.

4. Disconnect air supply hose and safety restraint from air pipe adapter. Use tape or rope to secure air hose
and pipe adapter.

Copyright © Sandvik Mining and Construction USA LLC

13500 NW County Road 235
Alachua, FL 32615 USA
www.sandvik.com
This document shall be incorporated in the "information of use" documentation and kept there for the life of the product.
Unless otherwise specified, Sandvik accepts no responsibility for changes, labor or replacements incurred from this bulletin.
 Original instructions

SAFETY BULLETIN 5 (11)

ID B000280
READ AND UNDERSTAND FIRST, THEN ACT Rev. 1
2023-05-01

5. Disconnect grease lines for auto grease systems as needed.

• Engage pipe support/ pipe centralizer/ break out wrench
• Raise winch hook to the top of the mast
• Disconnect hydraulic lines and electrical harness.
6. Secure the mast cylinders with turnbuckles.

7. Remove the pin retainer plates and drive the mast cylinder pins from the mast assembly.
8. Remove the stay rods from the mast.
9. Use straps to hold the ends so they do not move from lack of balance.

Copyright © Sandvik Mining and Construction USA LLC

13500 NW County Road 235
Alachua, FL 32615 USA
www.sandvik.com
This document shall be incorporated in the "information of use" documentation and kept there for the life of the product.
Unless otherwise specified, Sandvik accepts no responsibility for changes, labor or replacements incurred from this bulletin.
 Original instructions

SAFETY BULLETIN 6 (11)

ID B000280
READ AND UNDERSTAND FIRST, THEN ACT Rev. 1
2023-05-01

10. Position the mast cylinder rod ends as needed to aid pin removal.

Copyright © Sandvik Mining and Construction USA LLC

13500 NW County Road 235
Alachua, FL 32615 USA
www.sandvik.com
This document shall be incorporated in the "information of use" documentation and kept there for the life of the product.
Unless otherwise specified, Sandvik accepts no responsibility for changes, labor or replacements incurred from this bulletin.
 Original instructions

SAFETY BULLETIN 7 (11)

ID B000280
READ AND UNDERSTAND FIRST, THEN ACT Rev. 1
2023-05-01

WARNING
FALLING OBJECT HAZARD!

Do not allow anyone below the mast pedestal area when

removing pins as they can cause serious injury or death
if dropped on a person.

11. Remove the retaining plate bolts and slide the retaining plates from the pedestal pins.
12. Remove the pins from the mast and pedestal. The pins are heavy. Keep personnel away from area
below.
13. Move the mast as needed to get the pins to slide out.
14. Remove lock out/tag out so machine can be started after mast is lifted.
15. With all personnel clear of the area, use the crane to lift the mast.
16. Lift mast with crane less than 1 meter (3 feet) off the machine. Check the supported mast for stability
and balanced to both front/rear and left/right. Lower mast to machine and adjust straps as needed to get
the balance correct.
17. Once the mast balance is correct, continue to raise the mast so machine may be driven from under
raised mast.

18. One operator should be in the cab. Start machine.

Copyright © Sandvik Mining and Construction USA LLC

13500 NW County Road 235
Alachua, FL 32615 USA
www.sandvik.com
This document shall be incorporated in the "information of use" documentation and kept there for the life of the product.
Unless otherwise specified, Sandvik accepts no responsibility for changes, labor or replacements incurred from this bulletin.
 Original instructions

SAFETY BULLETIN 8 (11)

ID B000280
READ AND UNDERSTAND FIRST, THEN ACT Rev. 1
2023-05-01

19. On the GUI, select Menu > Maintenance > Bypass and set the Mast Lock Pins Extended bypass to ON.
Repeat that process for strut locks, Bit stow position, Mast position.
20. Tram from under the mast.
21. Lower mast down to rest on appropriate cradle or sawhourse to working level.

22. After mast is placed on appropriate sawhorse or cradle, the below outlined bushings in black need to be
removed.

Copyright © Sandvik Mining and Construction USA LLC

13500 NW County Road 235
Alachua, FL 32615 USA
www.sandvik.com
This document shall be incorporated in the "information of use" documentation and kept there for the life of the product.
Unless otherwise specified, Sandvik accepts no responsibility for changes, labor or replacements incurred from this bulletin.
 Original instructions

SAFETY BULLETIN 9 (11)

ID B000280
READ AND UNDERSTAND FIRST, THEN ACT Rev. 1
2023-05-01

23. For bushing removal you will need a Saw- all Like pictured below with metal blades to be able to cut the
old bushing out (do not cut into mast).

24. With old bushing out make sure the inner surface area of the weldment is clean of all burs and clean of
any debris. This will make the installation of new bushings easier.
• To install new bushings some heating may be required to the surface area of the mast where the new
bushing is going to be received.
• This will allow for expansion of the metal some to accept the new bushing. It is suggested that a trial run
might be done first as you also might need to have the new bushing placed in Dry ice to shrink them
down making it easier to install in the weldment.
Use caution if you are using a hammer on the bushing install as that will cause the new bushing to
mushroom out and it will not accept the new mast pins. After new bushings are installed, they should look
like the below.

25. Before re-install of mast take the new pins and make sure they go through the new bushing with no
issues.

Copyright © Sandvik Mining and Construction USA LLC

13500 NW County Road 235
Alachua, FL 32615 USA
www.sandvik.com
This document shall be incorporated in the "information of use" documentation and kept there for the life of the product.
Unless otherwise specified, Sandvik accepts no responsibility for changes, labor or replacements incurred from this bulletin.
 Original instructions

SAFETY BULLETIN 10 (11)

ID B000280
READ AND UNDERSTAND FIRST, THEN ACT Rev. 1
2023-05-01

WARNING
CRUSHING HAZARD!
All items of the machine are extremely heavy or can
cause serious injury or death.
Do not work under suspended loads, do not move loads
with personnel in unsafe areas, and ensure all items are
secured to prevent falling or tripping.

26. Re-install mast to drill base using the new pins provided. Use anti-seize compound on new pins before
installation (nickel or copper).

DANGER
The sudden release of a pressurized lid or hose can spray
hot oil.
Do not open hydraulic tanks or air reservoir or hydraulic
connection while machine is running or the systems are
under pressure.

WARNING
CRUSHING HAZARD!
Moving or falling parts can crush. Ensure all loads are
supported securely.
Parts are heavy, do not work under items while they are
loose. Keep all body parts away from pinch points.

9. Further details to Customers:

• No software required for this update.

• Take a picture of old Pins and bushings and please sent to Sandvik via Salesforce case.
• Please send one of the older pins and bushing back to Sandvik to be evaluated.

10. Warranty Information:

Parts will be issued F.O.C. per factory to customer.

Copyright © Sandvik Mining and Construction USA LLC

13500 NW County Road 235
Alachua, FL 32615 USA
www.sandvik.com
This document shall be incorporated in the "information of use" documentation and kept there for the life of the product.
Unless otherwise specified, Sandvik accepts no responsibility for changes, labor or replacements incurred from this bulletin.
 Original instructions

SAFETY BULLETIN 11 (11)

ID B000280
READ AND UNDERSTAND FIRST, THEN ACT Rev. 1
2023-05-01

11. Contact Details

Please contact Sandvik for any further information you may require at alachua.partsupport@sandvik.com.
If you need additional support, you can contact your local Sandvik office.

Copyright © Sandvik Mining and Construction USA LLC

13500 NW County Road 235
Alachua, FL 32615 USA
www.sandvik.com
This document shall be incorporated in the "information of use" documentation and kept there for the life of the product.
Unless otherwise specified, Sandvik accepts no responsibility for changes, labor or replacements incurred from this bulletin.